85fortheDrive

So I cleaned and electrically tested the fuel sensor in our 1985. Put everything back together and drove the car. Now, after filling up the tank, there is a strong gas smell in the car and most prominently outside the car near the passenger door. It’s stinking up the whole garage

I made sure to seat the sensor and tightly screw the plastic ring cap back on. Could it be an issue with the fuel return line?
Thanks.

Mrmerlin

yes the fuel return line is also a part that should be replaced if the tank is removed its about 7 inches long

chart928s4

Definitely don't mess with a bad fuel return line, or any pressurized fuel line.

You might also want to check the Y connector to the vapor capture system under the wheel well liner. They always break, and though not dangerous the smell can be alarming. Easy cheap fix if that is the problem.

The Forgotten On

Did you use a new seal for the fuel sender unit?

85fortheDrive

I did not. The unit looked fairly new and in good shape. But I will take a closer look, for sure. Thank you!

Bill Ball

The one time I was in the tank, I did not get the porthole top back on tight enough. I thought I did, but it needs to be TIGHT. And a fill up is when that overflows since it is lower than the fill tube. Below 3/4ths of a tank, you wouldn't know it was loose. If it seems tight, make sure you didn't cross-thread it and only get it back on partially. When I smelled gas, I immediately looked at the porthloe area and found a pool of gas there. I'm surprised you didn't take 30 seconds to check that. It takes a rather large spanner to properly tighten the cap.

The return line, if leaking, would be all the time the car is running and before the fill up regardless of fuel level. I vote for the porthole cap. Also, the return line is essentially zero pressure.

Jason89s4

Your seal is bad or not correctly installed. Thus, when you fill the tank, gas is escaping there.
-Jason

85fortheDrive

UPDATE: GO AHEAD AND SMOKE ‘EM IF YOU GOT ‘EM

Thanks to all the input here. Collectively, it helped me greatly.
The cap ring that tightens down the sender does indeed to be tight. This is a bit challenging, because it is plastic and should really be tightened by a tool that allows you to turn it via the flanges on it, as opposed to clamping and turning it. I put a little plastic lubricant on the threads and was able to get a few more turns on it, which helped seal the seal.

SwayBar

Nice job!

Bill Ball

Excellent. Glad it was that simple. When it happened to me, I don't recall that I smelled gas as the hole in the body above it is well sealed and covered by a closed cell foam pad and carpet. I saw gas on the ground under the tank as it overflowed after fill up, specifically when I parked on a grade. I knew that had to be the source as I had just been in there. It took me a while to find something that would fit well on that ring. The lube was a good idea. Carry on!