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Fuel leak

Discussion in 'T3 & T4 Tech Help Clinic' started by jsmiller, May 10, 2020.

  1. jsmiller

    jsmiller Active Member

    Messages:
    352
    Location:
    Adelaide
    Well much to my frustration after filling up yesterday it started pissing fuel out everywhere! During all my recent work on it I had the fuel tank out and changed everything! Every hose every seal every vent tube everything!! This was the third fill up sense it’s been back on the road and had no leaks before but now its leaking! Again.
    As far as I can tell the only place it could be coming from is where the sender and float goes in?
    But now after I let it drip out (about half a litre) it’s fine? Pulled it back in the garage and it doesn’t even smell like petrol anymore?? Parked it on my very steep driveway and nothing? Can’t get it to leak now?!?
    Now having had the entire fuel system out and apart etc I didn’t see any other vent or anywhere where fuel could come out of if it was say overfilled?
    I really don’t want to pull that bloody fuel tank out again! Getting that back in was the hardest thing I’ve ever done on one of these vans! Absolute Nightmare!
    Any ideas folks?
     
  2. Grantus

    Grantus Well-Known Member

    Messages:
    17,101
    Location:
    Southern ACT
    When you say you changed everything, where did you source the parts to do this?

    My guess is the source of the leak, is in the elbow connectors to the breather tank crossover fuel pipe.

    Before you take out the tank, go and fill it up again, and check up and inside the wheel arches around the top of the those plastic tanks, to see if the leak starts there.
     
  3. jsmiller

    jsmiller Active Member

    Messages:
    352
    Location:
    Adelaide
    Those where the first thing I checked and they were all still in place and dry! So given that and where is was leaking I reckon it was from the gauge send or/float location.
     
  4. Dapom

    Dapom Well-Known Member

    Messages:
    745
    Location:
    Brisbane
    It’s possible that you have dislodged one of the tees or grommets that they pop into. If it won’t leak when parked on a slopes driveway then I would say it’s unlikely to be the sender and more likely to be something higher up the tank. It is possible to get an arm over the chassis rail to check the tees without dropping the tank. Does involve a small amount of skin loss on the forearms but that’s less painful than dropping the tank ;)
     
    David H likes this.
  5. Barry

    Barry Well-Known Member

    Messages:
    4,784
    Location:
    Abbotsford NSW
    I replaced my tank and it took 18 months before it started leaking.

    there is a whole process of bending tabs to get the sender to seal properly

    my mechanic ended up making a cork seal
    That was 2 years ago. all good since then.

    Why someone doesn’t make a kit that just screws down is beyond me.
    Why VW didn’t do that the first time is a bigger WTF??

    you should be able to take a pic from the rear of the tank.
    See if I can find a pic
     
  6. Barry

    Barry Well-Known Member

    Messages:
    4,784
    Location:
    Abbotsford NSW
    Ok can’t find a pic

    but if you get under neath and take a pic “up the valley” of the tank- if the wet Mark is wide, it’s from the sender

    if it’s thin, it’s one of the grommets
     
    Dapom likes this.
  7. Grantus

    Grantus Well-Known Member

    Messages:
    17,101
    Location:
    Southern ACT
    I still think that maybe one of these numbers, is playing “I’ve got a secret!”o_O
    upload_2020-5-10_22-56-34.png
     
    Syncro27 likes this.
  8. Wattie

    Wattie Well-Known Member

    Messages:
    1,124
    Location:
    Mildura. Victoria. Australia.
    The leak will be from the crummy white plastic T on the crossover pipe, the small vent tube take off can develop a hairline crack or part altogether, the broken pit can be held in place
    by the unyielding vent pipe so that visually they look ok.
     
    Syncro27 likes this.
  9. Barry

    Barry Well-Known Member

    Messages:
    4,784
    Location:
    Abbotsford NSW
    I put the aluminium ones in mine

    believe there use to be brass ones you could braze in
     
  10. jsmiller

    jsmiller Active Member

    Messages:
    352
    Location:
    Adelaide
    I’ve got brand new plastic T’s in and from what I can tell they are all in place and not leaking. Why I think it must be from the sender area which has a new O-ring. I don’t know if there enough room to get my arm up in there through the tunnel to check?
    But dang what a pain in the arse! Maybe I’ll just leave it for now and fill up to 90%
     
  11. Grantus

    Grantus Well-Known Member

    Messages:
    17,101
    Location:
    Southern ACT
    My brand new plastic T’s were so badly made, they lasted 10 days, whilst I waited for the aluminium ones to arrive from the US.
     
    Last edited: May 11, 2020
  12. Barry

    Barry Well-Known Member

    Messages:
    4,784
    Location:
    Abbotsford NSW
    you should be able to get under the van and take a pic by just holding your phone up and snapping away.

    that O ring can be a pain
     
  13. jsmiller

    jsmiller Active Member

    Messages:
    352
    Location:
    Adelaide
    I wish I’d got those ones! But they aren’t leaking yet :cool:.
     
  14. Syncro27

    Syncro27 Well-Known Member

    Messages:
    6,418
    Location:
    Terrigal, NSW Central Coast
    See if you can get an inspection camera and just lower the tank bout 20mm - should be able to get one of those cameras in and allow it to move around.

    Might need to get a Jerry can and fill the tank again so that it leaks a bit so show you where it is leaking from - fuel dries up quickly.

    At least you can find the culprit before you end up cuddling it again.
     
    jsmiller likes this.
  15. Barry

    Barry Well-Known Member

    Messages:
    4,784
    Location:
    Abbotsford NSW
    If you jack the front up and take off the front wheels you can shove your head in just behind the strut and you can see those suckers

    I did this yesterday while looking for a rattle
     
  16. JohnE

    JohnE New Member

    Messages:
    3
    Location:
    Williamstown vic
    I think my little gem was number 4 into 16 , I managed to get a zip clip onto it and stop the leak but the tank Will need to come out before I feel happy putting more than 30 litres in there. Only 90.000 kms on the clock and on it's second fuel tank. But I forgive it.
     
  17. Barry

    Barry Well-Known Member

    Messages:
    4,784
    Location:
    Abbotsford NSW
    dunno ...... but I am surprised liquid fuel goes up that high, even in slosh round
     
    JohnE likes this.
  18. JohnE

    JohnE New Member

    Messages:
    3
    Location:
    Williamstown vic
    l know I overfilled the tank on that occasion but was surprised how easy it was to dislodge that line.
     
  19. General Vee

    General Vee Member

    Messages:
    26
    Location:
    2500
    T3 fuel tank...what a @#$% fight. Has any one been able to simplify at all / remove those plastic bottles and hoses?
     
    JohnE likes this.
  20. Barry

    Barry Well-Known Member

    Messages:
    4,784
    Location:
    Abbotsford NSW
    You mean take them out or get rid of them?
     

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