Just purchased a 2001 V70 2.4T FWD and turns out it has a cracked fuel tank. Doesn't appear to be impact related, but perhaps age related or manufacturer defect. Been trying to dodge replacing it with a new part ($1200-1600 for the part alone) and have been unsuccessful repairing it thus far. The tank is made of plastic and I have found someone who specializes in plastic welding (who knew this was a thing?), but he needs to know what exactly the tank is made out of before he can tell me if he can fix it. Ideally I have this answer before I remove it from the car, but haven't been able to get that answer. Wonder if anyone knows if this tank is high density polyethylene (HDPE) or polypropylene (PP) or a third substance and acronym I have never heard of. This is new knowledge domain to me, so please dumb down your answers like I was your kid (who knows everything, I'm sure).

 

Are you sure it's cracked and the leak isn't coming from the fuel pump?

 

Going by what my local Volvo-only specific shop mechanic is telling me, so I haven't witnessed first hand what the issue is. To quote him, "It is a different colored piece of plastic, round with a nipple that a vapor hose goes on. Not entirely sure where the fault is but our smoke is coming out from the area." He did some sort of smoke test in the tank and indicates the problem is on top of the tank. He has tried to patch with epoxy, but failed. I figure he is 1000x more versed in diagnosing this than I am (been working on Volvos for 40 years). Can't imagine he would mistake this for a fuel pump issue.

 

Ah okay, just making sure. If what he is talking about is on the driver's side, then it can't be the fuel pump.

Sorry, I don't know what kind of plastic the tank is made out of.