Smelling fuel issue

[DWW]

Hope someone can help as I am out of options. After filling up the car there is a lingering smell of fuel in the whole cabin (fhc). I obviously checked around the tank and the entire well all bone dry no leeks or sips. The smell eventually lessens but still a hint until the next fill up. Is there anywhere else?

[Series1 Stu]

Hi Danny

Is the ventilation pipe from the tank to the filler box in position and in good condition?

Regards

[Heuer]

If that happens when you brim the tank it is either a leak from the fuel level sensor gasket or the fuel pump gasket. Try new gaskets and also replace the annealed copper washers on the screws - always fun to work on a full fuel tank with the lids off!. If you have a 'new' in tank fuel pump it may be the power cable seal which can leak. More info here: viewtopic.php?t=4855

In all instances - disconnect the battery!

[nichmoss]

I'd also check the big diameter pipe that joins the filler neck to the tank - there are two jubilees there. See the parts manual, plate 34 items 8 and 9.

Good luck, Chris

[caveman]

That’s where mine was from.

[DWW]

Thanks for your suggestion the two plausible options are most likely the breather pipe from the tank or the filler hose. since I am almost convinced the filler hose is ok. I never investigated the breather pipe, will check tomorrow as that seems to be the likely culprit.

[vee12eman]

Hi.
Another possibility is that the fuel level sensor (or any other item/plate/pump etc.) gasket were “sealed” with the wrong sealant, for example, blue hylomar, which is not impervious to fuel. It impregnates the cork gasket, which, in conjunction with the not suited sealant, then allows vapour past the joint. You have to replace the gasket as it is no good after being coated with hylomar etc.
There are suitable sealants, read the data sheets but use them sparingly if at all.
I cured my fuel smell by replacing the gasket. It also helps to key the joint, i.e. the mating surfaces of the tank and sensor (or whatever), removing all paint and carefully keying with medium to fine wet and dry. This helps stop the gasket from squeezing out of the joint. Try to avoid getting media in the tank of course.

Hope that helps, good luck.

[DWW]

Thanks, the top side of the tank is bone dry and no odour emits from it as far as I can ascertain, will check this if all else fails. I have a feeling that there is a problem with the breather pips as this only occurs when filling up. because of this I never filled up beyond half a tank which of course never helped the issue and the smell persisted.

[JerryL770]

Do you have the correct petrol cap?

Some need a vented cap with a visible hole in it. My S2 stank of fuel until the cap was replaced with one with the vent hole.

[DWW]

I have the cap with the hole in the middle. I managed to feel my way to the spout for the breather, the muppets who installed the tank missed out on that detail. I will need to install one. I need to know the length of pipe required, the internal diameter (preferably in mm) and most importantly where to rout it to. Since it can all be performed by feel only due to limited access any help will be greatly appreciated,

[DWW]

Happy to report that since I installed the missing breather hose , no more fuel odor in the cabin when filling up.

[RICHOT]

Good result