T sport petrol leak

[Kenno]

Hi all,

I don't suppose anyone has any experience of the mk1 fuel system?

I've got a small hole in a fuel line but have no idea what to do. I can see the hole and get to it but I don't know where the line goes to other than up past the petrol tank as I can't see or reach any further. I assume it'll need a new line which probs isn't a diy thing but I obviously can't drive it. I've tried clamping it with some rubber tubing and a jubilee clip as a temporary fix to maybe get to a garage but it can't hold the pressure when the car starts.

I don't even know how this can happen and its only a tiny thing but I can see it being a very fiddly and very expensive fix.

Should I just be getting the car picked up and sorted by a garage or is there anything I can do (replace myself somehow / cut and repair pipe?

I'm worrying that it could end up not being economical to repair it, but obviously I don't want it to come to that.

Any advice/sympathy/miracles gratefully received...

[DerekHa]

Hi Scott,

I can only speak for a problem last year with my partners 2006 C1, not a Yaris I know but both designed by Toyota. The C1 had the fuel outlet break off on the intank pump so I had to replace the whole pump assembly, the fuel lines where ok.

Can't see that there's anyway of doing a safe repair to that fuel line anything I can think of that's restistant to petrol won't stick or hold on the fuel line as it's a nylon type of plastic, plus the fuel is under quite high pressure, so think you'll need the fuel line replacing, a garage job if you're not a DIYer.

That fuel line will run up and then over the top of the fuel tank to the intank fuel pump. I think you'll find the top of the fuel pump can be accessed by removing the rear seats where you'll find a metal plate thats held in place by a very strong adhesive/mastic type compound, it's very messy stuff! You can pry the access up carefully and get to the top of the fuel pump. On the Aygo/C1 the fuel lines have a special locking clip that holds them firmly on the fuel pump, a game to release them. Think it's likely both vehicles have a similar arrangement as they're of the same age and make. Youtube may be worth a check as to how to access the pump and release the locking clips.

If you're not confident maybe be best to get this done by a mechanic!

[Kenno]

Thanks, I got halfway through prising up the fuel pump cover but that mastic scared me and I decided not to mess with it. I'll have another look and see if I can make sense of anything.

I like to think I'm a pretty competent DIYer but I don't know anywhere near enough about this. I called a mobile mechanic but he seemed to think it'd be more trouble than it's worth.

I probably will have to resort to getting it towed to a garage etc. but I'm really worried about the cost of it all. The mechanic thought it might need to be a toyota job and my local dealer prices have always been extortionate (eg. £800+ quotes for a job a local garage happily did for £60).

I'll have another look myself just on the off chance I can get to the whole tube myself but if not I'll try ringing around some other garages.

[PCM]

https://good-garage-guide.honestjohn.co.uk/ 

[DerekHa]

46 minutes ago, Kenno said:

Thanks, I got halfway through prising up the fuel pump cover but that mastic scared me and I decided not to mess with it. I'll have another look and see if I can make sense of anything.

I like to think I'm a pretty competent DIYer but I don't know anywhere near enough about this. I called a mobile mechanic but he seemed to think it'd be more trouble than it's worth.

I probably will have to resort to getting it towed to a garage etc. but I'm really worried about the cost of it all. The mechanic thought it might need to be a toyota job and my local dealer prices have always been extortionate (eg. £800+ quotes for a job a local garage happily did for £60).

I'll have another look myself just on the off chance I can get to the whole tube myself but if not I'll try ringing around some other garages.

Don;t worry about prising the cover off the mastic, it does hold tight normally but when I had to tackle it the petrol had softened the adhesive and it came off too easy but it's messy the clean off. Petrol moves it quite well...lol! I had to buy a used fuel pump as it couldn't be repaired and did it myself. I also had a car floor, carpet underlay, and upholstery that had got soaked by the leak, at least your leak is out side the car but be careful of course with fuel!

You shouldn't have to disturb the fuel pump so long as your careful getting the locking fittings off but you're  going to need a replacement fuel line, eBay your best chance I think without costing too much. If you decide to tackle it make sure you use Youtube to see how the fuel lines are unclipped, from memory there a clip either side of the connector which I think have to be compressed together to unlock them.

I'm fairly sure I posted on here when it happened to me looking for advise but I can't find my old post!

[DerekHa]

4 hours ago, Kenno said:

Thanks, I got halfway through prising up the fuel pump cover but that mastic scared me and I decided not to mess with it. I'll have another look and see if I can make sense of anything.

I like to think I'm a pretty competent DIYer but I don't know anywhere near enough about this. I called a mobile mechanic but he seemed to think it'd be more trouble than it's worth.

I probably will have to resort to getting it towed to a garage etc. but I'm really worried about the cost of it all. The mechanic thought it might need to be a toyota job and my local dealer prices have always been extortionate (eg. £800+ quotes for a job a local garage happily did for £60).

I'll have another look myself just on the off chance I can get to the whole tube myself but if not I'll try ringing around some other garages.

Hi Scott,

Had to search for my old post from July last year re the fuel leak.

It may help if your doint this yourself, so link below for you:-

 

[flash22]

The line has gone brittle and split its a quick disconnect type, on the pressure side, bare with me and i will see what i can dig up

[Kenno]

Thanks everyone.

