Picture yourself driving on a highway and suddenly being stranded due to a fuel leak. Fuel tank issues are a more common problem than you might think. Globally, 11% to 42% of fuel systems have problems that allow water to enter the tank.
In the worst case, fuel tank issues can lead to engine failures, fire breakouts, or cause backup generators to fail when needed most. However, to help you avoid costly breakdowns and keep your vehicle in top shape, we’ll share common fuel tank issues and offer practical tips.
TABLE OF CONTENTS
The Role of Fuel Tanks
A fuel tank is a crucial part of a vehicle’s system, storing gasoline or diesel to power the engine. It’s usually located at the rear or under a vehicle. There are many types of fuel tanks, made from different materials such as:
- Metal Tanks – Made from steel or aluminum, these are strong and corrosion-resistant but can be heavy and prone to dents. Usually, above-ground fuel tanks are made of steel.
- Plastic Tanks – Lighter and corrosion-resistant, often made from HDPE or polypropylene, and safer in crashes.
- Composite Tanks – Made from materials like fiberglass and resin, offering a balance of strength, weight, and durability. These are common in racing and off-road vehicles.
Note: The choice of tank material depends on a vehicle’s type, use, and regulations. Plastic tanks are common in cars, while metal tanks are preferred for heavy-duty vehicles.
Common Vehicle Fuel Tank Problems and Their Solutions
Here’s a detailed list of common fuel tank problems, why they occur, and how to fix them:
1. Corrosion and Rust
Corrosion in fuel tanks, especially metal ones, happens due to a chemical reaction between the metal and fuel or environment. Fuel additives can speed up corrosion, especially in older vehicles while water Contamination in fuel tanks also creates a corrosive environment.
Not to mention, contact between different metals in a fuel tank and neglecting regular upkeep allows rust to develop. You might notice signs of corrosion in the form of rust in the fuel filter, fuel leaks, a musty or metallic smell, poor engine performance, and trouble starting the engine. Here’s how to treat and prevent corrosion:
- Use rust inhibitors and protective coatings inside the fuel tank.
- Regularly clean and drain the tank to remove water and debris.
- Add fuel additives to prevent corrosion.
- For small rust spots, scrape them off and apply a rust converter.
- For extreme rust, use a rust remover.
If you notice severe rust, leaks, or major performance issues, see a mechanic for repairs or replacement. In the event, you’ve got rental fuel tanks, contact rental service for repair or replacements.
2. Fuel Contamination
Fuel tank contamination can be caused by rain or condensation entering through the filler neck or vent. It usually occurs in warm, and humid conditions. Contamination symptoms include engine misfires, reduced performance, clogged fuel filters, and difficulty starting a vehicle. Here’s how you can remove fuel contamination:
- Empty the fuel tank and clean it to remove contaminants.
- Use a degreaser specifically manufactured for fuel tanks to clear deposits and improve fuel flow.
To prevent contamination in fuel tanks altogether you must use high-quality fuel, keep the tank sealed, and add a fuel stabilizer during long storage.
3. Fuel Leaks
Fuel can leak from fuel tanks due to accidents, corrosion, punctures, or worn seals in fuel lines. Spillage can also be caused by overfilling the tank.
Signs of fuel leakage include spreading fuel smell, visible leaks, lower fuel efficiency, and difficulty in starting an engine. You can fix fuel leaks by locating them. Here’s how to do that:
- Check for damage.
- Use a Leak Detector Spray to locate hard-to-find leaks.
- Fix damage, replace parts, or tighten connections.
Safety Tips: When handling fuel leaks you must follow some safety precautions to avoid flames such as ascertaining good ventilation and wearing gloves and protective clothing.
4. Clogged Fuel Lines
Dirt, rust, or sediment buildup in the tank can block fuel lines. A clogged fuel filter can also restrict fuel flow and cause blockages. When you have clogged fuel lines you might face difficulty in starting the engine, or the engine may sputter or stall. You’ll also feel a visible power loss in your vehicle. To unclog fuel lines and prevent it from happening in the future here’s what you can do:
- Use a fuel system cleaner for cleaning fuel tanks and lines.
- Replace the clogged fuel filter.
- Manually clean or replace fuel lines if needed.
- Regularly replace the fuel filter.
- Use fuel additives to prevent deposits.
- Avoid driving on low fuel to prevent sediment buildup.
5. Fuel Pump Issues
Fuel pumps wear out with use. Electrical problems can also affect pump function. Whining noise from the fuel tank, engine stalling or surges, and difficulty in starting the engine are some symptoms of fuel pump issues.
To find out whether it’s your fuel pump that has a problem use diagnostic tools to check for issues or test fuel pressure. Then, replace the fuel pump if it’s faulty. Following are some maintenance tips to avoid fuel pump problems in the future:
- Inspect the fuel pump during routine checks.
- Use fuel additives to maintain pump performance.
- Avoid overfilling the tank to reduce strain on the pump.
