Major fuel leak around fuel pump after replacing fuel lines with stainless steel ones

I finished the install of my stainless steel fuel lines, with new injectors, fuel filter, and David Mckeen's RPM relay.

The car ran great last weekend. The best it ever had since I've owned it.

However, today I have fuel leaks all around the fuel pump seal and one at the hard line connections to the fuel pump hose.

Attachment 67018

I've not touched any bit of the fuel pump. That was next on my list.

Could there be excess pressure building up in fuel system from something like a bad accumulator? The fuel frequency valve is buzzing, somewhat loudly.

Before changing out the fuel lines I did have a leak at the fuel filter. Maybe I just exposed another weak spot buttoning up everything in the engine bay.

Thanks in advance for any advice.

Dude you need to get rid of those orange fuel hoses immediately. They were originally sold by Grady many years ago but they will turn hard. I had a leak after playing around with them one time and when I called him he said throw them away immediately and he sold me better hoses. For some reason the material used was not a very good idea.

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Originally Posted by 82DMC12

Dude you need to get rid of those orange fuel hoses immediately. They were originally sold by Grady many years ago but they will turn hard. I had a leak after playing around with them one time and when I called him he said throw them away immediately and he sold me better hoses. For some reason the material used was not a very good idea.

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+1 on that!

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Originally Posted by 82DMC12

Dude you need to get rid of those orange fuel hoses immediately. They were originally sold by Grady many years ago but they will turn hard. I had a leak after playing around with them one time and when I called him he said throw them away immediately and he sold me better hoses. For some reason the material used was not a very good idea.

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+1 The average life of the Orange hose is 10-15 years. Mine lasted about 20 before failing at the pump banjo fitting Pressure. Also the fuel pump boot may have failed under the cover. Mine failed last year. It was new in 98. I ended up just converting to the new fuel pump module assembly.

June 2020
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September 2018
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That's good that you changed the fuel injection lines. I would also recommend upgrading to the all in one fuel pump module. I'm all for keeping it stock usually but this is one area where I made the exception. Be sure to drain and clean out the tank before you put the new one in. You'd be surprised at the debris that can be in there.

Here's my DMC setup:
http://dmctalk.org/attachment.php?at...0&d=1588468314

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Originally Posted by 82DMC12

Dude you need to get rid of those orange fuel hoses immediately. They were originally sold by Grady many years ago but they will turn hard. I had a leak after playing around with them one time and when I called him he said throw them away immediately and he sold me better hoses. For some reason the material used was not a very good idea.

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Originally Posted by DMC5180

+1 The average life of the Orange hose is 10-15 years. Mine lasted about 20 before failing at the pump banjo fitting Pressure. Also the fuel pump boot may have failed under the cover. Mine failed last year. It was new in 98. I ended up just converting to the new fuel pump module assembly.

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The previous owner had allot of work done at Grady in the late 90's, so those orange hoses are well beyond their prime.

My boot is probably in the same condition as yours. Guess it's time to upgrade to a new pump and new hoses. ...and to think I was feeling good last weekend after I replaced the stainless steel lines. :mecry:

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Originally Posted by DMC-81

That's good that you changed the fuel injection lines. I would also recommend upgrading to the all in one fuel pump module. I'm all for keeping it stock usually but this is one area where I made the exception. Be sure to drain and clean out the tank before you put the new one in. You'd be surprised at the debris that can be in there.

Here's my DMC setup:
http://dmctalk.org/attachment.php?at...0&d=1588468314

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That looks really clean! I need to do the same, but DMC is out-of-stock on that pump right now.

In the meantime I guess I could start by draining and cleaning the tank. I'm just getting tired of dealing with the fuel system at the moment and the constant smell of gas in my garage.

Are you sure they are out of stock? If so, DPI should have a kit available. I just got one a couple weeks ago.

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Originally Posted by Curt_DMC

That looks really clean! I need to do the same, but DMC is out-of-stock on that pump right now.

In the meantime I guess I could start by draining and cleaning the tank. I'm just getting tired of dealing with the fuel system at the moment and the constant smell of gas in my garage.

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Thank you. It works really well for me. Yeah, you shouldn't have any fuel smell with this kit. I have an early version aluminum blanking disc to cover where the fuel sender goes. I think they are plastic now in the kit.

One tip I follow: because the fuel cools most electric pumps, and because the tank is small, I try to keep a full tank as much as possible.

Good luck with the task.

If you look at this area with the engine running, what do you see? Is there fuel spraying from one of the hoses? Or dripping from somewhere else?

Reason I ask is because it could be that the fuel sender is not sealing well and the fuel is sloshing around when you're driving and coming up and over and these are the wet spots you see.

It's hard to tell when the whole area is wet like that. Perhaps let it all air dry first and wipe up everything as best you can. Then start the engine and stand there and watch this area and see if you can spot the source. Next step would be to take the car for a short drive down your street and (without anyone right behind you), slam on the brakes. Then get out and look at the fuel sender area and see if any gas sloshed up and out.

Also look under the fuel pump rubber boot/cover for fuel. As shown in the previous photo, if it is leaking in there, the whole pocket will be full of fuel. If it is only coming from the fuel sender or one of those orange hoses, that area under the pump cover will not be full of fuel.