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A friend here has an ’01 DII. The last couple times he’s gotten fuel there’s been a fuel spill under the truck.
In his words,
“The last two times filling up at Costco, I had gas running all over the place. As near as I can determine it is coming from the top of the fuel tank. It only happens when the tank is full. I heard what sounded like a belch and there was a huge puddle of gas under the car. First time it happened it was simultaneous with the auto shutoff.
The second time I did not wait for the auto shutoff. Filled the tank very slowly and just as I was finished it belched and there was a 7-foot puddle of gasoline under the car.”
I don't recall reading anything like this in my 15 years on this and other forums. My guess is the connection between the filler tube and the tank has failed such that fuel flow into the tank with no problem but leaks once the tank is full, but to me that doesn't explain the "belch" sound he describes. Any ideas?
He will need to get under truck and see where the spill is coming from, could be vent hose to the filler neck, could be evap hoses on top of tank. The other option is to remove or cut the carpet in the cargo hold and observe top of the tank.
not in my D2s but my classic has a blown/rotted vent hose that will leak upon filling all the way up..not overly difficult to fix but the replacement hose lasted all of 6 months or so which is pretty annoying. Going to just get my own hose next time I feel like replacing it.
Had a similar problem. The top of the fuel pump plastic flange had loads of cracks in it. Fuel pump metal flange needs to be replaced. I had intermittent evap codes.
My friend and I met at a gas station to try to find the source of the leak.
He replaced the fuel pump several weeks ago, so in addition to keeping an eye under the truck we pulled back the carpet and removed the fuel pump access panel. As the tank approached full, the leak became apparent.
The “moat” around the top of the fuel pump began filling with gasoline, indicating the fuel pump locking ring. He told me he didn’t replace the sealing ring that’s under the locking ring when he replaced the pump, so now he gets to disconnect the wiring and the fuel line to remove the locking ring and install a new sealing ring.
The electrical connectors are easy, but he said reconnecting the fuel line was a bit of a struggle he’s not looking forward to doing again. I took the pic after we’d mopped up the spilled gas. I wish I had taken it showing the fuel in the moat.
This doesn't explain the "belch" noise my friend described, but the leak is the same as zski128 described.
Fuel spill under the truck on Fillup
