2003 WRX fuel tank leak

Jsubie18 · 01-28-2018, 04:37 PM

Hi Guys,

I wasn't able to find any posts with the same issue I'm having, please feel free to move this post if necessary.

First off, this is a project car, not my DD. I've had it for almost a year now, and finally finished my JDM ej205 swap. Ecu came in last weekend, I was stoked to finally take the car out for a drive

. All was well, I put around 100 miles on the car throughout the weekend. At the end of the day, I filled it up at the local gas station and drove home.

At this point, I was starting to smell raw gas in the cabin. Fortunately I only live 1 mile from the gas station. When I pulled into the driveway, I got out to inspect why it was smelling like raw fuel, and gas was (heavily) dripping from the drivers side rear tire well. I threw a catcher underneath to see how much was actually being lost. I then took the rear seat out, and the driver side was soaked in gas.

This happened a week ago, and I was finally able to do some testing this weekend. My fuel gauge was now reading 3/4 full, so I put 3 gallons in a canister, and then proceeded to pour that into the wrx. Sure enough, going anywhere over 3/4 mark and the tank starts leaking again. I checked the three lines which come up under the rear seat, but they don't seem to be leaking. Also, fuel is seeping up through two rubber grommets on the body under the seat (see pictures). It literally melted the rubber insulation which was on the body. The gas looks like it's coming somewhere on top of the tank, dripping over the seam (see pictures below)

I'm not sure if the leak is caused by lines on top of the tank, or the tank itself. I checked the sending unit and fuel pump gaskets, and nothing is leaking from them. Any advice is appreciated. I'm probably going to schedule a time to get it looked at in the near future.

Thanks!

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Valarius Starchaser · 01-28-2018, 06:29 PM

Photo links are dead use something other then photobucket

Jsubie18 · 01-28-2018, 08:14 PM

Quote:

Originally Posted by Valarius Starchaser

Photo links are dead use something other then photobucket

Sorry, try these:

https://i.imgur.com/pj2tv16.jpg

https://i.imgur.com/VS98jv2.jpg

https://i.imgur.com/pHF5ATU.jpg

Samurai Jack · 01-29-2018, 10:50 AM

Where is the fuel pump located in your car, Driver or Passenger side?
Maybe fuel is leaking from the fuel pump gasket?

Jsubie18 · 01-29-2018, 02:25 PM

Quote:

Originally Posted by Samurai Jack

Where is the fuel pump located in your car, Driver or Passenger side?
Maybe fuel is leaking from the fuel pump gasket?

Hey Jack,

Fuel pump is on the passenger side, sending unit on driver side. Both appear to be fine, no fuel leaking. I'm leaning towards a hole in the tank...

wtdash · 01-29-2018, 04:15 PM

Yeah...that's a rusty NE car, based on 1st pic. Check your 'fuel filler neck' too.

Samurai Jack · 01-29-2018, 04:46 PM

Quote:

Originally Posted by wtdash

Yeah...that's a rusty NE car, based on 1st pic. Check your 'fuel filler neck' too.

Except the fuel filler neck is on the passenger side.

Samurai Jack · 01-29-2018, 04:47 PM

Quote:

Originally Posted by Jsubie18

Hey Jack,

Fuel pump is on the passenger side, sending unit on driver side. Both appear to be fine, no fuel leaking. I'm leaning towards a hole in the tank...

That's what is really starting to sound like
I just couldn't remember which side the fuel pump was on.

wtdash · 01-29-2018, 04:55 PM

Quote:

Originally Posted by Samurai Jack

Except the fuel filler neck is on the passenger side.

Yep...just like a Forester that has the 'infamous' fuel filler neck' rot.

Just another thing for the OP to check when they're dropping "shudder" the tank.

Jsubie18 · 01-29-2018, 10:37 PM

Thanks for the replies everyone. I've decided to attempt removing the tank within the next few weeks with a few friends. What a waste of $40 worth of 93 octane.

I'll post what I find.

Samurai Jack · 01-30-2018, 10:22 AM

Quote:

Originally Posted by Jsubie18

Thanks for the replies everyone. I've decided to attempt removing the tank within the next few weeks with a few friends. What a waste of $40 worth of 93 octane.

I'll post what I find.

Just collect it in a gas container and put it back when the repair is complete.
Oh wait, that's like 13 gallons so you'll need several 5 gal cans

Valarius Starchaser · 01-30-2018, 11:49 AM

Yeah there’s two drain bolt on either side. I got a new oil drain pan and then went from that to the gas cans to make it a nearly no loss operation granted I spent 15 on the drain pan but I needed another anyways

Jsubie18 · 01-30-2018, 08:24 PM

I might attempt dropping the tank this weekend if weather isn't too bad. I'll check the filler neck just to be certain first. I'll reply back with what I find on the tank regardless.

monkeyposeur · 01-31-2018, 11:44 PM

Some have reported that their gas tanks didn't have any drain bolts. I couldn't find any on my 03 WRX wagon, but that's not to say that they aren't there.

