You cannot repair a damaged polypropylene gas tank with epoxy or a plastic tank repair kit, because gasoline will quickly dissolve the epoxy and the leak will reappear. Polypropylene is a thermoplastic, which means that you can use heat to melt the plastic and create a permanent repair in the polypropylene gas tank. To heat the polypropylene, you need to use a specialized tool that has a controlled heat output. This reduces the chance that you will scorch the surface of the gas tank, which will result in an ineffective repair.

Step 1

Drain the gasoline from the polypropylene gas tank and remove the damaged polypropylene gas tank from the vehicle, per the vehicle’s repair manual, with the mechanic’s tool set.