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WillK

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Discussion starter · #1 ·
Yeah... after I finished putting in my fuel pump, which I did with the back end up on ramps, I had my tank still tilted down when I test started the engine to make sure it ran ok before I bolted the tank in again (I was getting tired of dropping the tank, I had to do it a few times because when I put in a new fuel pump, first time I forgot the pump gasket, then I kinked a hose.)

At any rate, I figure that test run filled the pump reservoir. I went to the gas station and filled up, some gas leaked out and I figured I just didn't get the retaining ring tight enough on the pump. I drove home with my needle on full. The fillup didn't seem like it was more than the expected tank capacity.

During the drive home, I still had intermittent hesitation. Ok. Guess it's not a daily driver yet, I tell myself I'll deal with it later.

2 days later, I drive to the parts store to read trouble codes. Everything seems like typical stuff from the pump being disconnected (code from the fuel pump fuse being out when I ran to depressurize, fuel rail pressure code) but there was an ignition coil code. Cleared codes, started, no codes. Hmm..

Drove home and this is when I noticed the fuel gage on E. I tell myself 'must be a wiring problem, I just filled up'.

Nope, the gage was right, I ran out of gas. Half mile drive to parts store, my car was just on the other side of the light, otherwise I might've pushed it home (mostly downhill) for how close to home it was.

So, I walk home and use my truck to get a 2 gallong gas can worth of gas. I put it in the tank, the gas ends up on the ground.. I look to see where the leak is, and it looks like it's coming out of the entire perimeter of the gas tank!

So a little gas got in, but not enough to get the car to run well enough to drive. Pull the car home with a tow strap and that's another day wasted.

I guess I must have abusively supported the gas tank while reinstalling it or something. So, money is tight these days... I'm really tempted to get a $50 salvage yard tank instead of spending the $209 for a new OEM tank.
 
If it weren't for bad luck, you'd have no luck at all.

Scrapyard, yes. Save the $150+. You already have the pump, so just make sure to check the tank over carefully before you walk out with it. And throw some gas in and let it sit for a bit before you install it to make sure.

The only issue I've ever had with a tank was from running over a metal bar on the highway that jumped up and punctured it. Fixed it with plastic epoxy...still leak-free two years later. They engineer those things to be pretty sturdy--not sure how yours ended up leaking all over like that.
 
If you can I'd just fix it with steelstick or jb-quicksteel or plastic epoxy (so long as the epoxy is gas resistant)... if the hole is small enough... I don't know if I'd do more than a quarter sized hole... Much bigger I'd just fiberglass it... Or get anotherone...
 
Discussion starter · #4 ·
Well, I finally got the back end back up on ramps and stuck my head under, more gas leaked out towards the front... I tried watching for the leak and it was coming off the top, which made me go hmmm... Unless there's an antigravity field in the tank, this makes no sense to see gas come out of the top of an empty gas tank before the car was ever turned on yesterday. Seemed more like I had a puddle of gas on top of the gas tank.

So as it turns out, the smaller of the two hoses from the filler had become disconnected. I don't know why I'd be able to fill the gas tank, see the gage, drive it home abd the tank be empty a few days later. The attachment for the hose is at the top, I don't get it.

Well anyway, I'll put in a couple more gallons and see if it manages not to dump all over the place this time. At least it seems that I don't have to replace the tank.
 
Discussion starter · #5 ·
As it turns out, the problem remains. Upon attempting to put gas in through the filler, once again, it all ended up on the driveway - none of it apparently remaining in the gas tank - the gas having leaked from some location not visible at the top of the gas tank.
 
Discussion starter · #6 ·
Okay now that I dropped the tank, I found the real problems.

A) The "empty" tank was a result of a disconnected electrical connector to the fuel tank level sender, same connector as the fuel pump and the reason why the car would not start.

B) The leak was the result of gas leaking out of the top when I added gas to a full gas tank, and a leak path was available at an improperly seated fuel pump retaining ring.

I'll try to get it right myself hopefully before anyone responds, but if I have the ring on straight, is hand tight adequate? I tried tapping it tighter, but the fuel pump starts turning with the ring and the last time I did that I kinked a $45 hose.
 
Discussion starter · #7 ·
Okay... A month later, I found that I actually still have the problem. Gas will come out of somewhere i I fill the tank to full. And the check gas cap light stays on, plus there's an evap canister code. P0457.
 
Did you secure the EVAP hose when you put it all back together? Also I'd check the fuel filler neck to make sure there isn't any holes or that it is fitted properly.
 
Discussion starter · #9 ·
I was thinking it would probably be something like that... Of course, being that I had just filled up, I didn't want to go through the expense of dumping another 8 gallons of gas again, so I was waiting to use up gas. I just have to remember to drop the tank and check before I fill up again. And I figured out of the hoses, the filler is probably less likely because the gas seems to come off the top of the tank towards the front.
 
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