Fix a leaky leaf blower fuel tank: repair tips and replacement advice

Got a leaky fuel tank on your leaf blower? It’s not just annoying—it can be downright dangerous. If you’ve caught a whiff of fuel or spotted any leaks, you’re probably asking yourself if you can fix it yourself or if it’s better to just get a new tank. We’re here to help you figure out what’s going on and decide the best way to keep your leaf blower running smoothly and safely.

Important: This article might not cover the specifics of your exact leaf blower model. Even though we aim to give useful tips for all DIY appliance repairs, different models and setups can mean variations in troubleshooting steps, error codes, parts, and so on. For the best advice, we highly recommend checking your manufacturer’s documentation or getting in touch with us if you’ve got any questions.

Common places where leaks occur

To fix a leaky fuel tank, you’ve got to figure out exactly where the problem is. Leaks can pop up in different parts of the fuel system, so knowing the source is key to fixing it right.

• Cracked fuel tank: Over time, the plastic tank can get brittle and develop cracks.
• Damaged fuel lines: Fuel lines might wear out, crack, or come loose.
• Worn-out grommets and seals: The spots where fuel lines go into the tank can have grommets and seals that deteriorate.
• Faulty primer bulb: If the primer bulb is cracked or damaged, it can leak fuel.
• Leaky fuel cap: The seal on the fuel cap might fail, leading to leaks when you’re using the blower.

Safety precautions   

When working on any appliance, remember to keep safety first. Here are some tips to keep in mind: 

• If working indoors, make sure there is adequate ventilation to prevent the buildup of exhaust fumes. Carbon monoxide poisoning can be a serious risk.
• Wear insulated work gloves to protect your hands from sharp metal parts, pinching hazards and debris.
• Never attempt to service or repair while it is running or when the engine is still warm. Wait for all moving parts to come to a complete stop.
• Exercise extreme caution when working near blades, augers, or any other moving parts. Keep your hands, fingers, and clothing clear of these areas at all times.
• If the appliance has recently been used, give it plenty of time for any hot parts to cool down before working on it. 
• Empty the gas tank before beginning any work. Refill using fresh fuel. 
• When working with wires, avoid touching any exposed wires or terminals. If you need to touch a wire, use a non-conductive tool or wear insulating gloves to prevent electrical shock.
• Take your time and don’t rush while working to prevent accidents and personal injuries.
• Work in a well-lit area so you can clearly see and access the interior parts.
• Clear your workspace of clutter and other obstacles. Keep children and pets away from the work area.
• Be gentle when handling or removing parts. Excessive force might damage the appliance or cause injury.
• Wear safety glasses when working with chemicals, dust or cleaning large debris to prevent injury. 
• When not in use, store the machine in a safe and dry location.

How to find the leak

1. Take a look: Check for any signs of fuel or wet spots on and around the fuel tank.
2. Check the fuel cap: Inspect the fuel cap and its seal for any cracks or wear and tear.
3. Look at the primer bulb: Give the primer bulb a press and see if any fuel leaks out around it.
4. Examine the fuel lines: Look over the fuel lines for cracks or if they’ve come loose. Gently pull on them to make sure they’re firmly attached.
5. Inspect grommets and seals: Check where the fuel lines go into the tank for any damage or wear.

Minor fuel tank problems

If there’s a small crack in your plastic fuel tank, you can try fixing it with a fuel-resistant epoxy that’s made for plastic fuel tanks.

What you’ll need

• Fuel-resistant epoxy or a fuel tank repair kit
• Heat-resistant gloves
• Safety glasses
• Clean rags
• Medium-grit sandpaper

How to repair it

1. Empty the fuel tank: Drain all the fuel and let the tank air out to get rid of any fumes.
2. Clean around the crack: Use a clean rag to wipe away any dirt or fuel residue near the crack.
3. Sand the area: Gently sand around the crack to help the epoxy stick better.
4. Apply the epoxy: Mix the epoxy as per the instructions, and apply it evenly over the crack, going a bit beyond the damaged area.
5. Let it cure: Allow the epoxy to cure for the time recommended by the manufacturer.
6. Check for leaks: Put a little fuel back in the tank to see if the repair worked.

Note: Keep in mind, this fix might not last forever. For long-term safety and reliability, you might want to replace the tank altogether.

Swap out bad fuel lines

Fuel lines that are damaged can lead to leaks and make your engine run poorly. Replacing them is pretty simple.

What you’ll need

• New fuel lines (Silicone or Tygon lines work great)
• Utility knife or scissors
• Screwdriver (if needed to get access)

How to replace them

1. Get to the fuel lines: Take off any covers or shields to expose the fuel lines.
2. Remove the old lines: Carefully pull the old fuel lines off the fittings on the fuel tank and carburetor.
3. Cut new lines: Cut your new fuel lines to the same length as the old ones.
4. Attach new lines: Connect the new lines to the carburetor and fuel tank fittings, making sure they’re nice and snug.
5. Secure everything: Check that the lines are routed properly and aren’t kinked or pinched anywhere.
6. Put it back together: Reinstall any covers or plates you took off earlier.

If you need more help, check out our repair help section.

When to get a new fuel tank

If your fuel tank is badly damaged or your repairs didn’t fix the problem, it’s probably time to replace the tank.

• Big cracks or holes in the tank
• Leaks keep happening even after you’ve tried to fix them
• The plastic of the tank is breaking down
• Fuel is getting contaminated because the tank is degrading

How to swap out the fuel tank

Changing the fuel tank isn’t too hard if you’ve got the right tools and a little patience.

What you’ll need

• A replacement fuel tank that fits your leaf blower model
• Phillips and flat-head screwdrivers
• Wrenches or a socket set
• Needle-nose pliers
• New gaskets or seals if they’re not included with the new tank

How to change it out

1. Find your model number: Before buying a new tank, find your leaf blower’s model number. If you’re not sure how, check out our guide on how to find your appliance’s model number.
2. Drain and clean: Empty any leftover fuel and clean around the tank area.
3. Disconnect fuel lines: Use needle-nose pliers to carefully remove the fuel lines from the tank.
4. Take off the tank: Remove any bolts or screws holding the tank in place. Keep track of any washers or spacers.
5. Swap over components: If needed, move the fuel cap, grommets, and fittings to the new tank.
6. Install the new tank: Put the new tank in place and secure it with the original bolts and screws, making sure to replace any washers or spacers.
7. Reconnect fuel lines: Attach the fuel lines to the new tank’s fittings, making sure they’re nice and tight.
8. Check all seals: Make sure all gaskets and seals are properly installed to prevent any future leaks.
9. Test it out: Add fuel and start up the leaf blower to check for leaks and make sure everything’s working right.

If you need help finding the right fuel tank or parts, our repair help section can be really useful.

Still need help?

If you’re not sure about fixing or replacing your leaf blower’s fuel tank, we’re here to help. Head over to AppliancePartsPros.com for expert advice, top-notch replacement parts, and lots of DIY repair resources.

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