The easiest way (for me) to drain the gas tank is to pull the ignition fuse and crank the engine to relieve fuel pressure. Connect the two green test mode connectors under the dash. Attach a long clear hose to the output fuel line post fuel filter. Stick the other end of the hose in a gas can and turn the key on. The fuel pump will cycle on and off and pump the gas into the containter.

Samurai Jack · 02-01-2018, 10:24 AM

Quote:

Originally Posted by monkeyposeur

Some have reported that their gas tanks didn't have any drain bolts. I couldn't find any on my 03 WRX wagon, but that's not to say that they aren't there.

I don't think I've ever seen any drain bolts on my 2002 wagon either.

How about just taking a big ass nail and drive it into the bottom of the gas tank? I mean, you're not going to re-use it anyway

Jsubie18 · 02-01-2018, 10:35 AM

Quote:

Originally Posted by monkeyposeur

Some have reported that their gas tanks didn't have any drain bolts. I couldn't find any on my 03 WRX wagon, but that's not to say that they aren't there.

The easiest way (for me) to drain the gas tank is to pull the ignition fuse and crank the engine to relieve fuel pressure. Connect the two green test mode connectors under the dash. Attach a long clear hose to the output fuel line post fuel filter. Stick the other end of the hose in a gas can and turn the key on. The fuel pump will cycle on and off and pump the gas into the containter.

Quote:

Originally Posted by Samurai Jack

I don't think I've ever seen any drain bolts on my 2002 wagon either.

How about just taking a big ass nail and drive it into the bottom of the gas tank? I mean, you're not going to re-use it anyway

Those are both good ideas!

I'll probably use monkeyposeur's method and store the gas. I also didn't see any drain bolts when looking around last night.

Samurai Jack · 02-01-2018, 01:17 PM

Well, I meant to use a big ass nail and drain into a storage container.

Fuel is too expensive to just throw it away like that.

FL4TOUTWRX · 05-14-2019, 08:24 PM

My 03 is doing this exact same thing, what did you find??

Boosdsubie · 11-09-2019, 10:19 AM

Find anything? I have same exact problem

Shik · 11-11-2019, 02:43 AM

My son's 2002 did the same thing only it leaked in the passenger side. It was NOT the fuel filler neck, but rather where the neck goes into the tank where it rotted. Would only drip for a little after filling it up, but I wasn't having any fuel leaks with my kid driving, soooo...

I replaced the tank with a brand new oem tank, plus the white valves on top of the tank, as you can't get the gaskets for them separately, plus some rubber fuel lines, plus new nuts for the fuel pump hanger. Not the most fun i had replacing something on a Subaru, but at least it's done and I shouldn't have to worry about it for a while.

01-28-2018, 04:37 PM	#1
Jsubie18 Scooby Newbie Member#: 350459 Join Date: Mar 2013 Chapter/Region: NESIC Location: Connecticut Vehicle: 2009 WRX WRB	2003 WRX fuel tank leak Hi Guys, I wasn't able to find any posts with the same issue I'm having, please feel free to move this post if necessary. First off, this is a project car, not my DD. I've had it for almost a year now, and finally finished my JDM ej205 swap. Ecu came in last weekend, I was stoked to finally take the car out for a drive . All was well, I put around 100 miles on the car throughout the weekend. At the end of the day, I filled it up at the local gas station and drove home. At this point, I was starting to smell raw gas in the cabin. Fortunately I only live 1 mile from the gas station. When I pulled into the driveway, I got out to inspect why it was smelling like raw fuel, and gas was (heavily) dripping from the drivers side rear tire well. I threw a catcher underneath to see how much was actually being lost. I then took the rear seat out, and the driver side was soaked in gas. This happened a week ago, and I was finally able to do some testing this weekend. My fuel gauge was now reading 3/4 full, so I put 3 gallons in a canister, and then proceeded to pour that into the wrx. Sure enough, going anywhere over 3/4 mark and the tank starts leaking again. I checked the three lines which come up under the rear seat, but they don't seem to be leaking. Also, fuel is seeping up through two rubber grommets on the body under the seat (see pictures). It literally melted the rubber insulation which was on the body. The gas looks like it's coming somewhere on top of the tank, dripping over the seam (see pictures below) I'm not sure if the leak is caused by lines on top of the tank, or the tank itself. I checked the sending unit and fuel pump gaskets, and nothing is leaking from them. Any advice is appreciated. I'm probably going to schedule a time to get it looked at in the near future. Thanks! * Registered users of the site do not see these ads.

