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gas coming out of vent under rub rail

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gelsby

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I have a 1995 gtx. new to me last year. previous owner rebuilt engine and it ran great last summer. I read on here about gray fuel lines so I replaced them. Then I found out about fuel tank recall and got the dealer to install a new tank under warranty and finish hooking up my new lines. Got it home yesterday and today there was gas all over the driveway. It is leaking out of the vent under the rub rail. tank is only 1/4 full. when I open the gas cap, air rushes out. But instead of air coming out of the vent under the rubrail gas is coming out. I checked all the gas line connections and they are hooked up correctly. This never happened once before the line and gas tank change.
Now here is the strange part. When I took apart the old lines I labelled them all. The return line was connected to vent nipple on the baffle and the vent line was connected to the return nipple on the baffle. So when I hooked it up I changed them to the proper places. It worked under the wrong configuraton and leaks when hooked up according to the labels. Is my baffle messed up? Could the previous owner have changed baffles and put in the wrong baffle? Or could he have somehow messed the vent vs return workings on the inside of the baffle?
 
Make sure all your lines are hooked up correctly. Also there's a check valve in the vent line, it may be installed backwards or not operating.

Lou
 
THanks Lou. I double checked all the lines last night and traced them to each connection. They are correct. The valves all worked fine two weeks ago before the changes were made. And the pressure release valve seems to be working. There is pressure in the tank - only the pressure release valve is releasing gas instead of air. How can the gas be getting in the line? I read on other threads where the pressure release valve doesn't work and it ends up forcing gas out the air intake vent - but I haven't found anyone who has had mu problem yet.
 
The check valve under the rub rail is designed to let off tank pressure at 1.5 PSI. (Like a pop off valve).

The check valve (vent) to help hold pressure in the tank is a one way valve. It lets air in the tank as gas is consumed but does not let air out...to help hold a small amount of air pressure in the tank to help feed the carbs.

These 2 check valves are NOT the same.

Double check your hose routing. I'm having to do the exact same thing right now with a '96 XP 800.
 
Sorry....

Lou responded before me.

Something's amiss as it worked fine until you changed the lines.

I've double checked myself many times to find out I .....missed something.
 
if you filled the tank full to the top when it was cold out, the fuel could have possibly expanded up to the vent tube level in the baffle, and is pushing fuel out the vent. i've even seen it in gas cans filled on a warm day and left in the sun.
 
Yeah, but he said it was only 1/4 tank full. If it's not your lines mixed up something has to be wrong with those check valves.

Sent from my SAMSUNG-SGH-I337 using Tapatalk
 
Is it possible when they primed the fuel system at the dealership after the new tank install that somehow they forced gas up into the vent line and it is just finding its way out? I can't see how there would be gas in the vent line. I just called the dealership and they also stated they are absolutely sure the lines are hooked up correctly. They took it out and water tested it and it ran perfectly. They said bring it in and they will figure it out - but I would rather fix it myself if it - especially if it ends up being an issue i have to pay for.
 
I really need help. I ordered new pressure relief valve and intake check valve for my vent llines. To stop this leak i took everything off at the t connector of the vent line and put a quart sized container under the line in case it dripped. Figured it should vent fine till the parts came in. What a mistake! while i was at work the vent line somehow siphoned gas out of the tank, overfilled the container and dumped about a gallon of gas in the bottom of my hull. THe tank was close to empty. How is gas pressurized enough to come out the vent line when the line had no valve on the end. It should only be vapours coming out not gas.
If i blow in the vent line i hear bubbles. That does't make sense either. I an definately connected to the vent nipple on the baffle. Please help me this is driving me crazy!
 
if you have bubbles in the tank when you blow into the line, the only thing i can think is that the pressure in the tank has pushed fuel all the way up the baffle to the vent opening, which doesn't seem very likely. if you open the gas cap, is there a lot of pressure in the tank?
 
