Fuel leak (or, this can't be good)

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14 years 6 months ago #7818 by Avid928
Discovered my '83 928S dripping gas from under the tank. (Glad the exhaust routes well to the other side!) Leak is most noticeable (obviously...) just after parking, and seems to stop after several minutes. Started to pull the tank cover the other day but quickly realized I was getting into more of a mess than I had time for. I see from maintenance records the previous owner had the fuel pump replaced three times over about ten years and 50K miles. Seems unusual to me. Any educated guesses where the leak is before I dig in again, or tips on removing the tank cover without dropping the whole tank?

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14 years 6 months ago #7819 by 928mac
Hi Avid928, whats your name, you should put it and your car in your sig for future referance to repairs.

So lets localize where the leak is coming from, at the tank to nipple hose, or at the pump to tank hose, or at the pump to filter hose.

I chased mine for a while and found it was leaking at the electrical terminals to the intank pump. If yours is the same I have a fix for that also.
If you have a compressor and a air line to blow it off, it will help see the exact place it is leaking. Take a picture and post it of the area and we will take it from there.

Brad

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14 years 6 months ago #7821 by the flying scotsman
The fuel output is from the tank to the pump then up to the filter then to the engine bay. The return fuel line is at the top of the tank where the fuel level sensor wires are.

Given the fuel pump has been changed too many times id start there. theres a metal S line that goes from the pump to the filter that has banjo bolts with copper sealing washers as theres a pressure valve.....see pic:

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14 years 6 months ago #7822 by Avid928
Thanks to both Brad and Malcolm for your quick replies. My name is Brian, sorry I didn't include that. Been a 928oc member for close to a year but this is the first time I've tried to post anything, or even check the forums much for that matter, so new to the etiquette. Car is an '83 928S, one previous owner, a trusted friend who left me with pretty complete records, at least back about fifteen years.

The gas tank cover has a hole in about the middle, a drain I presume, and that's where I see an actual drip for a few minutes after shutting her down. It's a bit wet a few inches around that. I started to remove the cover a few days ago, but realized the whole tank (which I had filled not long ago) was coming down with it. I was running out of time, so pushed it back up and thought I'd try to get educated a bit before proceeding further, thus my post.

The shop manual says, when replacing the fuel filter, to "Take cover off of fuel tank at bottom" but it doesn't mention the whole tank will come down on you as a result. It appears to be in two pieces, so maybe I started with the wrong half (front). I do have a compressor, so will be able to clean things up once I get it uncovered.

Hopefully just a loose clamp or something, given the strange frequency of fuel pump replacements in the past, or is that something of an Achilles heel on this otherwise amazing ride?

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14 years 6 months ago #7823 by the flying scotsman
first, glad to see you posting here and more important 'DONT DRIVE THE CAR'

not sure what is meant by removing the cover?

to confuse matters more some 928s were fitted with a intank pump as well as the regular external pump. If you look closely at the pic you can see the routing of all lines near the pump and filter. Post a pic if you can.

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14 years 6 months ago #7824 by Avid928
Thanks again, Malcolm. I'll have to wait for my girlfriend to get home to post a pic. I'm pretty techno-ignorant. She's the computer wiz. The cover I'm referring to is a big, maybe two-piece, plate under the gas tank, with four arms extending upward to bolt the whole thing in place. From what I can gather from the shop manual, if I'm successful in removing it I'll find the fuel pump and filter nestled within next to, and under, the tank. Just didn't get that far yet. Seems you ought to be able to access the filter and pump without dropping the whole tank on yourself, so I must have been doing something wrong. Appreciate any help!

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