Fuel Tank Leak

[Paul T]

My 2001 has a hole in the fuel tank about halfway up the unit in the rear. A mechanic told me that in order to effect a repair on the fuel tank (he says replacement) that the external "plastic nipples" that run to the fuel pump would be broken during removal and the fuel pump would have to be replaced as well.

I'm not so sure:

(1). Plastic Fittings on the Fuel Lines/ Sender ???

(2). I see products out there to effec tively patch the fuel tank without dropping it. Mechanic said it could NOT be pached. Didn't say why.

Any thoughts would be appreciated.

[wheelman1917]

The mechanic is covering his back side. You can run the fuel down below the leak clean it sand it Jb weld it. (Two part epoxy from Walmart) . Keep a fire Extinguisher handy. Do not make sparks.

[MT-2500]

How many miles on the fuel pump?
Is it a oem delphi pump?

The fuel pump line should come off and on with no problem if a person uses some caution.

Epoxy may just be a band aid repair.

Best to replace the tank and the fuel pump if high mileage on pump or a aftermarket pump.

Only replace with a delphi fuel pump.
After market pumps are junk.

[Paul T]

MT...Bought the truck with 60K miles and now has 93K. Never had a problem with fuel pump. Don't know mileage fuel pump or if OEM or after market but have a '98 Blazer that went hrough 4 pumps in 40K miles of use. Used Seafoam regularly on current 2001 Blazer and never had a problem w/F.P. or injectors, et al.

Yes it may be a band-aid but a tank and pump including labor must be close to $900 or more. That's a consideration for me.

[MT-2500]

Epoxy is getting better all of the time but on plastic tank it is a hit and miss.
Another tank is the best way to go on it.
And if pump is high mileage good time to replace it to.

Check around on a tank and good delphi fuel pump.
Delphi fuel pumps range 250-300$
Not sure on tank prices.

Maybe a good used fuel tank from salvage yard.

Good Luck

Good Luck

[Rick Norwood]

Originally Posted by Paul T

MT...Bought the truck with 60K miles and now has 93K. Never had a problem with fuel pump. Don't know mileage fuel pump or if OEM or after market but have a '98 Blazer that went hrough 4 pumps in 40K miles of use. Used Seafoam regularly on current 2001 Blazer and never had a problem w/F.P. or injectors, et al.

Yes it may be a band-aid but a tank and pump including labor must be close to $900 or more. That's a consideration for me.

Paul, I understand the expense, and the fact that it is a real factor in how we repair our vehicles. But PLEASE remember this. It is a Juryrig on the Fuel system, which is the last place I personally would want one. You certainly have the right to repair your truck anyway you like within your means, but at the end of the day, epoxy is a Juryrig fix and If the opportunity comes along to properly repair the tank, Please take some friendly advice and do it.

[Paul T]

Hello Rick,

Your advice is prudent. Yes, I would feel alot better if I did NOT RIG the fuel tank or any part of the fuel system. I'd always be worried.

Now if it were something else....Well...Shouldn't rig anything, really. I hate rigging unless I'm pitching a tent or it's a matter of survival. Neither applies here.

You have made me think and I have decided to replace the tank and fuel pump if necessary.

Good Advice and Good Job. You are obviously a man of wisdom and a great deal of experience.

Thanks, Paul

[mike2004tct]

Not to dis-agree with anybody here, but I would at least try the epoxy first.

Epoxy = $10.00, plus some time.
Fuel pump & tank = minimum $750.00. (Most mechanics will charge that or more for the pump alone)

If I read this correctly, your tank is plastic. If that's the case, it's electronically welded (I.E. melted). 2 part epoxy is some tough stuff.

I've broken those nipples on the fuel pump housing twice. I've replaced the pump on my '97 4 times. They're rather difficult to get at because of the short amount of slack in the lines. It's fine if you have real long, skinny arms (I don't), and dropping the tank too far causes the breakage. I might add this would not, should not happen if the guy is a professional mechanic.

[Rick Norwood]

Mike, your point is well made, but here are a few thoughts to consider. My own personal luck using some of these epoxy glues and adhesives is not good. For what ever reason, whether it is me, the "joint" preparation, the material that I am trying to fix, or just the product, most of these products just don't work for me. The joint may appear to hold initially, but breaks again sooner or later. That being said, knowing my luck and experience, I personally would not try to repair a fuel system with it unless it was a dire emergency, and even then, I would seek a permanent repair at a more opportune time. Maybe you have better luck with these products.

Now, here is a question for you, exactly what do the "Nipples" that break off do? Aren't they vent lines or vacuum lines? I am not trying to be stupid, I never broke one off. But I can't believe these nipples are on the main fuel line that deliver 60 lbs. of fuel to the injectors, so one might get lucky on an epoxy repair on a non-pressurized fitting. Paul states that his hole is in the main part of the tank, that would be subjected to a constant soak of gasoline. Paul does not say how the hole got there to begin with. If something punctured the tank, or if it is a crack or split, I don't know, but in my mind the tank is compromised and should be replaced.

The last thing I would want to live the rest of my life with is knowing that a catastrophic failure of a juryrigged repair that I made cost someone their life or injury. I don't mean to sound dramatic, but raw gasoline is dangerous and deserves due respect. In the end, Paul will need to decide how to fix his own truck.

[mike2004tct]

Rick;

I haven't epoxied a fuel tank in over 30 years, so I can't speak from recent experience, just my younger years/cheap car days. I'd still give it a try before investing the big $$ though.
Sooner or later, the tank will need to be replaced, and at that time I'd also go with a new fuel pump assembly.
My original thought is with the OP; This is a big exspense.

As for the "nipples", the pump assembly has 3 of them on the top of the pump housing. They snap off if you look at them the wrong way (not really, but this is my experience with them )

They are plastic elbow outlets that the feed, return, and vent tubes hook up to. They are molded into the top case of the pump assembly, thus they're not replaceable.
I've read in previous posts where someone broke one off, and tried to repair it (glue together, much like the tank repair ala JBWeld we're talking about here). The glue joint eventually failed.