Diesel leak from full tank
 

Hi all,

I've discovered that my 2004 Rover 75 CDTI is leaking fuel when it has a full tank. It leaks rapidly initially from where the tank is, but also stops fairly quickly so I'm assuming nothing to do with the tank itself, but rather the pipework leading into it. I've only just noticed it doing it for the first time, but there's a slightly suspicious patch on the driveway which suggests it might have been doing it for a short while.

Obviously this is far from ideal, even without current fuel prices. Is there anything obvious I should be investigating in the first instance?

Follow up question of is there a specialist anyone can recommend in the Warwickshire area?

Thanks all!

Probably one of the tank module seals has failed. Start with the offside as that one is the first usually to be disturbed as the ITP sits on that side. Lift the rear seat base, and then the cover over the module and then unscrew the retaining ring. Check the seal is fitted the correct way round and that it is fitted into the tank before the module is lowered in. If you fit the seal to the module and then fit them into the tank that can lead to a leak.

Hi,

Have a look at my experiences and suggestions here:

https://the75andztclub.co.uk/forum/s...d.php?t=288191

Some of the photos seem to have vanished :shrug: :mad:

Post #11 was the culprit for me.

Good luck

Another vote for a badly fitted tank port seal.
Most DIY mechanics can easily fit a new tank seal. There are several HowTos covering it. The last section of this one describes how to fit a new port seal: https://the75andztclub.co.uk/forum/s...ead.php?t=9108
TC

Thanks all for the helpful replies, looks like the port seal is a likely culprit then. Is there a likely reason for it to have been disturbed in the first place? I'm fairly sure nobody's been near there while the car has been in my ownership, and I'd be surprised if it had been leaking that badly for as long as I've owned it!

Unfortunately it's going to be a process of elimination.

Is it possible that someone's fitted a new in tank pump (ITP)?

I found mine because I tend to do brim to brim fill ups.

With a bit of luck once you get the back seat out and the plastic cover removed you'll be able to see what's been going on.

Good Luck.


PS. As for a specialist, get along to a Nano meeting. There you'll meet a top flight specialist - Arctic :}

http://www.midlandsnanomeets.co.uk/

Had this once once on my tourer after working on the pump module. I hadn't tightened up the locking ring enough. I've also seen on a Freelander the same issue when at work. The garage that had replaced the pump didn't have a clue how to fit the seal and when the owner brimmed it , the fuel was pouring out.
To fit them properly you lift the pump, place the seal into the edge of the opening of the tank, push the pump down pushing the seal against the edge then fit the locking ring.

- and ensure it's the right way up. The seals are handed (top/bottom) and the original BMW branded ones are marked 'This side Down'. There's also a recess on the upper edge to accomodate a positioning tongue on the pump flange. This ensures the float arm is clear.
TC
EDIT: There's a recess in the tank port collar. That's the white plastic ring onto which the seal is fitted before lowering the pump (or filter) module onto it.

I recently read a thread describing how difficult it was to remove the plastic collar. I think that's because it isn't meant to be moved. If you take that off, you may lose the positioning index for the pump/filter module. That will likely cause float interference from all the other in-tank gubbins.

Thanks all for the replies, I'll try and investigate a bit more this weekend if times allows, although the car's due a trip to a garage soon so it might be something I get dealt with then.

I still haven't managed to resolve this - I've had both module seals replaced and I've checked them again and it all looks dry around them. It's still only leaking when absolutely full, and it doesn't obviously look like it's coming from one side or the other - both sides of the tank look damp when looking from underneath. Is there anything else obvious to look at? Ideally I want to avoid having to have the tank dropped!