My 2004 Armada is leaking gas when the engine is on or ignition is on with the engine off. With engine cold, i turn key to on (one step before starting) and about 20 seconds later, fuel begins dripping from the bottom of the tank. The pump runs constantly and the drip rate is about 1 drip/sec. The fuel is clearly coming somewhere from the top of the tank as it runs down the side and pools at the lowest point before dripping.

My thoughts are a leak directly on top of the pump/lid assembly at the 90 bend. Anyone else run into this? Or, would there be a pressure sensor that would tell the pump to shut off when a certain pressure is reached in the line and perhaps that sensor is failing? Or does the pump run constantly and unused fuel is returned to the tank?

I was going to proceed tonite to gain access to the fuel tank via the interior access door. Any help, suggestions or gotchas anyone could offer on that chore would be great.

Thanks,
Daryl

Sorry to hear about your gas leak, it sounds rather significant. I don't know of this problem at all yet, have you spoke to a tech at the dealer yet?

Tools required:
14mm socket (deep and shallow)
Large/Regular phillips screwdrivers
Small flathead screwdriver
Putty knife

Remove driver's seat and the seat directly behind it. Be careful to disconnect wiring from driver's seat before lifting out. Remove any tabs and Bose subwoofer from underneath driver seat (if applicable). Remove rear bench seat (6 bolts total).

Carefully pull carpet out from underneath interior plastic molding along doors and doors midpost. I removed the threshold covers but i don't know if this is required. Peel carpet back against rear center console exposing floor access panel. Quarter turn three plastic tabs to remove access panel exposing top of fuel tank.

On mine, the high pressure side (outgoing to engine) fuel line had loosened and backed off almost completely from the output nipple on the pump side. I simply pushed the line back on and secured it to the other line with a couple of zip ties. I used a paint brush and soapy water to wash off all the fuel residue and poured an entire bucket of soapy water over the top to wash away most of the fuel.

Use putty knife to push carpet back under molding while reassembling.

Best of luck.
d