Leaking fuel tank fixed *pics*

[nickelmedia]

I bought this 240 about a week ago and smelled a little bit of gas on the way home. When I filled the tank, I noticed a few puddles of gas on the ground. So, today we decided to find the leak and stop it. I bought some JB Weld, expecting there to be a crack somewhere. Luckily there wasn't, but after removing the tank and holding it at different angles, we noticed it was leaking from the fuel pump surround.

The O-Ring is missing from where the pump rests on the tank. We could have replaced the whole thing without taking off the tank but oh well. Here's the solution we came up with.

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pull the fuel pump fuse. turn the car over a few cranks to release pressure from the lines.

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plugging the lines

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Outer ring measures 6 1/8"
Inner ring is 5 1/8"

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Makeshift gasket material since the nissan dealer had no o-ring.

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Compass the circles, cut with scissors.

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test fit

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draw screw holes

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leather tools to cut out the holes

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gasket sealer

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lining it up

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replace fuel pump


After all that I waited about 5 hours and filled the tank. No leaks, No smell! I have no idea how much the O-ring costs, but I know the gasket material was $2 and the sealer was older than me sitting in my dad's garage.

Problem solved and I'm happy :)

[klattr1]

good writeup man. very organized!

[tokes¹]

great work!

[HyperTek]

wow good idea or solution when a gasket is not availible, i woulda never thought of making my own.

[Demik]

awww i love write ups.. so cute.. ! nice work y0

[nickelmedia]

awww i love write ups.. so cute.. ! nice work y0

hehe.. I thought at the beginning it would be way more involved until I realized it was just making a gasket, so to make up for it, I took like 4 times as many pics as needed to make it look more involved :P