Help guys, my 4.0 P38 (97 model) has just developed a strong smell of petrol evey time I use it (outside the car) it runs fine and does book mpg and have looked and can see no leaks - but the smell is very strong outside the car particularly near the filler cap area.
I'm stumped been underneath and can see no problems.
Having it gas converted so need to get it sorted first - just don't want to pay dealership prices (can't afford it really).

Hi,

Had the same problem on my 1998 model. Wasnt until I had to do rear brake pipes which ment taking the tank out and found the inlet and outlet pipes had corroded through on the fuel pump unit. Thats were the leak was. So had to put a new fuel pump unit in.

To top it all of the fuel pump fitted is faulty and its playing havoc with my fuel gauge and MPG calculations. When I get a spare day I will be changing it again.

all good fun though.

B.

P38 Owner said:

Hi,

Had the same problem on my 1998 model. Wasnt until I had to do rear brake pipes which ment taking the tank out and found the inlet and outlet pipes had corroded through on the fuel pump unit. Thats were the leak was. So had to put a new fuel pump unit in.

To top it all of the fuel pump fitted is faulty and its playing havoc with my fuel gauge and MPG calculations. When I get a spare day I will be changing it again.

all good fun though.

B.

Click to expand...

Thanks for that - gutted now though - Is it much of a job to take the tank out - it does sound favourite because it only seems to smell when the engine has run which would seem to logically point to the pressurised fuel line. Hoping it's not much of a job - regardless I still love this motor - even though I know I'm going to have no end of problems it's a sheer joy to drive.

Don

Hi Don.
Don't worry, your not on your own, i have to change my fuel pump too, so i'm looking into it. I had to change one on my classic once one friday afternoon. I filled up at the local garage, daydreaming of a weekend of Welsh watersports and offroading and was rudely awakened by the gentle sound of draining fuel landing on the forecourt. My friend picked up a fuel tank and i fitted it that afternoon and still managed a barbie with friends, all be it with the faint aroma of BP's finest.
I am going to have alook under the car tomorrow, but if p38owner has already done it, his info would great.

Cheers, Nick.

Hi All

Heres your lesson for the day. How to change your fuel pump in a few easy steps.

The first tool you are going to need is a 4 or 2 post ramp. You need to get the vehicle up in the air or you are going to struggle like bugary with out. Also make sure ther is next to no fuel in the tank.

Remove the RH rear wheel, and take out the wheel arch mud shield. You should now be able to get to the hose fittings for both the fuel filler hose and fual tank breather. The next thing to undo is the fuel pipes both flow and return. I found it easier to undo the unions on the filter housing next to air tank. on the inside chassis face. What ever you do, do not tern the ignition one!!. If you do you will pump fuel every were. As a safety measure I pulled the fuze for the fuel pump to stop this from happening.
If you look at the tank you will see it is mounted in a cradle. from memory there are three bolts at the rear and two at the front. The middle bolt on the rear is a jacking bolt used to lower the tank and cradle. if you remove the mounting bolts and lower the tank using the jacking bolt. You should be able to put your hand through on top of the tank and disconect the multiplug on the top of the fuel pump unit. Once disconected you can remove the tank and cradle down out of the vehicle.

To remove the fuel pump unit. undo the unions holding the fuel pipes onto the pump. Undo the read threaded collar which holds the pump in and remove pump. As easy as that.

When I fitted my new pump unit, I also purchased the two fuel hoses from the pump to the filter housing and a new rubber sealing gasket as these dont come with the pumps. I also put a new filler and breather hose on to the tank as mine were perished. When you fit the fuel tank breather pipe back onto the pump, dont push it on all the way on, as you find as I did that the pipe will not reach the plastic breather fitting on the fuel filler neck.

Hope you find this of some us. There may be some little diffrances as It was a while ago and my memory isnt that good. Still will be doing it again in the next week or so to fit yet another pump. At least all my bolts and fittings wont be siezed as I copperslipped everything.

Will be intersted to see how you get on.

Bryan

Thanks so much for taking the time to help Brian.

I will let you know how I get on (still got 3/4 tank at the minute but that doesn't last long does it?)

Hi there.
That info is just brill. I will definately let you know how i got on.

Cheers, Nick.

Hi chaps,
been out of town for a while - the update on the petrol smell is:

New petrol pipes (2) new petrol pump and sender unit.

Cost: £325

The pump unit was in a terrible state and I wonder how the car worked at all, the pipes were badly corroded also.

The plus side - the rest of the underneath looks to be in very good condition, thanks to everyone who advised on this topic.

Don

Bit late here but I had the same problem with my '89. Turned out the steel fuel line from the pump to the filter was rubbing on the frame. It eventually rubbed through and sprayed gas all over the top of the tank and running down all over. All quite dramatic, specially driving 40 miles to Seattle to have the line changed at British Auto Center. The problem was I had just filled up and didn't have anywhere to store 15 or 20 gallons of gas while I dropped the tank myself to investigate. They replaced the line and filter, cost was $400 'murican dollars so what, 200 quid? there abouts...

Hi all.
Have not got the time to change pump so have booked it in for next fri, 320 pounds and should sort the low fuel pressure fault and one hundred and forty two faults recorded, is that a record?
Bless it it still tried to run.

Cheers, Nick.