Smelling gas fumes in car after fuel pump was replaced

You need to repair the exhaust/manifold leak. Possibly a blown gasket.

It's possible you have a connection that is loose and has a slight leak. Is your fuel pump in the tank? That could have a small leak. It does not take much of a leak for gas fumes . What about gas hoses.

Drop the tank remove all fuel replace the filter and fill with fresh gas

A mechanic would check the vapor canister to see if it is full of liquid gasoline. If it is, you would need to replace it and find out if the EVAP system is working correctly. It should only have fumes in it from the tank.

Was fuel smell present before you had fuel pump replaced? If yes I would sugest you drop tank and see if fuel vent hose is plugged forcing fuel back pressure line to vent through cap. If fuel smell was not present before you replaced fuel pump and seal. I would suggest you drop tank back out and check all fittings and hose conections. also if you still have old sending unit you could check to make sure they are exactly the same. As Sometimes you have to pull relief valve from old sending unit and install it in the new one, as some sending units wont have one in it. and some will have one that is regulated at a different fuel pressure. hope this helps Vic

there must be a kink or blockage in the filler pipe or the breather pipe is blocked

sounds like you have a leaky gas line,...the fuel pump is in the gas tank, so when you turn the key on, the pump is activated and pressurizes the line,..... good to get it checked out on a lift,....good luck, cracklin joe

vapor recovery system, should clear itself, some liquid fuel got into the vapor system. Avoid topping off the fuel tank.

this sounds like a gas pressure regulatur. a few minutes after starting,you start smelling fumes,and are getting bad gas mileage right?

I also have a 2004 XC90 and a couple of months ago I had the exact same probelm... after multiple visits to my dealer's auto shop they figured out that it was the fuel pump. They replaced the fule pump and the smell disappeared. Good luck!