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Fuel Leakage while filling the Petrol-Tank

Discussion in 'Exteriors / Body' started by Navin talati, Aug 1, 2016.

  1. Navin talati

    Navin talati Timido

    Dear friends,

    My car is Fiat Palio 1.2 nv Petrol - 2004 dec.Model.

    For last TWO times, I have observed that the petrol is dripping (in substantial quantity) while filling the petrol at petrol pump. It gets poured on the floor. Some quantity is coming out and then onward there is no issue. I suspect that either Filler Hose is cracked/loosen or some other pipes-connection might be the culprit.

    I seek your guidance for resolving this issue with relevant pictures, literature, and appropriate information. How should I proceed to assess the problem and what may the possible causes?

    Thanking you all in anticipation.
  2. nkrishnap

    nkrishnap Staff Member Janitor

    Linea 1.3
    My Palio too is facing the same issue. Will be figuring it out soon and update the fix here.
  3. kedarbendre

    kedarbendre Esperto

    MH 12
    Petrol Leakage Problem in my S10 smiley-shit-happens.gif

    One day before going to HP drive I have changed the O ring on Fuel pump and Canister as well at Pandit Auto. They removed the petrol tank to check other problem and I think while refitting it they torn the rubber bushing in between petrol tank and fuel line, so there was continuous petrol leakage. I Rectified this problem in Chandigarh FIAT Authorized service Center (Speed FIAT). Kudos to Speed FIAT Team for rectifying and resolving the problem within an hour.

    You may need to remove the petrol tank and check the rubber gasket which is there at the opening of Petrol tank.

    Order this part from 99RPM and you will get rid of this problem.

    1 x Gasket Lower| 59062735| 46465357 Rs. 104
    prabhjot, Navin talati and PradeepM like this.
  4. Navin talati

    Navin talati Timido

    Dear friends,

    I thank you all very much for the responses submitted to this issue. It has guided me a lot and initiated to focus on the actual culprit/cause. I am now updating the issue “Fuel Leakage while filling the Petrol-Tank” and put forward the efforts I made.


    I removed the rear wheel and jacked up the car. From underneath the car, I observed very minutely for the places/locations from where the fuel (petrol/gasoline) may come out. Looked in detail about the symptoms for some fuel patches or dampness etc. Then also cleaned all pipes and lines and surfaces. Also removed a bottom cover on the fuel filler pipe/hose assembly and cleaned the surfaces. Nowhere fuel leakage symptoms were found. The concerned video is uploaded on Youtube () under title “Fiat Palio Filler Hose to Tank pipings” and also adding pics titled as 1-Checking of all the pipings


    Then I opened the connection assembly of fuel pump which is located under the rear seat. Folded the rear seat and opened a lid having 6 screws. Around the upper fiber surface of the sending unit (fuel pump) some patches of liquid spreadings were found. Though it was not wet ! I am adding pics titled as 2-Initial Observation around Fuel pump


    I also poured couple of liters of petrol to filler pipe/hose through fuel filling bunk with some expectation to find leakage somewhere. But nothing happened. The fuel went into the fuel tank.


    In order to conclusively establish the location of the leakage, I am left with no option but to physically observeall the suspected leakage areas while filling the petrol in the tank to the full at a petrol pump / gas station.

    Obviously the prime areas under observation were

    (a) Underneath the rear part of the car

    (b) Sending unit’s upper surface (on the fuel tank under the rear seat).

    Naturally an assistant was essential to take sharp observation with a camera. Single person can not focus simultaneously to all around while filling petrol. Finally I did it.


    Resultantly, as the tank became full, the petrol overflowing observed. The excess fuel was found coming out profusely from the fuel pump’s / sending unit’s connection’s round part.

    The video is uploaded on youtube () under title “Fiat Palio Fuel Tank Leakage found”. I am adding the pics titled as 3-Fuel leakage location on sending unit.

    (I cherished this moment despite fuel wastage ! ! ! …).

    So ultimately the leaking location could be identified. Now, I need your advise and guidance for the following:

    (a). Is this issue repairable? How?

    (b). Should this culprit require the replacement of the whole fuel pump? If this is the essential solution, then it may dig a big hole in my pocket!

    Please GUIDE and oblige.

    Navin Talati / 21-08-2016

    1-Checking of all the pipings.jpg

    2-Initial Observation of Fuel pump.jpg

    3-Fuel leakage location on sending unit.jpg

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