Club 80-90 Forums

Hi all. Have an ongoing problem with the fuel tank that I could do with some help with. There are two issues which may or may not be connected.

1. Had a constant issue with the tank over-spilling for some time now. Tend to avoid this by not filling the tank fully but would like to resolve it!

2. Smell of fuel coming from the tank. This happens even if there has been no over-spill. Used to happen only when the tank was pretty full and would then disappear as the fuel lowered. Now it also happens when the tank is only a quarter full. The smell is only really noticeable and it's pretty strong) when driving with the windows down.

Have spent quite a bit trying to resolve this but without success and have had the following done so far:
- replaced fuel tank
- replaced breather pipes across the tank
- had existing breather pipes extended
- all seals checked

Not sure where else to go with but something clearly isn't right. Thanks for any advice you can give.

Change seals/grommets. You won’t be able to see it they are leaking. As long as it’s the right side pipe that all it can be


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Yes it will probably be all the seals. You could first try just replacing the filler tube grommet though as that can be done without removing the tank. Mine had split adn was causing the exact same problem. It could also be the other seals which are simple to replace but do require removing the tank.

This makes it leak!!

Thanks guys. Feel like I had the seals/grommets checked previously but perhaps I'm mistaken and need to revisit. I assumed the garage would check this whilst fitting the new tank - maybe they didn't. Everything else appears to be as it should be so agree this needs looking at again. Ta.

Oh the assumption there it is!!!!!


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Check vapour bottles for cracks. Or the fuel cap seal. Or the rubber collar where fuel filler fits through body panel.

Thanks. Someone else has mentioned possible cracks in vapour bottles. How easy are these to access? Can they be got at with the tank still in situ? Thanks

mariner wrote: ↑31 Aug 2022, 08:35 Thanks. Someone else has mentioned possible cracks in vapour bottles. How easy are these to access? Can they be got at with the tank still in situ? Thanks

Yes. One bolt next the the seatbelt bolt as you enter vehicle, under wheel arch lining.. Often a bit crusty, though...
Two lower pipes on container need careful disconnecting by twist and pull. Top vent hose (shrek ear) comes out with vapour container.