Fuel Leak Found.... Pics inside

[Kraut.Burner]

Hi there guys, I posted a thread about a really strong fuel smell that was coming from the inside of the cabin. A few responses led me to search under my back seat. Well, looks like I've found the problem; Gas seems to be leaking from one of the hoses.

So, here is the initial damage after taking off the tank covers, nothing too concerning:


But, after closer inspection, the puddle can be found:


But, unlike the other common leaking situations. The leak isn't originating from the two hoses that are clamped in the center of the fuel pump? Its coming from this crimped Blue/Black hose in the upper corner. Every time I give it a flick, gas can be seen dripping out.


another shot:


So, that seems to be the problem on the top side. But I always look around for other relating problems, and I came across some more gas leaking from the bottom of the fuel sending lines that run across the bottom of the car....

Side shot (drivers side looking towards pass.):


another


another

last one:


So my main question would be where should I start. Im really hesitant to take apart the upper hose because its Crimped. Does anyone have any experience with this problem.

Any help is much appreciated

[LockDots84]

If it's crimped you really can't take it apart unless you have new crimps and a crimp tool for the new hose. I'd take it off and bring it to a machine shop or autoparts store with a shop and have them make you new hoses.

[Kraut.Burner]

bump.... anyone know how I might be able to fix the crimped wire?

[E36 For Life]

Get one from the dealer, don't play games when it comes to fuel leaks.

[jijacob]

You could probably jbweld that mofo that would work for at least a little while till you figure out what to do.

[Kraut.Burner]

^ thanks for the idea. Looks like I'll be trying this out

[E36 For Life]

Do not use jb weld. They make a gas tank repair, but that is for an area that is not under high pressure (on a hot day maybe only 1 or 2 psi). There is only one repair for fuel leaks replacement with oem or better. I have never seen any car come from the factory with jb weld patches and to answer your next question, yes I have used jb weld for repairs before, but only in my high school days and it never lasted long.

[E3625i]

I might have the same problem...

[E36 For Life]

In your post you said all your lines look good.

[110reef]

By the looks of it I would replace it all. Looks like someone previously "rigged" it up and now you are stuck with the results...

[Kraut.Burner]

Originally Posted by E36 For Life

Do not use jb weld. They make a gas tank repair, but that is for an area that is not under high pressure (on a hot day maybe only 1 or 2 psi). There is only one repair for fuel leaks replacement with oem or better. I have never seen any car come from the factory with jb weld patches and to answer your next question, yes I have used jb weld for repairs before, but only in my high school days and it never lasted long.

where might I be able to pick this up?

[Meatball546]

I hate those crimps BMW uses on their hoses....

Anyway, when I had a leak in my power steering hoses running from the reservoir, I initially wanted to tighten down the clamps, but I found they were those crimps. So, I cut them off (it was a bitch to do) and replaced them with normal hose clamps. You could also use a T-clamp. I'd recommend replacing your crimps with real adjustable clamps.

[Kraut.Burner]

Originally Posted by 110reef

By the looks of it I would replace it all. Looks like someone previously "rigged" it up and now you are stuck with the results...

How do you figure? you must be seeing something I dont... Please elaborate

Originally Posted by Meatball546

I hate those crimps BMW uses on their hoses....

Anyway, when I had a leak in my power steering hoses running from the reservoir, I initially wanted to tighten down the clamps, but I found they were those crimps. So, I cut them off (it was a bitch to do) and replaced them with normal hose clamps. You could also use a T-clamp. I'd recommend replacing your crimps with real adjustable clamps.

This ^ might just be the way to go.... Looks like I have another winter project ahead of me

[Meatball546]

If the hoses are cracked or damaged, then you'll probably have to replace them too. I'd definitely go with the hose clamp upgrade.

[jijacob]

Originally Posted by E36 For Life

Do not use jb weld. They make a gas tank repair, but that is for an area that is not under high pressure (on a hot day maybe only 1 or 2 psi). There is only one repair for fuel leaks replacement with oem or better. I have never seen any car come from the factory with jb weld patches and to answer your next question, yes I have used jb weld for repairs before, but only in my high school days and it never lasted long.

I've never seen a car come from the factory 15 years old, either. JB weld works great on radiator holes, which are under more than just 2psi also. Considering the area of the leak, I would be surprised if jb weld didn't solve the problem at least temporarily until he found a replacement part somewhere. And if they have a specific gas tank repair kit, even better!

[E36 For Life]

[QUOTE=jijacob;17839779] JB weld works great on radiator holes

My bad I thought it was a fuel leak.

[Kraut.Burner]

Originally Posted by E36 For Life

My bad I thought it was a fuel leak.

it is a fuel leak

[jijacob]

Originally Posted by E36 For Life

My bad I thought it was a fuel leak.

[darkislight]

Be very cautious with gas leaks. Do repairs outside away from the house with a fire extiguisher nearby.

As you can see from this thread the mechanic simply wanted to tighten a line but static from his body started a nice fire. He was burnt on his hands and arms.

http://www.bmwquebec.ca/forum/showthread.php?t=4529

[Kraut.Burner]

^

[epmedia]

That first blue line attached to the rubber does not look proper - may have slipped out abit?
If the blue lines are cracked, or leaking - need to replace them.
If it's just the coupling leaking on the other blue line - should be able to get new orings?
I'm not sure what your lines connect to - but don't even bother with JB Wels on pressurized plastic fuel components, may only last a day, and be worse afterwards.
Some fuel filter kits come with orings for those couplings too. Not sure about yours though.
Robert

[Kraut.Burner]

Alright guys, reviving this thread for a progress update. Im happy to say that everything's fixed and working the way it should be. No more gas leak, no more fumes in the cabin.

I found out that the crimped tube was part of the line that can be seen here on the far left (underneath car):


It was also routed to the fuel sending unit on the right side of the tank. Thankfully, both ends were attached by screw type clamps, and were easy to remove. This also allowed me to go out to kragen and buy one solid piece of 180psi rated fuel hose (about 2-3ft). I just routed the hose from the fuel sending unit on the right, to where it connected to the fuel rails underneath the car on the left, and bingo!

I have no idea why BMW used the crimped style hose that seemed extremely prone to cracking

Anyways, problem solved for about $20

[Meatball546]

Good job!

[95325i5sp]

Originally Posted by epmedia

That first blue line attached to the rubber does not look proper - may have slipped out abit?
If the blue lines are cracked, or leaking - need to replace them.
If it's just the coupling leaking on the other blue line - should be able to get new orings?
I'm not sure what your lines connect to - but don't even bother with JB Wels on pressurized plastic fuel components, may only last a day, and be worse afterwards.
Some fuel filter kits come with orings for those couplings too. Not sure about yours though.
Robert

to clear it up for anyone searching and finding this thread- the blue line is the vacuum source for the EVAP system, it carries no fuel. it comes from a valve under the intake boot in the engine bay.

[Kraut.Burner]

Originally Posted by 95325i5sp

to clear it up for anyone searching and finding this thread- the blue line is the vacuum source for the EVAP system, it carries no fuel. it comes from a valve under the intake boot in the engine bay.

What? If you're talking about the blue line that runs into the crimped tube, you're nuts. When I removed the other side of the line that connected to the right side of the tank, fuel came shooting out under pressure.

The line was constructed in this order:
Black Tube-Crimp-Blue tube-crimp-Black Tube

the blue tube was used i guess for fitment space between the tanks. But I had no trouble fitting a single fuel hose through the middle on top of the tanks