01-28-2018, 06:29 PM	#2
Valarius Starchaser Scooby Newbie Member#: 459312 Join Date: Dec 2016 Chapter/Region: MWSOC Vehicle: 2004 WRX Wagon Hybrid 6MT Swapped WRB	2003 WRX fuel tank leak Photo links are dead use something other then photobucket

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01-29-2018, 10:50 AM	#4
Samurai Jack Scooby Guru Member#: 21145 Join Date: Jul 2002 Chapter/Region: NESIC Location: Not in my own time Vehicle: 2002 Enemy of Aku	Where is the fuel pump located in your car, Driver or Passenger side? Maybe fuel is leaking from the fuel pump gasket?

01-29-2018, 04:15 PM	#6
wtdash Scooby Specialist Member#: 59182 Join Date: Apr 2004 Location: N. Idaho Vehicle: 2002 WRX GG>> 2016 Focus RS	Yeah...that's a rusty NE car, based on 1st pic. Check your 'fuel filler neck' too.

01-29-2018, 10:37 PM	#10
Jsubie18 Scooby Newbie Member#: 350459 Join Date: Mar 2013 Chapter/Region: NESIC Location: Connecticut Vehicle: 2009 WRX WRB	Thanks for the replies everyone. I've decided to attempt removing the tank within the next few weeks with a few friends. What a waste of $40 worth of 93 octane. I'll post what I find.

01-30-2018, 11:49 AM	#12
Valarius Starchaser Scooby Newbie Member#: 459312 Join Date: Dec 2016 Chapter/Region: MWSOC Vehicle: 2004 WRX Wagon Hybrid 6MT Swapped WRB	Yeah there’s two drain bolt on either side. I got a new oil drain pan and then went from that to the gas cans to make it a nearly no loss operation granted I spent 15 on the drain pan but I needed another anyways

01-30-2018, 08:24 PM	#13
Jsubie18 Scooby Newbie Member#: 350459 Join Date: Mar 2013 Chapter/Region: NESIC Location: Connecticut Vehicle: 2009 WRX WRB	I might attempt dropping the tank this weekend if weather isn't too bad. I'll check the filler neck just to be certain first. I'll reply back with what I find on the tank regardless.

01-31-2018, 11:44 PM	#14
monkeyposeur Scooby Specialist Member#: 333468 Join Date: Sep 2012 Chapter/Region: RMIC Location: SLC, UT Vehicle: 93 SS - 06 OB XT 03 WRB GD 205/22T 20G-XT	Some have reported that their gas tanks didn't have any drain bolts. I couldn't find any on my 03 WRX wagon, but that's not to say that they aren't there. The easiest way (for me) to drain the gas tank is to pull the ignition fuse and crank the engine to relieve fuel pressure. Connect the two green test mode connectors under the dash. Attach a long clear hose to the output fuel line post fuel filter. Stick the other end of the hose in a gas can and turn the key on. The fuel pump will cycle on and off and pump the gas into the containter.

02-01-2018, 01:17 PM	#17
Samurai Jack Scooby Guru Member#: 21145 Join Date: Jul 2002 Chapter/Region: NESIC Location: Not in my own time Vehicle: 2002 Enemy of Aku	Well, I meant to use a big ass nail and drain into a storage container. Fuel is too expensive to just throw it away like that.

05-14-2019, 08:24 PM	#18
FL4TOUTWRX Scooby Newbie Member#: 501586 Join Date: May 2019	My 03 is doing this exact same thing, what did you find??

11-09-2019, 10:19 AM	#19
Boosdsubie Scooby Newbie Member#: 508085 Join Date: Nov 2019	Find anything? I have same exact problem

11-11-2019, 02:43 AM	#20
Shik NASIOC Supporter Member#: 132 Join Date: Jul 1999 Chapter/Region: Tri-State Location: PA Vehicle: 2006 GT Ltd 5spd sdn '15 WRX 6spd CWP, '02 WRX	My son's 2002 did the same thing only it leaked in the passenger side. It was NOT the fuel filler neck, but rather where the neck goes into the tank where it rotted. Would only drip for a little after filling it up, but I wasn't having any fuel leaks with my kid driving, soooo... I replaced the tank with a brand new oem tank, plus the white valves on top of the tank, as you can't get the gaskets for them separately, plus some rubber fuel lines, plus new nuts for the fuel pump hanger. Not the most fun i had replacing something on a Subaru, but at least it's done and I shouldn't have to worry about it for a while.