Leak in Fuel/Gas Line!

[FishNinJay]

Just got my first FJ40.. runs and looks great. Just few issues..
There is a gradually worsening fuel line leak, which I have isolated to the
actual line from the main tank (under passenger seat) to the Aux fuel switch.

Here's the line going up towards the main tank.

I located the drip, and gently wiped the line. There is a small oval patch that
looks either burnt? or somehow weakened? The line does not touch the exhaust,
but does run nearby. Immediately after wiping off the line, gas seems to seep
thru the actual wall of the rubber hosing here (see 2nd pic below, close-up)

So it's really stinking up my garage, and even my house. I went to a local 24hr
autozone to see if there was a way to fix this without replacing the whole line right
now. The guy told me that probably wasn't a good idea. True? I was hoping I could
just get a bigger tube to place over like a sleeve and ring bracket down to seal the
leak, possibly temporarily. I'm not sure if the main-aux switch works, but if so, as a
last resort, I guess I could siphon out the gas from the main, and put it in the aux?
Any ideas on how I can quickly get this fixed? Thanks in advance for your expertise!!

Ok.. speaking of leaks. Here another one.. much tinier and probably no big deal.
Wondering if that is the speedo/odo cable. The speedo/odo does not work consistently,
but they do move, especially when idling. I'd really like to get this fixed, but have no
idea how big a job it might be.

 

[stuckinnz]

hey there for a quick fix I'd cut the rubber pipe at the leak and fit the 2 ends over a pice of quater inch steel pipe or find a $5 inline fuel filter and join them with that.
New rubber hose would be the way to go though. Good luck

 

[FishNinJay]

great ideas.. I was considering the inline fuel filter.. but concerned about how close it is to the exhaust. Is there some kind of heat shield wrap? The quarter-inch pipe sounds interesting too. I probably should just replace the entire line, but not sure how to get at it under the passenger seat at the main tank without removing the whole seat.

can I safely clamp this rubber fuel line? just on tank side of this leak? or both sides? Has like 3/4 tank full, and just don't want to have to siphon it all out!

again, thanks!

 

[Trollhole]

Pinch the line on both sides with some vise grips or a c clamp. the cut out the section to be replaced and install a section of fuel line and some barb fittings and hose clamps. Then when the gas runs almost out Remove that hose and replace the whole thing. Might want to think about using a steel line instead of all that tube. What ever you do use some fuel line mounting clamps and remove any play in that line.

And that hose going through the body needs to have some sort of grommet around it.

You can always siphon off the gas out of the tank and fix it right the first time.

 

[FishNinJay]

Pinch the line on both sides with some vise grips or a c clamp. the cut out the section to be replaced and install a section of fuel line and some barb fittings and hose clamps. Then when the gas runs almost out Remove that hose and replace the whole thing. Might want to think about using a steel line instead of all that tube. What ever you do use some fuel line mounting clamps and remove any play in that line.

And that hose going through the body needs to have some sort of grommet around it.

You can always siphon off the gas out of the tank and fix it right the first time.

where do you get those barb fittings?

I need to figure out how it's connected to the tank, above the point where the line goes through the body.

of course, I need to replace the whole line eventually .. so I should probably just siphon out that tank.. ugh..!

 

[SD_rdcruzer]

Couple of thoughts.
I would make sure to take the time and do the right thing. You have a very nice 40 and it would be a shame to repair things in a half-assed way, even if it is just a temp fix.

I'm no expert, but it appears from your pictures that the fuel line is very close to the exhaust. If you can reroute the line a little further back, there appears to be a step up in the tub and would give you some breathing room.



That said, if the fuel line is bad in one spot, it is suspect all the way through. I would hate to fix the line where it is leaking, take it out for a run and have it start leaking somewhere else, leaving you stranded or worse, start a fire.

As for the speedo cable leak, there are some O-rings inside the housing that can be replaced. That should take care of the leak.
Here is a thread on what to do.