yes- lots of pressure hardly any gas. that is why i blew in the vent line to get all the gas out. My guess is with the bubbles its that it is just pushing the air out of the screeen at the bottom of the baffle which is the bottom of the tank where the gas is
 
Dude...sorry man but you MUST have crossed up some lines SOMEWHERE when you did the change from the Tempo. Look at the logic. It worked fine before, now it doesn't. Re-trace everything again from the baffle to the tank to the selector. The ONLY thing different is you changed fuel lines out, right? Ergo, that is where the mistake is.
Sometime 2 + 2 = 5 and you have to go back to the beginning.
 
bajaman123 said:
Dude...sorry man but you MUST have crossed up some lines SOMEWHERE when you did the change from the Tempo. Look at the logic. It worked fine before, now it doesn't. Re-trace everything again from the baffle to the tank to the selector. The ONLY thing different is you changed fuel lines out, right? Ergo, that is where the mistake is.
Sometime 2 + 2 = 5 and you have to go back to the beginning.
Click to expand...
+1 on this..
 
You will have to remove the four lines from the tank's fuel baffle top and read the top ring that is marked on ... res... vent... ret (return) then reattach the lines with zip ties to the fuel baffle top.

I usually draw on the tank with a marker a circle with four dots inside, and two short wire locations, for noteing the orientation of the baffle.

Note that the vent is a single line that branches, so that it operates as in-breath and out-breath, as noted in post #4. The two check valves are the same, face opposite directions. Up by steering is the
in-breather location, out is under rub rail.

Bills86e
 
Thanks guys. I appreciate the advice but I have checked it all three times. I have everything labelled and followed it through from baffle to switch to filter to carbs and read the labels on each. What is wierd though is when i originally took out my old gray lines the VENT was connected to the RET (return) on the baffle and the RETURN was connected to the vent. Everything worked fine then. gas never came out of the vents ever and the machine ran fine. Now I have a new tank ,new switch, new gas lines, new fuel filter, new float in the baffle and they are all hooked up according to the labels on each piece. absolutely beyond any doubts. and now the gas is coming out of the vent . I am thinking i should reverse the vent and return so it is like it used to be. I know it sounds wierd but it worked before. I read in two other threads that peoples said they had the return and vent lines reversed on their baffles too and didnt know why but it worked. Could there have been a problem with the old baffles
 
Are you SURE than you haven't mistaken 'RES' for 'RET' on how your lines are hooked up? It is an easy mistake to make.
 
Guess what? I fixed it! I switched the vent line and put it on the return nipple, and I put the return line on the vent nipple. This is how it was before I started taking out the gray tempo lines. It never ever vented gas out the vent lines before.
So with those lines reversed, it stopped venting gas. Now it is venting vapours like it is supposed to!

So the baffle is either mislabelled at the nipples, or something funky is happening inside and the chamber created by the circuit board is airtight and creating its own siphon to get fuel to the top of the baffle when the tank is almost empty. Could there be an airhole in there that is plugged?
 
I'd be interested to see inside that baffle. Pretty sure they are mislabeled, the way that sounds. Very odd.
 
Aren't the vent and return on the 95 GTX 1/4" and the other two 5/16" ... just asking since mine are but it's a different ski.
 
gelsby said:
Guess what? I fixed it! I switched the vent line and put it on the return nipple, and I put the return line on the vent nipple. This is how it was before I started taking out the gray tempo lines. It never ever vented gas out the vent lines before.
So with those lines reversed, it stopped venting gas. Now it is venting vapours like it is supposed to!

So the baffle is either mislabelled at the nipples, or something funky is happening inside and the chamber created by the circuit board is airtight and creating its own siphon to get fuel to the top of the baffle when the tank is almost empty. Could there be an airhole in there that is plugged?
Click to expand...

And there you go! Sometimes you just have to use logic, i.e., "What did I do different than what it was before it had this problem?". As Sherlock Holmes said, "

"How often have I said to you that when you have eliminated the impossible, whatever remains, however improbable, must be the truth?"

Sherlock Holmes Quote

-The Sign of Four
 
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