P1496 EVAP System Leak Major: Help Needed?

[Mic]

I just had the P1496 code pop up again; the 6th time since I had my fuel pump replaced in May. It started as P1492 and then went away until a gasket and locking ring on the pump cracked twice while fueling and allowed fuel to pour out of the tank from the top. I just had the gaskets and locking ring on the fuel pump replaced again and the code was cleared but keeps coming back. The dealer is telling me that it's residual fuel being picked up by some sensor near the tank and will go away when the fuel vapor from the original overflow dissapates but that seems like BS to me. My local mech is doing his best but seems a little baffled. Any suggestions form anone on things to check would be greatly appreciated. Thanks.

 

[Disco Mike]

There is no sensor new the gas tank that could pick up old gas residue, the dealer is feeding you a line.
Mike J.

 

[Max]

gas cap?

Could it be you fixed one problem and have a 2nd one? When I get those codes it is always my gas cap. Can't be to much to replace it. Max

 

[Mic]

Haven't tried the Gass Cap but I would think that if I'm getting that much evap loss that the cap would show signs of wear; ie real loose etc. I do think I'm getting a line from the dealer but I'm not sure what things along the fuel lines woul be easy fixes and easy to check. Any ideas there? I don't want to go screwing around with fuel lines blindly since this should be my daily driver.

 

[Sirfoss]

Vac leak

I had this happen with a cust car also.... The hose from the tank to the filler must be tight also there is a small line prone to cracking, This is what I found once replaced no issues.
Mike

 

[Mic]

Line cracking

Micheal,
Thanks. I had the filler tube mod done as a result of the recall but I'll check it again. Which line is it that you mentioned is prone to cracking? Does it go into the breather box or should I look for a trouble spot somehwere else?

Regards,
Tom

 

[BradN]

Sounds like vacunm leak and the dealer is full of crap. Maybe the attached file will help you out. It is from my obd2 manual and covers dicover series 1.

good luck

 

[Mic]

Vac leak

Brad,
Thanks. I'll try to get on the Rave Disk for the Disco and trace it back on one of the lines. If anyone else has any experience with these vac lines and wants to chime in, I'd be more than happy to learn from experience rather than my mistakes.

Best Regards,
Tom