28/04/2026
Fault finding is often the hardest part of any mechanical job.
This one started as a real head scratcher. With the engine running, fuel would slowly rise up the fuel filter neck, then overflow out of the cap and down the side of the car.
The only way to get to the bottom of it was to tap into both the feed and return fuel lines to see exactly what was happening. We needed to determine whether air was being introduced before the engine or somewhere on the return side.
As you can see in the video, one line is a steady flow of fuel with no air, while the other is heavily aerated.
Long story short — the issue turned out to be a faulty fuel injector. Instead of sealing properly when closed, it was allowing combustion pressure to pass through, into the leak-off system, and back down the return line to the fuel tank. This ended up pressurising the tank and forcing fuel back up and out of the filler neck.
Mental, I know. 20 years in the trade and that’s a first for me.
Vehicle: Mercedes A-Class 2.1 Diesel