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2007 XC70 -- ECM-439C -- Fuel filler pipe hole

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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mtd240
Posts: 326
Joined: 7 December 2011
Year and Model: 2007 XC70
Location: Ellicott City, MD
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2007 XC70 -- ECM-439C -- Fuel filler pipe hole

Post by mtd240 »

Hi all! I've had an ECM-439C ("major evap leak") on my '07 XC70 for a few years now. It was intermittent in the past, so I was able to limp it through emissions a couple times via some luck with code-clearing and emissions readiness timing. But, now it has stuck.

I bought a smoke tester* and hooked it up to the purge valve line running to the back of the car. After figuring out that I had to cap the air intake/filter for the evap system (#7 at link), I was able to find the leak. It's the small pipe attached to the main tank filler pipe (see small pipe in part #13 below). Looks like it has been rubbing on the frame for the past 160k miles, slowly wearing a good sized hole into a segment right up where it is basically inaccessible (can either see it with a mirror, OR feel it with my fingers -- probably halfway between where the #13 label is pointing and where it attaches to the tank in the diagram).

Image

My question is: given that I don't intend to drop the tank on this car or actually properly replace this pipe, but that I do hope to get a few more years out of it -- what sort of epoxy/rtv/other adhesive would you all recommend using to patch the hole? It is rubbing up against the frame, so obviously I'd have to put a paper towel or similar over the adhesive to avoid gluing it to the frame. I've seen JB Weld's TankWeld -- is that a good option? There isn't any room to cut the pipe and splice in a hose. I'm sure the AWD P2 owners out there are well aware of the tight quarters around the fuel tank.

Any and all advice is greatly appreciated!

* I was surprised by the quality of this tool given the price. I'd recommend it for anyone looking for a home smoke tester. This is the heavier-duty version -- there's a $90 version with no built in pump and a little cheaper materials if you want to save $40. I don't know the manufacturer, and I'm not getting paid to advertise.
https://www.amazon.com/dp/B0B2JV8YDP
2007 XC70, white/oak, 175k miles
2008 XC70 3.2L, 115k miles
2016 XC60, osmium grey / off-black, 95k miles
Gone:
1990 240 DL Wagon, M47, lots of goodies. 372,000 miles
1978 242, lots and lots of work to get a reliable daily
1998 V70 XC, Almost done replacing everything, then I sold it :lol:
1996 850 NA, victim of sporadic tree falling. Protected the wife. RIP Volvo

mtd240
Posts: 326
Joined: 7 December 2011
Year and Model: 2007 XC70
Location: Ellicott City, MD
Has thanked: 23 times
Been thanked: 7 times

Post by mtd240 »

Forgot to follow up on this. Used JB TankWeld - tight quarters there, had to do it blind. But it worked. No more code, passed emissions!
2007 XC70, white/oak, 175k miles
2008 XC70 3.2L, 115k miles
2016 XC60, osmium grey / off-black, 95k miles
Gone:
1990 240 DL Wagon, M47, lots of goodies. 372,000 miles
1978 242, lots and lots of work to get a reliable daily
1998 V70 XC, Almost done replacing everything, then I sold it :lol:
1996 850 NA, victim of sporadic tree falling. Protected the wife. RIP Volvo

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jonesg
Posts: 3501
Joined: 16 January 2008
Year and Model: 2004 V70
Location: Northern maine.
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Post by jonesg »

mtd240 wrote: 08 Jun 2023, 16:16 Forgot to follow up on this. Used JB TankWeld - tight quarters there, had to do it blind. But it worked. No more code, passed emissions!
good fix, thanks for the follow up.

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