Kia Sportage Gasoline Leak

Replies to this message:
• lightpainter (Sep 26, 2007 6:04 pm)
  • kim48 (Sep 27, 2007 2:30 am)
• lmp4 (Oct 10, 2007 1:54 am)
  • steve_ (Oct 10, 2007 8:00 am)

Replying to: kim48 (Sep 15, 2007 4:51 am)

Replies to this message:
• kim48 (Sep 27, 2007 2:30 am)

Replying to: lightpainter (Sep 26, 2007 6:04 pm)

Replying to: kim48 (Sep 15, 2007 4:51 am)

I would not have imagined that should be included in the "perfect Sportage owner maintenance book" ...but after investigating a fuel leak I endured for some time (Sportage 2000), here are a few hints.
This tank is subject to a recall (inspection !!) in the USA, but not in Canada .
The tank is easy to remove ...but disconnect all hoses and electrical connectors first from the top access panel, under rear seat. The clamp for filler hose can be cut with a Dremmel tool then replaced, rather than trying to remove .
THe tank has a drain plug ...quite unusual...but a welcome feature that has a flaw : main cause of fuel leak proved to be the corrosion of the fuel tank drain plug seal/washer. This washer is aluminum and contact with steel tank and plug creates electrolysis and unavoidable corrosion of washer .

I replaced it with a steel washer and used teflon to seal the plug.
 
The corrosion was all over the tank
tankbefore
top
 
 Leaving it unattended would have lead to a total disintegration down the line but it still proved worthy at this time. The metal used is lower grade than tanks I have had on other cars. The padding between the shield and the tank keeps water and is a problem in itself.
 
After buffing the tank I covered it with 2 coats of spray rubberised asphalt as sold for undercar protection.
after1
after2
After reinstallation a tiny leak on bottom proved to have been exacerbated . TO be sure, I had not reinstalled the shield specifically in prevision of such an event so I did not have to remove the tank again.
  The leak cleared the asphalt coating a few incles around: emptying the tank again and tilting the car slighty on one side allowed to cure the hole with epoxy as the little remaining fuel was on the other side of the tank.
I painted the shield with Tremclad
skid plate
 but did not reinstall the padding .
 
An array of hoses are sandwitched between the tank and frame
lines
and the space was filled with sand and other debris: this is a trap for corrosion and I will ensure to wash that area from time to time. After removing as much rust as possible, I covered it all with spray asphalt.
 
Bottom line: this tank NEEDS maintenance in the first place, and then needs being washed with water specially in areas where salt is used in winter. Access from the top is easy and it can be washed from there, as well as the space between tank and frame.
Replace the plug seal as soon as possible as the aluminum original will corrode away inevitably.

Replies to this message:
• steve_ (Oct 10, 2007 8:00 am)

Replying to: lmp4 (Oct 10, 2007 1:54 am)

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• lmp4 (Oct 17, 2007 1:12 pm)
  • robjbp (Dec 05, 2007 3:03 pm)
    • lmp4 (Dec 05, 2007 4:50 pm) and 1 more...

Replying to: johnfarmer (Oct 15, 2007 8:31 pm)

Replies to this message:
• robjbp (Dec 05, 2007 3:03 pm)
  • lmp4 (Dec 05, 2007 4:50 pm)
    • robjbp (Dec 06, 2007 10:41 am)

Replying to: lmp4 (Oct 17, 2007 1:12 pm)

Replies to this message:
• lmp4 (Dec 05, 2007 4:50 pm)
  • robjbp (Dec 06, 2007 10:41 am)

Replying to: robjbp (Dec 05, 2007 3:03 pm)

Replies to this message:
• robjbp (Dec 06, 2007 10:41 am)

Replying to: lmp4 (Dec 05, 2007 4:50 pm)