Gushing Gasoline...

[Threehz]

So I've smelt fuel around my car randomly for some time, months ago upon investigating the fuel inspection area there was bubbling of the paint around the fuel pump but it was dry. I suspected it was the o-ring but didn't get around to changing it.

Right now we go out to my car to go to the grocery store and my girlfriend sees this on the passenger side...



Fuel dripping out, then it began to leak fast...

So I immediately get a glass, and rip out the back seat cushion. Remove inspection lid to find this...



It's continuing to leak right now. I'm guessing that it is just from pressure? I don't see why it would be coming up through there otherwise.

Anyhow, anyone know the specific O-ring that this needs or suggestions?

Otherwise tomorrow I'm going to pull the pump and just find a matching o-ring at Ace.

At least I know where it is now.

[DREWHALL]

Don't just get any o ring. Gasoline is nasty stuff and will eat up a lot of rubbers/plastics in a pretty short amount of time. 16111744369 looks like it is the P/N for the large o ring on realoem, but going off the picture that may not be the only thing leaking.

[Threehz]

Thanks man! It's weird though, knowing the part it's supposed to measure 58.8x4.2 mm as in Diameter x Thickness.

When I first got the car, under the rear seat bottom I found a large O-ring just tossed aside down there. I kept it because it seemed that it could be important. I just went and measured it and the thickness is spot on, the diameter is within a millimeter or so as well.

I'm wondering what happened, if the fuel pump was replaced and they didn't replace the o-ring?

Do you think some of the components connecting on top are leaking as well?

[Threehz]

Alright..

All four nuts on my fuel pump sender are stripped or something??

They all just spin it place, I've tried applying pressure from underneath so they can catch (the screws all have full thread) but it didn't work. I have tried pulling up while screwing and still no help...

I cannot get them off. Any ideas?

I thought maybe I can just take the whole unit out and it is totally free and loose now but I can't pull it free because the sender is in the way.

Is there any way to pull the entire pump out with sender still attached?

Any idea for the nuts on the sender unit? I don't see how all four are stripped and stripped to the point where they are stuck in place, am I missing something?

Any help would be appreciated, thanks.

[Kershaw]

shoot i wish you were local, i'd come out and help you. you wont get the assembly out with the sender still in unless you break something.

the braided line looks like it's leaking. i'd cut off a half inch and put a hose clamp on it. usually it's just the end that is destroyed.

in fact, i'd go so far to say as that's the reason for the spillage. gas coming out through the o-ring when you're parked..... ahhh it just doesnt add up. my guess is that a fuel return line is leaking. im not actually sure what that braided line is though....

clean it up. dry it. put some paper towels down. start the car and run it for a bit. see where it actually leaks out of it.

[b*saint]

Yea I agree with Kershaw. You have to have the car in operational mode and cleaned up to see the leak.

[Threehz]

Well I'm going to permatex the seal where the fuel pump goes in, along with the o-ring. I'm going to check into that woven line as well. Another thing was, while the system was under pressure, I touched the hose that is on the right side, and not slide all the way onto the metal tube, it literally squirted fuel... I put it all the way on and tightened it down well.

I'll give it a shot and see if it continues to leak after all that.

Thanks for the help guys.

[jlevie]

Alright..

All four nuts on my fuel pump sender are stripped or something??

They all just spin it place, I've tried applying pressure from underneath so they can catch (the screws all have full thread) but it didn't work. I have tried pulling up while screwing and still no help...

That and the loose o-ring sounds like a previous repair gone bad. The nuts were probably over tightened and the threads stripped. So that pump housing is probably trash. You'll have to cut the nuts off to get the sensor out and then get the pump out. Because of the gas and danger of fire, use a hacksaw blade and not an abrasive wheel.

Based on the picture, I'd say the o-ring under the pump is bad or that the locking ring that is a part of the pump housing has partially or fully separated. There could be a slight leak at the braided hose, but the bubbled paint looks more like a leak at the pump.

[Threehz]

Well the o-ring that was there was pretty thrashed, it's removed now, I'm going to try and work everything out right now.

[AndrewBird]

Someone correct me if I'm wrong, but doesn't the entire fuel pump/sender turn like a quarter turn, then just come out as one whole unit? I haven't pulled one out in a while and couldn't remember.

[dnguyen1963]

The whole unit should come out. You have to stick your finger in there to push the fuel line in to get enough clearance to get the pump out. Be very careful with the sender unit if it is the arm-type. There is no hindrance with the tube-type sender.

[jlevie]

Someone correct me if I'm wrong, but doesn't the entire fuel pump/sender turn like a quarter turn, then just come out as one whole unit? I haven't pulled one out in a while and couldn't remember.

Close, the sender has to come out first. Then a quarter turn of the pump flange will unlock the pump and allow it to be lifted out.

[Threehz]

Yeah I tried taking it all out in every possible way, but the sender unit must be removed first.

So. Permatex around the fuel pump and where it goes into the tank, with an o-ring as well, and it appeared sealed and fine.

I let it sit a while and then a couple hours later I reparked it in front of my house to wash her (traveled maybe a total of 200 feet...) Gasoline was gushing out more than more.

I can say that none of the hoses appear to be leaking, and it is definitely the seal between the tank and pump.

I have some putty that is made for this type of purpose so tonight or tomorrow I'm going to clean and try this.

It's strange because the Permatex specifically said it is resistant to gasoline, yet the Permatex washed right away as the gas poured out...

So much gas, I have a headache...

[DaveSmed]

The only thing thats gonna work and hold up over any amount of time is the o-ring.

New is best of course, but used is even preferable to trying to seal it any other way. Lube the o-ring up with a bit of grease to prevent pinching it when you install.

[Threehz]

well I've got sealing puddy that is supposed to be good up to 1000psi, extreme heat, and gasoline. I'm going to try that tomorrow.

The O-ring would be great but I have to cut the nuts to free my sender unit, this would've been an easy job if all four weren't impossible to remove.