Volvo AWD V70 Forum

Hello folks,

I recently did the dreaded AWD fuel pump job. It was a long haul, but I did get it done and it's working well. Described here: http://www.brickboard.com/AWD/volvo/1360913/V70/help_start.html

Unfortunately, when I was taking everything apart, the little plug for the fuel pump power/ground wires busted off (it must have been cracked/weak before) and so I drilled a hole in the top of the assembly (the part that plugs the tank up when installed) to thread my new power/ground wires in.

I have had a terrible time sealing this hole up!

The first time I used silicone because it was the best I had on hand. I figured it would last a couple of days until I got some real gas tank sealer stuff, but it didn't even last that long. It did buy me enough time to get to Canadian Tire and buy some Permatex gas tank repair epoxy.

But I have not been able to seal it up using this either. I tried both the 'stick' style where you mash the two parts of the stick together to form an epoxy paste/dough and mash that in to seal thing up.
http://www.permatex.com/products/Automotive/specialized_maintenance_repair/radiator_fuel_tank_repair/Permatex_Instant_Gas_Tank_Repair.htm
I think it sealed to the metal part but leaked around the wires.

I then tried another Permatex product that is more liquid - again an epoxy that you mix together, this time applied with a little brush.
http://www.permatex.com/products/Automotive/specialized_maintenance_repair/professional_repair_systems/Permatex_Fuel_Tank_Repair_Kit.htm
I had to apply it over top of the old stuff, which is now hard as a rock and bonded well to the metal. I was sure I had it this time, but I see it's still leaking a bit, though not as much.

I need some help!

Should I try to seal it again with more of this Permatex stuff (I have lots of the 'stick' stuff left)?

Should I stop right now and take it to a gas tank repair place? Will they be able to help me? Do they have better sealants than the Permatex epoxy stuff?

Has anyone ever done anything like this before?

Any other products/methods to look at?
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1998 V70 AWD Turbo 195k+