P80 Fuel tank - what type of plastic? [HDPE with Nylon additive] Topic is solved

[ZionXIX]

Could buy a junkyard fuel tank and just cut it into pieces for repairs? Assuming the junkyard one has holes in it.

[erikv11]

You could also just install a junkyard tank and be done, no figuring out new configurations or wondering if you got the material right.

[callahanoffroad]

This thread is why I love MVS.

[BlackBart]

Good ideas - just none around here. And it will be used and the same age and maybe have the same crack. It's right at the rear heat shield bolt.

[ZionXIX]

I would think all the P80 gas tanks from that era are probably made of the same material. Might open your options?

[erikv11]

Mine. I believe it has expired some time ago, and my closest dealer is 3 hours away anyway.

The leak is coming directly from the rear heat shield bolt. Many others have said the same thing....6 gallons is all you get before it leaks there.

It's all 850s, 1994-1997. Service bulletin 140.

Fortunately I've never run into this problem in all my years with various P80 cars. It's rare on the forums but does pop up, though pretty much not any more as the P80 fades into the sunset. Likely many P80 cars still out there were already fixed (the fix was to put rubber bushings in between the heat shield and the tank, and replace the tank if already cracked though Volvo often just replaced the tank anyway). It's reportedly worse in warm climates, FWIW.

If you do end up doing some kind of melted plastic repair, I guess you'll want to be sure it is a very smooth surface, and to use rubber bushings on the bolts. Are there bushings in there now?

[matthew1]

I had my 850 checked at a dealer for this circa 2008. All was well, no repair.

[ZionXIX]

I had mine checked last year and got a free replacement. I called volvo customer service ahead of time and then contacted my nearest dealer. All they can say is no. Might as well give it a try.

[BlackBart]

No bushings that I can see yet. I’ve had it since 60k miles. It did start it’s life in Dallas, so....
Not putting the heat shield back on those bolts - I’ll figure out an alternative.
I tried dealers long ago - they said drop it off, 3 hours away or 8, & leave it. We’ll inspect and contact Volvo in a week. They may or may not approve replacement. If not, we’ll fix it at full dealer prices. Then get a ride 3 hours to pick it up.

[scot850]

I had a problem with a V70 plastic tank. Looked like the owner had backed it over something bending the heatshield and breaking the mount on one side. If I recall I glued it back with a plastic epoxy as well as a little work of melting the plastic with my little propane plastic welder (like a soldering iron with a wider tip and comes with a selection of plastic weld rods). Car is still running fine with my buddy.

Neil.