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Cracked Fuel Tank Covers?

2.2K views 16 replies 7 participants last post by  Hong Kong  
#1 ·
I had the XC90 on a lift today while trying to figure out some exhaust work, and noticed that the fuel tank (black) on either side of the exhaust run had some cracking in the outer plastic cover/housing. The passenger side cover looks like it had developed a crack and a large portion of it is now missing (and another piece very loose), while the other side just had a break in the plastic. How difficult is it to replace the plastic housing itself, is it all one unit when sold as a fuel tank, and should I be worried about the tank itself, or do I have a decent amount of protection from the underside of the vehicle in addition to this thin plastic that I can see?

I purchased the vehicle used, and have not made any contact with road debris or curbs large enough to do any damage, that I can recall. The vehicle has been at the Volvo dealership multiple times for basic maintenance in the last year, and nothing was ever mentioned as needing to be replaced (and I'm sure they would have mentioned it if they could have made any money off of a replacement).

While I'm at it, the two thin lines that run alongside the driver side underneath the car (doesn't appear to be the fuel lines, but are they the brake lines?) appear to be missing one of the clips, so a line is loose and not tight up against the car. I'm trying to locate everything on http://www.volvopartswebstore.com/ but don't see either of the above items in the parts breakdown or exploded views.
 
#3 ·
Yes! Those are the droids err..clips I'm looking for. At first I thought they matched up with this retainer part HERE, but it doesn't appear to be the same item.
 
#6 ·
Brake line clip part mystery solved and remedied (30645058 / 9169146), now just for the fuel tank cover question. You guys are fast, thanks.
 
#10 ·
I started disassembly on the fuel tank of my posts car today. It seems as though the cover are adhered to the tank. Did not have enough time to get the whole tank out yet. I think it would not be worth the hassle to fix the cracked plastic. A lot of stuff would need to come out.

He is a diagram of the tank itself.

Image
 
#12 ·
Plastic.

And plastic covers that snap crack bellow tank don't worry place anything similar to protect if you can't find original parts that Gglevit placed codes.

Other fuel line and even big long plastic cover of fuel line attached to cover I lost of course when making 50 cm snorkeling with car in deep water ;)

I didn't use new clips as many fail by time but used sponge tape first around pipes than metal cable ties around in 8 and all is kept by metal washers pushed in original on body screw before keeping plastic clips.
Will try to find photos as I have many as allways. Not nice but 100% sure decade keep now fuel line in place.
 
#13 · (Edited)
So the actual fuel tank is 2 layers of plastic, with the main tank pretty robust, but the cover is thin and can crack?

PS: does anyone know the exact reason why the cover cracks?

Attached is a photo so ppl can see the cosmetic (or protective) cover cracks...

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Image
 
#14 ·
It's crack bcs is plastic, vibration of air here is very strong, heat of exhaust is dispersed as well weather by time and plastic is wellknown to snap soon if exposed to such a ways...
To not mention many small chirps rocks sand ext kicking this constantly while drive especially raining weather will bring a lot of dirt between external part exposed...I simply put black strong tape years forgot it...dont worry main tank dont have any issue even if this is broken. Nice from you to change...I supose it's glued to tank. I suggest if only crack use good black silicone for car windshield and seal all cracks if you can't find parts.
 
#15 ·
Especially if engine is running and exhaust is very hot after drive heat will add one drop to cracking for sure...this side near pipe is more broken to me ad well to you...
 
#17 ·
Yes my xc90 2006 in Europe have this crack but frankly speaking in few years. I think most of this is from heat of exhaust as it's flowing from bottom of engine exactly under the car and passing through this plastic. Maybe some aluminium plate well dumped with soft tiny sponge tape on tank will do better cooling as well. ;)
If you can't find original parts and change remove plastic if possible shape same aluminium plate and voila. Or use some plastic good plate few mm more fat... cut and fix.