[YammyxJammy]

Pulled the two fuel lines from under my gas tank in order to test fuel pump and both ports are steadily leaking fuel as soon as I pull the lines, and continues as long as fuel is in the tank. Is that normal?

 

[tdoss1980]

No not normal, when the lines are disconnected they should let a little out but then stop. You say two lines so you must have a 2003-2005 R6 or a 2006-2009 R6"s" model correct?

 

[YammyxJammy]

Yes that is correct it’s a 2003 R6, so one port has a regular hose with a hose clamp and the other line is a quick disconnect (both were leaking once the lines were off) I know a few drops is normal but this is not a few drops but a constant stream. I took it apart last night to test the pump motor, so I’ll put it back together after work and see if it’s still doing it and update then.

 

[mordantly]

Mine self seals when tank is off.. 2017 but that should not matter year wise.

 

[tdoss1980]

The one with the clamp is the low pressure return and the other is the high pressure output, when you pull it apart make sure all the orings are seated properly

 

[Intuit]

@YammyxJammy - Wouldn't worry about it. I have to cap my ports or they will continue to leak fuel. The 2nd Gen 2003-2005 do not have a sealed tank; it's vented. Cali models are an exception; they have a valve that vents tank emissions back into the (running) engine's air intake.

Buy an assortment pack of vacuum line caps.

I insert one white one inside a black one and use that, to cap the port. If you just use one or the other, it's going to come off when you're not around to catch it.

 

[Hoonatic]

Both mine would stop after a few seconds but after replacing the pump the send side will constant leak now. Put the old pump back in and same issue. It doesn’t seal anymore. My return side did and does stop leaking still. I’ve been inside the pump plenty times and can’t find the solution. Replaced all orings. Same deal. I know the return side has what looks like a schrader valve on the pump housing. I’d check that

 

[Intuit]

I suspect everyone's 2nd Gen tank leaks/seeps when disconnected. My first experience wasn't that of a pool of fuel garnishing the garage floor, but just a garage that wreaked of fuel vapor smell. Ever since then I cap the ports.

 

[Hoonatic]

Both mine would stop after a few seconds but after replacing the pump the send side will constant leak now. Put the old pump back in and same issue. It doesn’t seal anymore. My return side did and does stop leaking still. I’ve been inside the pump plenty times and can’t find the solution. Replaced all orings. Same deal. I know the return side has what looks like a schrader valve on the pump housing. I’d check that

This is only when the lines are disconnected btw. Neither leak when hooked up. My return line did start leaking when the oring in there gave but I globed fuel sealant around a piece of hose to seal it

 

[Spider64]

Pulled the two fuel lines from under my gas tank in order to test fuel pump and both ports are steadily leaking fuel as soon as I pull the lines, and continues as long as fuel is in the tank. Is that normal?

Its normal for me too! You have to drain the tank & remove & disassemble the fuel module to test the pump for pressure & flow. But you can just pop off the quick connector fuel supply hose , leaving the reg recirculation hose still connected up, & with ya finger over the open supply exit hose end, & with it pionted to a bucket or something, & turn on the key & this should kick in the fuel pump where it should piss in the bucket? & if it dont? You have either a strainer, or filter, or pump problem? That will need the fuel module removed & disassembled for inspection of those 3 above parts.

 

[Spider64]

This is only when the lines are disconnected btw. Neither leak when hooked up. My return line did start leaking when the oring in there gave but I globed fuel sealant around a piece of hose to seal it View attachment 379737
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I see you epoxyed around the module return connector pipe section, & i dont want to sound like a smart ass, but if it was leaking because there was a split or crack on the module's bottom plate? & it's currently working? Well on ya mate! But if it was leaking around that recirculation port pipe? It would of been the seal O ring that is found & replaced by unclipping the port plastic join with a O ring pick, where that whole pipe section drops out exposing the sealing O ring, where you just take it to your local auto shop where they match it, & you buy a new on for $0.70c. Also this O ring repair can be found on utube, where you can get a good understanding of the recirulation port pipe removal & Oring swap out, as your R6 model year, fuel module, are not available in seperate parts, where if you need just 1 part? Too bad! As ya got'a buy the whole complete fuel module which is big $$$.

 

[Intuit]

Using a temporary hose, couple of tee-connectors, fuel grade of course, you can insert a fuel pressure gauge in-line with the pump for a reading. May be able to avoid draining and disassembling things that way.