Fuel leak between tank and filler - suggestions?

[jim290s]

Hi all, I used a UV leak detection kit this eve as my TVR has been stinking of fuel since I bought it at the start of summer. Turns out the leak appears to be at the top of the tank, where the fuel filler pipe meets the tank. The flexible tube appears to have been replaced at some point, and seems in good condition, but the seal between it and the tank obviously isn't working. Apart from cranking up the jubilee clips as far as they will go, are there any other tips to fix a leak in this area?

I'm imagining a fuel system equivalent to PTFE tape that you could wrap around the top of the tank neck before clamping on the flexi pipe? Anyone else had this issue or found a good fix?

[phillpot]

jim290s said:

The flexible tube appears to have been replaced at some point, and seems in good condition

Is it the correct diameter pipe, should be two and a quarter inch?


ETA, a look at your photo seems to show ....1/4 so it probably is?

If yes, I'd take it off, ensure tank neck is clean (no rust, old paint etc.) and refit. The neck is about inch and a half long so plenty of room for two good quality "Jubilee" type clips.

Various sealants, potions and pastes exist but they shouldn't be necessary, imho.

Edited by phillpot on Wednesday 1st October 20:55

[Elfit]

Yes you'll have to take it off but that ain't easy.
I know because I had to refit mine when I took the tank out. I put the tank in without fitting tube at same time.......
I'll know next time.

Hopefully it will be a split hose or badly fitting jubilee
If there's a hairline crack in tank it'll be more difficult to fix

Best of luck.

Tim

[S2Andy]

Are you sure the smell is coming from that joint? Some years ago my car stank of petrol. After much investigation I found that the metal filler tube was wrongly fitted and did not butt up to the filler cap but those 2 bits were fitted either side of the fibreglass skin of the wing. They should be joined up with a gasket. A bit left field but may be worth a check. Once sorted no more smell. Andy

[jim290s]

Thanks Tim and Phil for the suggestions. I'll bear both in mind when I take it all apart. I'm guessing i'll have to totally drop the tank out to inspect the tubes properly?

S2Andy said:

Are you sure the smell is coming from that joint? Some years ago my car stank of petrol. After much investigation I found that the metal filler tube was wrongly fitted and did not butt up to the filler cap but those 2 bits were fitted either side of the fibreglass skin of the wing. They should be joined up with a gasket. A bit left field but may be worth a check. Once sorted no more smell. Andy

Andy, see a photo of the join below. I think you could be right, as there is a gap where the tube does not butt up to the filler cap.
On closer inspection, the fuel is leaking both out of this gap (and onto the outside of the tube and therefore inside of the boot) but also around where the tube meets the tank as in the previous pic. I think there might be a couple of things to sort out. Extra jubilee clips required I think...

[phillpot]

jim290s said:

Thanks Tim and Mike for the suggestions. I'll bear both in mind when I take it all apart. I'm guessing i'll have to totally drop the tank out to inspect the tubes properly?

Can you not remove the cap/filler neck from the bodywork to get the hose off rather than drop the tank?

[S2Andy]

Jim

Suggest you work from the top by taking the filler cap off first and then work down to the tank. There is also an overflow pipe in the filler neck which is also worth checking out. The photo of the filler cap doesn't look right. There should be an absolutely positive seal at this point. You shouldn't need to drop the tank. Andy

[greymrj]

I would agree, try to sort it from the top first but you might still find it difficult. There are two separate flexible pipes for the filler, with an angled section of steel pipe in between. So 4 jubilee clips. There is also a sealing piece like a large grommet where the pipe passes through the fibreglass above the tank. The lowest jubilee clip is below this seal and it can get badly corroded. Yours may have been replaced recently. It is possible that the person who fitted the new pipes found it very hard to get the lower jubilee clip in place and took the short cut of fitting it above the seal. Lift the seal out and then get the flexible pipe right down butted to the tank, the bottom jubilee clip (which would best be stainless) then needs to be fitted so the adjusting nut is accessible from under the fibreglass, from the front side of the tank. Get that one in right first. Then put the seal in place. Then get the angled section, put the top hose well down on it, put it in and turn it until you get the best alignment to the filler neck. Certainly the pic on yours suggests very bad alignment. The filler neck on mine had rusted and had a pin hole in it causing a slight weep. I had a nice new one made in stainless!
Hope you can understand all that. As you will have gathered I have recently had the whole lot out.

Ohh, when you are putting the actual filler cap on, do get it the right way round.......... 2 quesses which silly b....r had to take it off again! (get it wrong and it will foul the paintwork when opened!)