ZX Diesel Leak

AthlonZX · Unread post by **AthlonZX** » 15 Apr 2003, 00:58

Hi everyone. My much loved Citroen ZX turbo diesel has developed a diesel leak somewhere on the tank. I belive it is at the top of the tank as it is only pronounced when full.
On first inspection it appeared to be the seal round the fuel gauge unit which sits on the top of the tank. I tried to order the part through my local specialist, but having been given the wrong part twice I finally relented and booked it in to be fitted by themselves(in the hopes this would encourage them to get the right part [:p]).
They fitted the part, but I still have an apparant diesel leak when the tank is full. Despite another visit today and a full inspection by my "local specialist", I'm still loosing diesel. It pours from the top of the tank over either side of the exhaust [:(].
Any ideas what else it could be? I've heard the tanks can change shape over time and this can lead to leakage. Any other ZX owners had the same problem?
Cheers
Dave
Citroen ZX Turbo Diesel Aura (Mettallic Grey)
114457 [:)] miles

NiSk · Unread post by **NiSk** » 15 Apr 2003, 01:28

Check the state of the filler pipe and overflow pipe, especially where they connect to the tank.
//NiSk

JohnD · Unread post by **JohnD** » 15 Apr 2003, 02:02

You'll have two canvas covered rubber pipes going from the top of the tank down to the hard pipework running the length of the car. One or both will be filled with tiny holes. Replace them both using new jubilee clips. Loosen off the crimped clips and tie a length of string to each tube before pulling it through. Use the string to pull the new pipe into place. Be careful removing the rubber from the plastic fitment going into the tank. The plastic easily breaks. New tubing can be bought off the roll at the accessory shops.

jeremy · Unread post by **jeremy** » 15 Apr 2003, 13:36

We had this exact problem when we bought our 94 ZX diesel at the end of last year. We found that the bottom of the tank was wet and on removing the back seat and the two black discs found the there was fuel all over the top of the tank and round the gauge unit and the pipe outlets. I thought it was the largish vent pipe and duly removed its clip, examined the pipe and fitted a new clip. NO IMPROVEMENT!
Next step was to purchase the 2 sealing rings (Citroen - about £8 for both). I took out the gauge unit and replaced that one but couldn't find anything wrong with the old one and so left the pipe outlet one as no fuel had collected there.
We filled the car up again - and no improvement - so I was thinking that there must be a defect in the tank itself, but decided to have a more thorough investigation as the fuel seemed to be coming from somewhere high up, to the near side of the gauge unit.
Eventually I found another pipe joining the tank under the floor, a couple onf inches to the nearside of the gauge unit and towards the front of the car (behind the larger vent pipe). I didn't fancy dropping the tank for many reasons, one of which was that it had about 7 gallons in it and ended up cutting a small access hole in the seat box to get at the pipe clip. When I removed the pipe I found a split about 1 inch long on the concealed side. I replaced the pipe with a length of new fuel tubing and sealed up the floor and have had no further problems.
A word of caution before you attack it with a drill - remember the tank is made of plastic and is only just below the seat box.
Jeremy

AthlonZX · Unread post by **AthlonZX** » 15 Apr 2003, 14:14

Thanks for your input NiSk, JohnD & Jeremy. I'm going to have a bash with the pipe that Jeremy has suggested, as I've tried all the over breathers on the tank for condition. I dont fancy dropping the tank myself so (for the same reason of having nearly a full thank of fuel in it lol [:)]), so I'll probably drain the than first.
Will let you all know how I get on
Thanks again [:)]
David
Citroen ZX 1993 Aura (Mettalic Grey)
114457 [:)] miles

jeremy · Unread post by **jeremy** » 15 Apr 2003, 20:46

Athlon
I don't think I said in my earlier post that having cut the hole in the seat box and repaired the pipe I pop riveted a plate over the hole and put seam sealer under the plate before fitting. Beats draining the tank and removing it, which means removing the exhaust and handbrake cable.
Jeremy

AthlonZX · Unread post by **AthlonZX** » 23 Apr 2003, 02:58

Hi everyone
As promised an update, just managed to cure my diesel leak following the advice given here. Had the tank droppped in the end to get to the affending breather hoses
Thanks again to everyone who helped
David
Citroen ZX Turbo Diesel Aura (K reg 1993)
114576 [:)] miles