Fuel Tank Heat Weld Update (Long) and Other Question - Saab 9-5 Bulletin Board - Saabnet.com
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Fuel Tank Heat Weld Update (Long) and Other Question
Posted by K.Daehnke [Email] (more from K.Daehnke) on Mon, 8 Aug 2011 12:01:26
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So, a few finger burns and some molten HDPE plastice fumes later, and I think I have successfully corrected my 19999 9-5 fuel tank evaporative leak problem with a plastic welder kit. I thought it was the pedestal seam coming up out of the tank, but in prepping the area for heat welding, I noticed a crack in the top surface of the pedestal which ran into the molded receiving hole for the leak sensor and the crack also went down and when I carved into it, I could see it was through the bottom. I put the welding heated tip down into this crack and then added more weldd plastic to fill the area in at well as the stripped out screw hole. For extra measure, I added stainless steel screen reinforcement all around the pedestal and tank seam and melted new HDPE plastic over this. Finishing required filing off the excess and rounding the hole back out.
Hopefully this will do the trick, as my registration has not been renewed without passing emissions. I hope to pressure test the tank before hanging it back under the car. I've got PVC cap plugs for the big and small rubber fuel fill lines and will be making a round fiberglass plate with a schraeder valve in place of the fuel pump plate. I've got to also cap off temporily the quick disconnect vacuum line which usually pressurizes the tank. I also hope that this isn't a contributor to any vapor leak, since I can't yet see where there a sealing O-ring in this connector. Any advice?
Kirk D
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