 

[K2KK]

You can get the barb fittings/inline brass couplings at just about any plumbing, Ace, auto parts store. And as Trollhole suggested just pinch each side of the leak an inch or so back. Just cut out the bad and replace with some new fuel line. Insert the new couplings and secure with some hose clamps. That's about as temp as you can get it until you can change the whole line.
A leak in your fuel line can be dangerous and should be addressed now. You do not know when your line will change from a seaper to an actual hole and start dumping fuel. It can be dangerous and potentially fatal to your rig and you.

 

[fjnutter]

Like someone already mentioned, you need to address this problem ASAP.Fuel leaks are dangerous, especially when its near an exhaust system.Don't forget about why the leak occurred in the first place.You may fix the leak but did you fix the real problem.
Does the line look melted or does it look like it was rubbing against something.I wouldn't go with a quick cheesy fix.Address the real issue now .Either re-route the line,use a hard line in that section,maybe use stainless braided hose.Just some suggestions in no particular order.

 

[Devilmans Hand]

If you haven't already done so push your cruiser outside. You don't want gas vapor filling an enclosed area.
I had the same thing happen to me last New Years Eve...at about 16degreesF

 

[FishNinJay]

Pinch the line on both sides with some vise grips or a c clamp. the cut out the section to be replaced and install a section of fuel line and some barb fittings and hose clamps. Then when the gas runs almost out Remove that hose and replace the whole thing. Might want to think about using a steel line instead of all that tube. What ever you do use some fuel line mounting clamps and remove any play in that line.

And that hose going through the body needs to have some sort of grommet around it.

You can always siphon off the gas out of the tank and fix it right the first time.

*UPDATE, sorry no pics yet.. I'm at work *

I really wanted to fix this right, but was thwarted.

To get to the main tank under the passenger seat, I'm going to have to pull the bolted-down seat and somehow get to the spot where this fuel line goes up thru the tub. (any ez tips, cuz it looks like a major PITA). Anyways, more than I can handle on the small amount of time I had yesterday.

Nevertheless, I went to see about buying fuel line, and learned that there are several sizes. I decided to try and siphon off the main and put the gas into the aux to dry out this line, but there is some kind of gooseneck or something, and I couldn't get the tubing down into the tank. Failed.

I decided to go under and just clamp the line, but couldn't find anything that could fit in such a tight space. I ended up using a few spare surgical clamps I had from my job, that worked out great! I cut out the leaking segment, which was about 1.5 inch of tubing, and put in a small metal $3 inline filter which actually fit nice. This fixed the leak and got my wife off my back for now.

So, it's no longer leaking gas all over my wife's driveway for now. But, I'm not entirely comfortable driving it, with this inline filter patch job so close to my exhaust. For now, it's on injured reserve list on my driveway until I can get a better fix. So far, almost 12 hours and no signs of leak on the cardboard.

I don't know why this line was routed like this. This is the only area where the tub gets close to the exhaust. The line gently loops around and heads back towards the front where it joins the fuel switch. The inlet to the fuel switch is actually in line with the hole where this main line entered the tub, and there is more "breathing room" here (and further back by the aux tank). I want to just run the main line directly here, but I'll need some kind of right angle elbow off the fuel switch. Do they make that? I don't know if I can just use fuel line, because I think it will kink making this sharp turn.

My question, where can I get steel-braided fuel lines to replace this entire line and fix this right? I asked at the local autozone, and the guy didn't seem to know what it was, and didn't any in stock.

Sorry for the long post w/ no pics. I'll edit and post pics of my hack job, as well as the segment I cut out. There are diagonal scrapes, as if it rubbed against something? It was also right at the gentle bend, which was kind of close to the exhaust (but seems like at least 1.5 inches clearance away?). Could just be an area of weakness at the bend close to heat? Regardless, I don't trust the entire line now. May also change the other fuel lines too while I'm at it.

 

[K2KK]

Any decent plumbing shop will have the angle, style and size you need.
If the guy at the AutoZone didn't know what you were talking about go somewhere else. It is out there. Perhaps a high performance parts store will know. Not sure I would of put an inline filter there. That could be problematic depending on the condition of the inside of your tank...i.e. rust and other debris. If you are not changing the entire line give it a thorough visual inspection and actually run your hand on the line where you can to feel for any irregularities or thin spots, places that the line is rubbing and such. If there are places that do rub and the line is still good just wrap with a good tape to protect what you have...

K2