Resolved Fuel Leak by Tank

[Tristan]

Long story short, there is a hose coming off the gas tank and into the filler neck. This is a vent hose and not the main fuel line. I wanted to write up the repair because I don't seem to see any other information online about it and know it can't be just me it's happening to.

I noticed a very faint fuel smell a few weeks back after filling my tank all the way up, and I never "top it off" after it clicks. I just fill it up till it clicks once and then go about my day.
Smell was faint and I didn't see any fuel actively leaking, smell never came back. No fuel was leaking onto the ground at any point... that I could see, because fuel evaporates so quickly.

Topped my car off again just a few days ago not even thinking about that smell, otherwise I probably wouldn't have done it to full, parked it at home, immediately see a big puddle of fuel! Of course it dries up very quickly, which only confirmed to me it was fuel.

The puddle was right under the vapor canister/tank area, but as you guys know the canister shouldn't necessarily have fuel running through it, only vapors...

Today I was able to get the car onto a lift at work, (questionable to even drive I know... everything was fine) and it took some time pin pointing the leak. We had to smoke test it to really confirm it was this hose. I removed the 2 10m bolts holding on the vapor canister to move it out of the way so I had more visual access on the three hoses coming out of the tank. Sure enough, there was a big crack in the vent hose from the tank into the filler neck assembly. I will show a diagram and the hose with the crack below.

Part number: 42-23X

Either way, I wanted to briefly explain the replacement process. I was able to replace the hose without dropping the tank at all, but just moving the vapor canister a little. It's a big unit, and couldn't come out completely, but it being loose but still in place was enough to fish some hands around to get the hose loose on both ends. I had to use one of the "remote" or "long reach" pliers, and a long pick to help pry the hose off once the clamp was loose. It's all very tight... but took me maybe 2.5 hours? Maybe a little less. And that includes cleaning all my crap up and setting it up in the first place. It has the crappy pinch clamps which I replaced with hose clamps.

Anyways, can't think of any other details now. Let me know if you have questions or need help identifying your fuel leak if you think it's this one.

 

[Awafrican]

Thanks for the write-up you got any pics of the underside where you replaced it?

 

[L337TurboZ]

Hey that's a good write up! Did fuel make it's way into the canister?

 

[Tristan]

Thanks for the write-up you got any pics of the underside where you replaced it?

Hello, thanks for reading it. Unfortunately I was too occupied during the process and forgot to take any pics at all. But I do have this picture from my exhaust install of the underside that can show a very rough representation of where the hose is located.

So there a red squiggly line that represents where the hose is above all the components you can see now.
The blue line is the crack where you have to move the canister to stick your hand in to gain access to either side of the hose.

Hey that's a good write up! Did fuel make it's way into the canister?

Thanks for reading! It did not! Fuel was leaking onto the canister for sure, so there was residue everywhere but the canister is self seemed to be functioning perfectly fine. Honestly the cracked line was a vent line so it's kind of odd that fuel was even in that, but it makes sense it only leaked when the tank was full. Besides its a fuel tank vent line going to the filler neck assembly and not going to the canister, there was another hose for that one. So long story short no fuel made it to the canister.

 

[cobra]

I know this is an old thread but I appreciate the insight on this! I’m going to attempt the repair in a little while after using some fuel. Once the fuel levels get low, the leaking should stop which confirms the issue and allows me to disassemble without gas everywhere. I’ve done a lot of research, so if you experienced this, please report at the below link so a recall investigation will be started… it’s very dangerous driving with fuel leaks.

https://www.nhtsa.gov/report-a-safety-problem

 

[Awafrican]

I highly doubt they're going to recall 10+ year old fuel lines considering they rot over time this isn't new. Heck they won't even recall the 11-13 drivers seat brackets which fail just like the 10 but they "fixed it" yet I've had mine replaced twice only because I had an extended warranty.

Certainly worth reporting but wouldn't hold my breath, then again never know if it doesn't get reported

 

[Mtnbker3531]

I highly doubt they're going to recall 10+ year old fuel lines considering they rot over time this isn't new. Heck they won't even recall the 11-13 drivers seat brackets which fail just like the 10 but they "fixed it" yet I've had mine replaced twice only because I had an extended warranty.

Certainly worth reporting but wouldn't hold my breath, then again never know if it doesn't get reported

Ahh the loose seat, my 13 has it also need to pull the seat out of the car and take a look at whatever the hell fails and fix it. From what I've gathered it's some spot welds/washers that fail?
Tried searching for some photos or a thread all I've come across is some references to how people have fixed it.

Sounds like a good excuse to buy another welder