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#576624 - 15/05/19 09:30 AM New fuel leak
Bunny Offline

Talk Morgan Regular

Registered: 15/03/14
Posts: 759
Loc: Leicestershire, UK
Yesterday, after filling up with fuel, there was a noticable whiff of petrol while driving along. There followed a forensic inspection of all the usual places leaks may occur: hoses around injectors; hoses behind engine; hoses on fuel tank link pipe; fuel tank brackets; etc. In the end, I noticed signs of fuel weeping from where the filler pipe meets the left hand fuel tank. It appears that the weld has cracked where it meets the tank.



In retrospect, this is not too surprising because we know that the tanks move up and down and we also know that aluminium is fairly brittle and doesn't flex too well.

My plan is to seal the area with fuel compatible PU sealant but I couldn't help wondering if a flexible section of pipe in the region shown might have prevented the problem in the first place.

My car has covered just over 10,000 miles. It's possible that the crack may have been there for some time and I've only just noticed it. I did give the car a particularly generous fuel fill on this occasion!



Edited by Bunny (15/05/19 09:35 AM)
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#576637 - 15/05/19 11:46 AM Re: New fuel leak [Re: Bunny]
Phil Bleazey Offline

Learner Plates Off!

Registered: 06/04/15
Posts: 286
Loc: Lancaster
Seems to be another case of the convenience of " just weld it all together" being overpowered by the reality of needing less stress on the welds. Yes, your flexible connection near the tank will do the trick - good luck.
Phil
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2013 M3W www.bleazey.co.uk - Builder of upgrade kits for the Centa coupling and BB mounts for M3W

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#576641 - 15/05/19 12:12 PM Re: New fuel leak [Re: Bunny]
PaulR Offline
Just Getting Started

Registered: 01/10/16
Posts: 81
Loc: Nr Haverhill UK
Hi
Looks like bad weld penetration at that start and stop point,
maybe grounds for a no charge replacement
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2016 M3W

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#576644 - 15/05/19 12:30 PM Re: New fuel leak [Re: PaulR]
LightSpeed Online   content
Learner Plates Off!

Registered: 18/02/19
Posts: 425
Loc: Port Orchard Washington, USA
Originally Posted By PaulR
Hi
Looks like bad weld penetration at that start and stop point,
maybe grounds for a no charge replacement


+1 for the very poor weld. I too think it should be replaced for free.

Your idea of adding a flexible section seems reasonable, but why not just replace the entire metal tube with a flex tube?
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M3W, "Make it so Number One".

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#576653 - 15/05/19 01:25 PM Re: New fuel leak [Re: Bunny]
Dan_Lockwood Offline
Talk Morgan Regular

Registered: 23/01/14
Posts: 918
Loc: O'Fallon, Missouri USA
Just a word to the wise, it takes a special rubber tube for petrol/gas. Using radiator type hose will not last long for petrol.

So just make sure you purchase the correct hose and you should be good to go.
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#576654 - 15/05/19 01:29 PM Re: New fuel leak [Re: Bunny]
LightSpeed Online   content
Learner Plates Off!

Registered: 18/02/19
Posts: 425
Loc: Port Orchard Washington, USA
MiniCooper has twin tanks and a long path from the cap to the tank. Worth checking out.
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M3W, "Make it so Number One".

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#576688 - 15/05/19 05:53 PM Re: New fuel leak [Re: Bunny]
Bunny Offline

Talk Morgan Regular

Registered: 15/03/14
Posts: 759
Loc: Leicestershire, UK
Thanks for everyone's thoughts on this. If the car was under warranty then the tank may have been replaced f.o.c., however at seven years old (and with the benefit of past experience) I don't even think it's worth asking! What worries me is that, as far as we know, they are still fitting the same design of fuel tanks to new cars, design faults & all.

Oh, and remember to double check the tension of your fuel tank webbing straps folks! If you can move the rear of the tanks up and down by hand the straps are too loose. soapbox


Edited by Bunny (15/05/19 05:58 PM)
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#576690 - 15/05/19 06:03 PM Re: New fuel leak [Re: Bunny]
rcmatt Offline
Learner Plates Off!

Registered: 05/02/19
Posts: 351
Loc: New River Valley, VA
It sure looks like a poor weld. But I agree with everyone. A short pipe and then flex hose would have been better.... of course then I remember I have occasionally filled to the tip top of the piping pantsdown
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2018 M3W
2004 Plus 8 (wife's)
Lots of old Goldwings and a couple of Harleys
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