I have a plastic tank paired with a saddle tank that I got installed a few weeks ago by my mechanic. Right after install, I filled it up all the way and was disappointed to find it leaking diesel onto the pavement.
I initially thought the problem was a bad seal between the saddle tank and the plastic tank, so I pulled everything out to inspect yesterday. Everything looked fine and tight, but it turned out that instead of connecting all the breather lines together like in the manual (image below), my mechanic attached hoses to each fitting individually and routed them to a high point near the body. This makes sense in theory, as it would let the air escape, but I am guessing as the tank fills up and air rushes out the high cavities in the plastic tank, some fuel ends up squirting out the end of these exposed breather lines, causing the leak onto pavement.
My hypothesis is that the right way to prevent this is to join them all and route them to the high point on the filler neck, as the manual suggests. This way any splash-back is contained to inside the system, while still letting air get released.
Since I am connecting to a saddle tank, not the filler neck in the diagram, it turns out I don't have enough breather fittings on my saddle tank to follow the instructions in the manual.
The manual describes attaching the tank to a filler neck that has three fittings (24, 25, 29 in diagram). but my right saddle tank has only one breather fitting, as you can see here.
How can I achieve a properly working system with the components I have?
More specifically, the questions I'm looking to answer are:
- I don't have a steel T-fitting line (7) that the manual assumes is being used. Instead of sourcing one, I am planning to mate the hoses to a T fitting from the hardware store instead. Any better ideas?
- Since I am looking to connect all breather lines to one fitting on the saddle tank, I am planning on joining hoses marked by (14c, 14b) with a Y and connecting them to the single breather fitting on the saddle tank.
- What fittings should be plugged up in my configuration? The manual mentions 9 and 19. Any others?
This is my first major "under the car" mechanic attempt on the G, so any advice or tips appreciated