'94 fuel tank - repair possible?

christhekiwi · Post by **christhekiwi** » 02 Oct 2011, 18:05

After noticing the odd waft of fuel around my '95 850 turbo i read up on the "common" problem of cracking/weeping around the heat shield lugs. I got underneath and found a wet track coming from a lug.

I have removed the tank (whew) and found i have stress cracks around 2 of the 3 lugs.

Getting a new tank here in NZ would cost more than the car is worth so i am looking for repair recommendations.

Plastic welding or chemical sealing seem to options, i am leading toward plastic welding, mainly because no one seems to stock a chemical solution. (or know what type of plastic it is made from )

Any tried and true remedies?

Then i will need to find an alternative way to mount that heat shield.........

Post by **confused_al** » 02 Oct 2011, 19:47

Have you seen Lee's report?
https://www.matthewsvolvosite.com/forums ... 09#p208009

Sounds your gas tank should be covered by Volvo's recall.

elchopperfreak · Post by **elchopperfreak** » 03 Oct 2011, 02:27

I found the hard way, about a sealer they use for barges and ships, the shipping company somehow cracked my gas tank getting my truck on board, they put that epoxy there ( gas and al) and it sealed quick, its been a few years too.
Might try JB weld if available in NZ and cant find the miracle ship epoxy..
I might find the name with a couple calls..let me see.....

christhekiwi · Post by **christhekiwi** » 03 Oct 2011, 03:38

Thanks, Yes i have some JB Weld. Am going to ask the dealer about the recall mentioned but i get the feeling this will not be an option in NZ. I woudl appreciate the name of the product you used if you can find it . Thanks.

Post by **Xilikon** » 03 Oct 2011, 09:37

Try epoxy putty ?

christhekiwi · Post by **christhekiwi** » 04 Oct 2011, 20:23

confused_al wrote:Have you seen Lee's report?
https://www.matthewsvolvosite.com/forums ... 09#p208009

Sounds your gas tank should be covered by Volvo's recall.

I have got as far as the national service manager and await his response.

It is a shame that the service given by the dealer here seems designed to discourage me from ever owing a new Volvo.

The options are; either pay the approximate current value of the car for any significant repair, or scrap the car.

Local dealer price for a coolant expansion tank $275. Price of after market unit from Pelican Parts in USA approx $40

Marcobrick · Post by **Marcobrick** » 05 Oct 2011, 02:35

christhekiwi wrote:
I have got as far as the national service manager and await his response.

It is a shame that the service given by the dealer here seems designed to discourage me from ever owing a new Volvo.

The options are; either pay the approximate current value of the car for any significant repair, or scrap the car.

Local dealer price for a coolant expansion tank $275. Price of after market unit from Pelican Parts in USA approx $40

I hear you Chris! I have never bought anything except a set of spark plugs for my car from around here. Sometimes when I want a laugh, I phone my local dealer for a price on something I need, and I have only once gotten them on the phone, most of the time they have it go to answerphone! I have over the last 12 months spent probably $2k on parts from FCP for 3 Volvos, and the service has been great and even with the punitive cost of freight it still comes out to half the price and often less.

christhekiwi · Post by **christhekiwi** » 17 Oct 2011, 22:22

christhekiwi wrote:Thanks, Yes i have some JB Weld. Am going to ask the dealer about the recall mentioned but i get the feeling this will not be an option in NZ. I would appreciate the name of the product you used if you can find it . Thanks.

Well i gave up waiting for Volvo NZ and completed a repair using JB Weld.

Fitted a garden hose to the fuel line to the rail, jumpered the FPR and ran the fuel into my "other' volvo.

Removed the sender, pump, tank.

De-greased the area around the heat shield fitting points - all were cracked and leaking.

Sanded around these points with 60 grit and thoroughly keyed the surrounding area. Applied JB Weld.

I left the repair for 3 days to cure then tested. All good.

Re-fitted heat shield using the two upper fixing points only - (to reduce diagonal stress?)

Fitted rubber grommets between each fixing and the shield. Refitted everything.

During this job i found one end of the 15mmm line was also split and just starting to leak.

Notes;

1 Fit the collar to the pump before fitting the lines

2 Fit the smaller 15mm (return) line that goes to the spigot at the top of the tank before re-fitting the tank due to poor access from the top.
3 Fit the heat shield before re-fitting the tank.
4 Note the direction that fuel is running before you connect a hose to drain the fuel otherwise you will drench the engine with gas when you fit the jumper.