This is the best forum!

[flash22]

That line goes from the pump to that hard line

Part number 77209-52020

it looks to be a standard item on a lot of XP10 yaris (Jap built), get it off the car and see if you can get one if not a place like Pirtek or Hosequip may be able to make one

[Kenno]

Thanks again.  Looks like I can order the part from Japan but I'll wait to get some quotes back first and also check I can get enough access to replace it myself.

Feeling a lot more optimistic now!

[Kenno]

First quote was £99 for them to just look at it - and I have to arrange for the car to be towed there myself too (and tow it back if they can't fix it or I don't want to pay their price).

 So, I've ordered the part and I'll see if I can sort it myself. Worst case scenario is I can still take it to a garage with the replacement hose so it'll save a bit of time/money.

[APS]

33 minutes ago, Kenno said:

So, I've ordered the part and I'll see if I can sort it myself. Worst case scenario is I can still take it to a garage with the replacement hose so it'll save a bit of time/money.

It'll be worth spending a bit on that. The T sport is one of the last really good hatchbacks from Toyota. It's got ABS - all the driver aid you'll ever need. You won't be able to find a new Toyota like it (bar the GR Yaris).  

[DerekHa]

30 minutes ago, Kenno said:

First quote was £99 for them to just look at it - and I have to arrange for the car to be towed there myself too (and tow it back if they can't fix it or I don't want to pay their price).

 So, I've ordered the part and I'll see if I can sort it myself. Worst case scenario is I can still take it to a garage with the replacement hose so it'll save a bit of time/money.

To be fair £99 for doing that job for you doesn't to bad, but like you say you've got the recovery costs to think about unless you someone who can get your Yaris there for nowt!

Being a skin flint and one to have a go myself I'd be doing exactly the same as you Scott. Hope you don't have to wait too long for your parts from Japan though.

Either way hope it all works out for you.

[Kenno]

8 hours ago, DerekHa said:

To be fair £99 for doing that job for you doesn't to bad, but like you say you've got the recovery costs to think about unless you someone who can get your Yaris there for nowt!

It's £99 just for them to look at it! God knows how much they'd charge me to do any work on it too!

[DerekHa]

58 minutes ago, Kenno said:

It's £99 just for them to look at it! God knows how much they'd charge me to do any work on it too!

Oh that sounds like a main stealer sort of price then! Have they told you they need to run diagnostics on the Yaris too?

Better having a go yourself Scott! Or find a decent independant garage.

[Derek.w]

Get the replacment part if it goes pear shaped

then this is your back up plan cut the tubing and insert a copper pipe inside rubber then twist solid copper wire around it to pull it tight.

That will get you to the garage.

Problem with jubilee clips is finding some that small, to cope. 

[flash22]

14 hours ago, Derek.w said:

Get the replacment part if it goes pear shaped

then this is your back up plan cut the tubing and insert a copper pipe inside rubber then twist solid copper wire around it to pull it tight.

That will get you to the garage.

Problem with jubilee clips is finding some that small, to cope. 

It's a hard plastic line the ends are barbed, and you need the correct tool even to join them, line pressure is anything up to 115 psi

 

[Derek.w]

Flash22 Thanks for the vidieo you can also use air fittings (brass or plastic) with simlar barbs the brass ones will take more abuse.

[Derek.w]

Flash22 \\\\\\\\\\\\regarding the video.

I was suprised he has not used any Jubilee double ear clamps on the pipes.

This is for pipes on top of fittings I know some fittings the pipe goes inside the fitting.

[flash22]

No need to crimp them as they are rated to 300-500 psi, once fitted you will never pull them apart by hand

[Kenno]

I was hoping to have a proper look at the fuel pump to see what my access is like to the other end of the pipe but I haven't had a chance. Hoping the part arrives later this week. Thanks for the info on the fittings etc. My hope at the mo is that I can disconnect both ends and tie a piece of string or something to one end and pull it through to enable me to get the new pipe in place, without there being any other clips and fixings holding it in place. Might be wishful thinking.

[DerekHa]

The string idea sounds like a good one but you may need the help of a willing assistant Scott. If the "string theory" doesn't work another option is a length of old curtain wire it has some rigidity but is still quite flexible so will feed around corners well.

[Kenno]

Minor update - the new hose has arrived. Hoping to have a crack at it later this week.

[Kenno]

Well, I've finally had a go at it, but I don't seem to be able to pull or push the old pipe through. It was held in place towards the bottom with a clip so I've got it out of that. I don't think it's clipped in anywhere else but it feels like the connectors are too big to fit through the gap. There may be another route to push it through but I can't get enough access to see or feel anything further.

New plan, now that I've released more of the hose and have much better access to it is to look at maybe taping it up or cutting and connecting it to get it to a garage for them to fit the new hose.

[Kenno]

So, I've covered that section of the old hose in plastic JB weld then wrapped it tightly in ptfe tape and finally rubber amalgamating tape. Seems to be holding well for now. I've let it run on the drive for a 10-15 mins and no signs of leaks. If anything I feel like it must be stronger than ever!

I've got it booked in at a local garage next week for them to take a look at replacing it with the new hose, and have just noticed that the MOT's due at the end of this month!