Possible Fuel Tank Leak 2002 205 Osprey

[Gabe-F]

Good afternoon all,

I just joined this Aquasport forum and I have found so much interesting information so far. I took out my new boat last weekend and I noticed there was pure gas coming out my rear plug drain. I haven't notice this before, I filled it up almost 3/4 of the tank. I would like ask for some advise on how I can determine if there is a leak without cutting out the floor. Thanking you all in advance for any info you can provide me on this matter.

[Capt. Bob]

OK,
Now you have your own thread. First, can you remove a deck plate and determine what type tank you have either aluminum or poly?

I can't recall what type was in that model but poly has been know to leak at the gauge entry and in spots where the tank was chaffed and cracked. Aluminum leaks where pit corrosion has occured due to water trapped between the tie downs or the bottom of the coffin.

Let us know what you have.

[Gabe-F]

Thanks Capt Bob,

Well, my tank material is poly, I wondering if the leak could be happening at the junction of the gas hose and the tank, or if there is a possibility that it may be at the sender gasket since the tank was 3/4 full. I really hope that since I don't have a clue how difficult or expensive could be replacing existing tank. This is a boat that is in great overall condition, it has been stored for a long time. Original engine has only 50 hrs. I have access to hoses and sender through out round deck plate right under console. Does it has any other hose or fitting at the back of the tank?

[wingtime]

Gabe,

You should have three hose connections to your tank.  In order from large to small:  Filler hose, Vent hose, Fuel line.  As mentioned you should have a sender unit for the fuel gauge with two wire connections.  The poly tanks have metal inserts where the nuts for the sender thread into.  It is either a  metal ring or individual inserts.  Be careful taking out those screws.  Soak them with PB blaster for a day before trying to remove them  You don't want to spin an insert.  Odds are your leak is(in order of likelihood) at the fuel sender, hose connection, bad hose, or a split in the tank.  If the boat has been fed a steady diet of ethanol fuel I'll bet you have swollen gummy hoses at the least. Open up your inspection pie plates and see if you can find all the connections.  I'm not sure if the 205 has a molded in cut line in the deck or not.  If it does you would have to cut the deck along those lines to get the tank out.  If the cuts are done right you just have to seal up the edges of the deck and new "hatch" with epoxy before installing and sealing with 4000UV caulk.

[Gabe-F]

Thanks wingtime,

I have taken and attached some pictures to get a better understanding and also to confirm if the cut lines are the ones I have marked out. Thanks again and I will try to replace the filler and fuel line hoses and sender gasket as well. If the leak persist after this, I should confirm the tank is cracked correct?

[RickK]

I don't see anything that indicates a leak at the connections. If you're having a leak, that's not a good sign. :-(
I don't understand the arrows - have you used a tape measure to illustrate where the edges of the tank are?