Fuel Pump Installation Trouble...

[aliciaford]

We just installed a new fuel pump in our 94 Q45. Everything went smoothly, however, every time I drive it I smell fuel. Obviously something is wrong. Yesterday I thought it was just fumes, but today, I rolled down the windows, ect to air it out, ran to town and it reeks. We sucessfully installed one in our 1990 a few months ago, followed the same directions, ect and this time not so great. Ideas on what went wrong???

[elwesso]

did you replace the O-ring?

[goody90q45]

Assuming the smell wasn't there before you changed the FP and it's coming from the rear deck, then it can only be one of three things:

- One of the two metal inlet/outlet tubes was not tightened correctly, or- The oring slipped out of its groove in the gas tank opening (most likely), or- One or more of the attach bolts is over tightened and stripped.

Remove all the bolts (8?) holding in the float/FP assembly and recheck the o-ring. Were any bolts loose/stripped? Was the (new) oring in its groove? I use 1/8" wide x 3/4" long vinyl tape strips spaced about 1" apart to hold the oring in place while the assembly is bolted to the fuel tank opening. You shouldn't have to remove the rear seat to check this. Access will be from the trunk.

[aliciaford]

I think the O ring is out of place, will check it out... just out of curiosity, why is the O ring so big? I know its the right one, but it sure seems like it would fit in the smaller circle...am I making sense? Just wondering.... I think its a curse, because I sold my 1990 Q last night. I almost cried... I loved that car but I love my $100 car so much more. ha ha.. Thanks guys, we will check the O ring and bolts in the am.

[Infinitiguy19]

Personally I would have sold the 1994 Q45.

Make sure your using the new gasket, the new on will fit perfectly in the grove. Where as the old one you would have to really work to get it in the grove.

[goody90q45]

I think the O ring is out of place, will check it out... just out of curiosity, why is the O ring so big? .....

Some materials swell when exposed to fuel and vapors. The FP oring holds in place well when it's bolted down but once removed it's swelled and needs to be replaced.

[elwesso]

when the O ring is brand new it fits in the groove perfectly, then expands to provide a good seal.

[aliciaford]

The O ring had moved out of place when we tightened it....Thanks.

[Q451990]

I'm glad it was something simple. If the fuel smell is still bothering you, go buy a bag of charcoal (for grilling) - the regular stuff, not the match light type. Toss it in the trunk or back seat for a few days. It should absorb the fuel smell quite nicely.

Heath

[Infinitiguy19]

I know from experice that once she gets the seal back in place the fuel will evaprate and take the smell with it. Or maybe I got less sensitive to fuel smells after driving around for so long with my previous Q like that.

[elwesso]

in my experience as long as you keep everything well ventilated you wont have any problems with fuel smell..

[aliciaford]

More Trouble! Ok, so we reseated the Oring, its brand new, OE and everything is fine. Then, I fill up, uh oh, I smell gas.... its freakin leaking. By the time I drive home from the gas station, fuel is all over in the trunk. . So, upon further inspection, 4 of the 6 bolts look slightly stripped. So, off to the parts store I go...new bolts, no problem, right? Its still freakin leaking....I am so frustrated. What the heck???? This is easy, we have done it before with not a problem what so ever, what went wrong this time? The only thing I can think of is to get OE bolts, the only reason I didnt was the 5-7 day wait.

[Infinitiguy19]

You need a new fuel tank, no easy way around it.

Unless your crazy enough to have someone weld a new neck on the tank, But that's a whole different crazy and laziness for me.

[aliciaford]

Why a new tank? It never leaked before I put a new pump in it...

[Infinitiguy19]

I have some spare screws in the 10LBS+ bag of Q45 screws,bolts and nuts from ONE 1991 Q45 that I parted out, If you want I can find them and send you some.

But I am fairly sure that you will need a new tank. None of that Autozone, Pepboys...Stuff will work in this case because the fuel will eat away at it.

[Q45denver]

Usually the bolts strip before the female treads in the tank so new bolts should work. Just be sure to tighten them evenly and lightly. If the tanks threads are stripped you could probably get by with some short sheet metal screws as their torque is only a few foot lbs.

[aliciaford]

Ok, I hate to beat a dead dog, but I swear, new OE gasket, new screws, ect. Everything seems correct, and this is the second time we have done this to a Q45 (the '90 last month). Is there a possiblility that there is a pressure issue? It seems like the pump is building too much pressure...

PS. The fuel tank threads are not stripped...

[Q45tech]

How much liquid gasoline is lying under the tank in the well?Put someone you don't like in the trunk with an explosion proof flashlight then drive around until they find it..............no cell phones.

I would check underhood first for leaks. Did you break/crack the various returns and vents for tank, filler pipe..........see FSM.

[hiQ45]

I believe you need a new O ring. Wes is absolutely correct. I got a new fuel pump and O ring from IOS. Took me a couple tries to get the O ring to seat. By that time, the O ring had expanded to 1/2" too large, never got it to seat properly. Did the unthinkable, cut out 1/2" out of the O ring, reinstalled with fuel proof sealer, just until I could get a new O ring.

[aliciaford]

Ok. Problem solved. One bolt was stripped and we replaced it with a bolt from Napa which was the same size mm, then a new OE gasket but it still leaked. Just needed a fresh set of eyes to look at it I guess... The napa bolt was a hair too long and the screw was bottoming out on the inside of the tank and it wasnt completely tight. Replaced the screw with a shorter one, no leak. Thanks for everyones help.... If I had it to do over again, I would have ordered the pump, six new OE screws and the new OE gasket BEFORE I started the installation. Thanks again, what a difference in the performance of the car!