6. Tank Overfilling
Overfilling fuel tanks cause spillage that in turn creates safety and environmental hazards. It also adds pressure to fuel system parts, increasing wear and tear. Besides, excess fuel can affect engine performance. If there’s fuel spillage, lower fuel efficiency, or frequent engine misfires, your fuel tank is likely overfilled. Therefore, for proper fueling, stop when the fuel pump clicks off, avoid topping off, and monitor the fuel gauge. Here are some refueling tips for fuel tanks:
- Turn off the engine before refueling to prevent vapors from igniting.
- Stay focused to avoid distractions.
- Check for leaks around the filter neck and lines after filling.
Refueling portable fuel tanks is a bit different than refueling non-portable ones. But where should portable gasoline fuel tanks be filled? Fill the gas in a ventilated area, away from flames, and make sure the fuel tank is on ground level to avoid overfilling. Also, secure the cap and store the fuel tank in a cool, dry place away from sunlight.
Preventing Fuel Tank Problems
Cleaning fuel tanks is not the only solution to prevent problems. But you must also maintain them regularly by inspecting, replacing parts when necessary, and storing them properly. Here are some fuel tank maintenance tips to prevent issues in the future:
Fuel Filter Replacement
The filter blocks dirt, debris, and rust from entering the engine and a clogged one reduces fuel flow, harming engine performance. Therefore, regularly replacing a fuel filter is important to maintaining your fuel system. To do that, follow your vehicle manufacturer’s manual. Though it’s recommended to replace every 15,000 to 30,000 miles. If you notice poor fuel efficiency or engine issues, replace the fuel filter sooner.
Fuel System Cleaning
Regular cleaning keeps the fuel system in good shape and maintains optimal engine performance. You can either use fuel system cleaners to remove deposits after every 3,000 to 5,000 miles or hire professional cleaners to deep-clean the system.
Fuel Quality
Use high-quality fuel to avoid contamination in fuel tanks and protect your engine. Choose reputable suppliers like Fuel Logic. Also, add fuel additives to prevent corrosion in tanks and improve engine performance.
Regular Inspections
Check your fuel tank and its related components regularly for leaks, corrosion, or damage. Inspect fuel lines, pumps, filters, and connections.
Storage and Handling
Proper storage helps avoid fuel tank problems, especially during long periods of inactivity. Therefore, store the tank in a dry, ventilated area. Add a stabilizer to prevent fuel degradation if you’re going to store it for an extended period.
Seasonal Maintenance
Adjust fuel tank maintenance based on season such as in winter use winter-grade fuel to prevent gelling, and consider a fuel line heater. Also, park your vehicle in a heated garage if possible. In summer, check for leaks, avoid overfilling, and use fuel additives to protect against heat.
When to Seek Professional Help?
If you notice symptoms like severe fuel leakage, fuel system failure, engine performance issues, and strong fuel odors, see a certified mechanic right away. This is because a certified mechanic will have the skills and tools to diagnose problems accurately and suggest suitable solutions.
When replacing fuel tank parts, always choose genuine or high-quality components. Cheaper parts can fail quickly, causing more damage and costs. On the other hand, quality parts fit and work well with your vehicle, they’re built to last, meet original standards, and can help prevent issues like fuel leaks. Quality components also come with warranties for extra protection.
Key Takeaways
A well-maintained fuel tank is crucial for your vehicle’s performance and safety. Spotting problems early on such as corrosion, contamination, leaks, clogged lines, fuel pump issues, and overfilling can prevent severe issues and ensure smooth driving. Make certain to regularly check your fuel tank for leaks, monitor fuel levels, replace parts, and make repairs as needed. If you notice any severe fuel tank issues, seek help from a certified mechanic.
FAQs
1. What is the best way to repair a fuel tank?
To repair a fuel tank in the best way you’ll first need to identify the damage and then, use appropriate methods. For small leaks, epoxy or fiberglass can be used. However, larger holes may require welding or patching.
2. You may be asking “Why won’t my gas tank let me put gas in?”
If your gas tank won’t let you fill it, common reasons include a clogged fuel cap that prevents air from escaping, causing the fuel pump to shut off early. Issues with the evaporative emissions (EVAP) system, which controls fuel vapors, can interfere with filling as well. Blocked fuel tank vents may also prevent air from escaping, leading to pump stoppage. In some cases, damage to the fuel tank itself can cause filling problems.
3. How do you fix an airlock in a gas tank?
To fix an airlock in a gas tank, make certain the fuel line is clear and the fuel tank is properly vented. If the problem persists, consult a mechanic.
4. What are the symptoms of air in the fuel tank?
Symptoms of air in a fuel tank include engine stalling & decreased power, and difficulty in starting a vehicle.
5. How do you get air in your gas tank?
Air can get into the fuel tank through loose or damaged fuel caps, leaks in fuel lines, or if the tank is not properly vented.
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