BMW F10 Gas Leak

The other day I got an F10 with a gas leak in the shop. The customer was complaining about a pretty bad gas leak. Sure enough, after having the car idle in my bay for about 5 minutes, there was a pool of gas by the right rear tire. I raised the car and inspected the gas tank, just in case they somehow hit something down the road and had broken it, but it looked like the leak was coming from higher up in the gas tank. I took the seat out and checked the right fuel tank cover and found it was full of gas. at this point I thought the seal was leaking, but then I saw the real issue. The connector with the big power and ground wires had over heated, causing it to melt the plastic and make a hole on the top of the fuel tank cap.

In this picture you can see the connector wires melted, and the burnt pin exposing a hole on the fuel tank cap. This will also turn on the check engine light due to an evaporative emission system leak.

Here's a closer look at the hole on the pin at the gas tank connector.

Here's a closer look at the connector.

As for repairs, I had to replace the right fuel tank cap, which comes with the fuel pump, and I had to cut the wiring and replace the connector and the pins. Not a difficult repair. The worst part of the whole deal is having my face right above the gas tank with the lid off. After a while of smelling so much gas I get a little woozy. No biggie, though.