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Old 09-05-2009, 11:25 AM   #1
another broken syncro
 
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fuel leak at the fuel line disconnect

so i had my car up on a lift at a local shop checking my suspension out. i have the notoriuos progress sway clunk that wont go away so i was checking for anything loose. while i was walking under car towards the rear i noticed my gas tank was covered in gas. so i pulled out the inspection mirror and a flashlight to find that my fuel line coming out of my fuel pump is leaking from the quick disconnect. has anyone else had this problem. i immediately pulled the service cover off and tried replacing the o-ring in the line. after a new o-ring was installed it still leaks.

what should i do i dont really want to go buy a new fuel line from mazda its $80 and i dont have any extra money saved up right now because of school.

also my cars an 04 6spd with 82k on it.
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WTBRotary!: Why won't my car start?
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Old 09-05-2009, 11:32 AM   #2
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Get it fixed ASAP! Fuel leak=big boom or fire. Does the line connect fully? See if you can zip tie the line to the pump, it may stop the leak...olddragger had the same problem but on the opposite end, in the engine bay, and it leaned out his motor just enough and it blew up.
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Old 09-05-2009, 11:52 AM   #3
another broken syncro
 
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ive tried holding pressure on the line and it still drips a little ive called a few of my friends that work for mazda dealers and they have never seen this problem. the weird thing about it is that my car is still running its original fuel pump its never been messed with that i know of. also ive noticed the smell of fuel for a few months but i always thought it was just that i had spilled gas cuz i only noticed it after i filled up. im thinkin about cutting the quick disconnect off my fuel line and getting a piece of high pressure rubber hose and a couple good hose clamps on it and seel if that stops the leak.

yeah with how low my car is i scraped the ground often so that could cause a spark and then me and my car go boom
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Old 09-05-2009, 12:02 PM   #4
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Adding a high pressure line should fix the problem without having to replace the whole line itself. If you do that, make sure you use a small pipe cutter to avoid sparks and have extinguisher on the spot just to be safe.
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Old 09-05-2009, 12:07 PM   #5
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ive got a small extinguisher that sit on the floor in my back seat to begin with you never know when your rear bumper will catch on fire after a backfire lol.

ill have to find my pipe cutter or go buy a new one though i was going to use a very sharp pocket knife but the pipe cutter sounds a lot safer.

thanks so much for the help
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Old 09-05-2009, 12:10 PM   #6
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You can buy a small pipe cutter at Lowe's or HD. I have one good up to 5/8", didn't cost more than 10 bucks.
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Old 09-05-2009, 12:15 PM   #7
another broken syncro
 
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i work at autozone so ill just get one from work but i think i have one somewhere in one of my tool boxes. should i get a barbed fitting to put in the end of the plastic stock line or just get a rubber hose that fits over it snug?
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Old 09-05-2009, 12:24 PM   #8
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I'm not sure what would be best for that. You would think a barbed fitting there would restrict the fuel flow from the pump...I also think that line is actually aluminum, I think it has a plastic coating of some kind. I haven't messed with mine in a while so I can't be sure.

I think the rubber hose is the best quick fix option.
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Old 09-05-2009, 12:30 PM   #9
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well the rubber hose option is out i just got a text from a friend of mine that works at a local mazda stealership and he said that the fuel lines on our cars are made of plastic, and that if i cut the quick disconnect off i might run into problems with the plastic fuel line collapsing as i tighten the hose clamp down on it. my day keeps getting better and better.
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Old 09-05-2009, 03:02 PM   #10
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It's metal about 10" from the tank..you can use HP rubber fuel line and 2 hose clamps to fix it....

Just carefully trim back the plastic tube from the metal..and be careful not to notch the pipe...
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Old 09-05-2009, 03:10 PM   #11
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ok cool i got 18 inches of high pressure fuel injection hose. ill just cut that off and run new line all the way up to the fuel pump
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Old 09-05-2009, 04:19 PM   #12
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so after replacing the the fuel line quick connect i found out its actually the fuel pump nipple that is leaking so now i have to buy a new fuel pump
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Old 09-05-2009, 04:23 PM   #13
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Don't buy it from the dealer, you'll pay way too much. Check out a couple vendors here, try Mazmart, Paul always some good deals. I know he has a new and used '09 pump instock for a good price, it will only take a small amount of modding to fit it to an '04.
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Old 09-05-2009, 04:28 PM   #14
another broken syncro
 
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the problem is im goin out of town tomorrow and my 8 is the only car i have thats legal to drive right now.

but if i cant find it locally ill try to seal it with something and then order it from one of them
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Old 09-05-2009, 04:32 PM   #15
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Just to let you know, no dealership carries them in stock, they'll have to order it. And you can't get them at an autoparts store. See what you can do to seal it for now and hope it holds.
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Old 09-05-2009, 04:56 PM   #16
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thats what i found out now so im just gonna let it sit in my driveway and my dad agreed to let me borrow his truck until i get it fixed i just gotta keep gas in his truck which is no big deal it gets better mileage than the 8 does also i found out i can order it through work and its only 150 brand new
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Old 09-05-2009, 05:09 PM   #17
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Yeah, you can get an '04+ pump for that price. Mines been modded, I got mine from swoope here on the forum. He installed a 3rd Gen RX7 fuel filter on it for me, flows alot better and let me run a higher amount of 2 stroke oil without having to worry about it clogging up.

Good luck man, make sure you get the pump ring removal tool from the dealership...mine here let me borrow it for free. Made the removal and install a breeze. The universal tools seem to jack the ring up pretty bad.
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Old 09-05-2009, 05:38 PM   #18
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i was gonna call my friend at the local dealer and see if i can borrow his personal tool. im sure for a case of beer or something i can get him to come over and help me oout with installing the new one.

thanks again for all the help
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Old 09-05-2009, 05:41 PM   #19
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Yeah man, no prob. Takes less than 30 mins from start to finish. Have fun!
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Old 09-05-2009, 06:40 PM   #20
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so after replacing the the fuel line quick connect i found out its actually the fuel pump nipple that is leaking so now i have to buy a new fuel pump
samething happen to mine. i put them o clamps on the line where the nipple is with the o clamps you use a flat head screw driver to tighten them to the nipple. i went to autozone and got a vac line just largenugh to pull ovwer the stop ring at the front of the nipple. i used 2 clamps one right behind the ring one in front.
you can get the o clamps at autozone and homedepot.
worked for me.
dont tourq to hard the clamps will cut the hose.
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Old 09-05-2009, 06:43 PM   #21
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Apparently he had crack or leak in the fuel pump nipple itself. He's looking at buying a new pump now.
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Old 09-06-2009, 02:07 AM   #22
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Oh right.
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Old 09-07-2009, 07:32 PM   #23
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i guess it takes 2 days to figure out a temporary fix now, because while i was driving home from ordering my new fuel pump from work, i thought maybe i could take a piece of rubber fuel line and hose clamp it around the nipple where its leaking and it might be a temporary fix so i can drive to work while i wait on my new pump. so i just got home and did it and amazingly it doesnt leak now. heres a pic of what i ended up doing to the fuel line and the nipple to get it to temporarily stop leaking

Click the image to open in full size.

i had to slice one side open to wrap the hose around where it was leaking because it wouldnt stretch over the rib on the nipple, so i used the hose clamp and really torqued it down on the hose and no more leaks.
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Old 09-07-2009, 08:31 PM   #24
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Glad it worked for ya.
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Old 10-07-2010, 08:13 PM   #25
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Did you have to de-pressurize the system before removing the fuel line?
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Old 10-07-2010, 08:13 PM
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