Gas Smell

Hello All,

For the last couple of weeks as I make my commute to and from work and wherever else I go, when i stop and park my Bronco I smell gas.  A strong smell.  i have waited to see if a leak is present i have opened the hood and did a visual.  I smells like I have a flooded carb.  The thing is i have an EFI truck. 

I can't think of any possiabilites of what it may be.  I am worried I have a pool of gas somewhere.  Like I have said though there aren't any leaks so I guess that rules out.  It is something new but it is on a long list of things that need to be addressed.

Any thoughts or ideas to where or what this may be.  i could be just be over worried about nothing but I am curious of anybody here has dealt with this.

Good you're not taking this lightly. Gas leaks don't always drip. The fuel can spread out on something

& evaporate pretty quickly. That's what you're smelling, those evaporation fumes.

One suspect would be the filler hoses. They can crack & leak.  Fuel splashes around & up in there,

especially with a full tank.

Filter connections..?

Maybe rent a fuel pressure tester & see if the pressure drops off after eng. is shut off.

Ahh good idea.  Time to get dirty and investigative.  i will look into it thank you for some insight on how to start.

I'll bet the Supreme Commander :-B   suggests looking at he injector seals. . 

yo Grizz, As the guys advised;

This from 1996 F-150, F-250, F-350, F-Super Duty and Bronco with Gasoline Engines Workshop Manual (PARTIAL)

Same as most earlier years exc. for OBD II in 96, 4WABS (93-96); ABS (87-92); Air Bag (94-96); 3 ***** Automatic Locking Hubs (Built from May 95 through 96); Spark Plug Wire Routing & Firing Order (The firing order for 1987-1993 5.0Ls is 1-5-4-2-6-3-7-8. The firing order for 1994- 96 5.0Ls & all 5.8Ls is 1-3-7-2-6-5-4-8.);

2-piece Spindle Rolling Diaphragm Seal (RDS) used on 5/95 to 96 Broncos & F Series 1/2-ton 4WD

and a few other items that I still need to research

http://www.diesel-dave.com/vehic/manual/stj/stjleft.htm

Section 10-01A: Fuel Tank, Filters, Tubes and Electric Fuel Pump, Gasoline Engines

http://www.diesel-dave.com/vehic/manual/stj/stja1a01.htm

DESCRIPTION AND OPERATION

Fuel Injected Engines

WARNING: TANK-TO-INJECTOR FUEL INJECTION SUPPLY MANIFOLD REMAIN UNDER HIGH PRESSURE AFTER THE SYSTEM IS SHUT OFF. DEPRESSURIZE THE FUEL INJECTION SUPPLY MANIFOLD AT THE SCHRADER VALVE LOCATED ON THE ENGINE FUEL INJECTION SUPPLY MANIFOLD RAIL BEFORE DISCONNECTING ANY FUEL TUBE. DISCONNECTING FUEL TUBES WITHOUT DEPRESSURIZING THE SYSTEM AS DESCRIBED IN THIS SECTION CAN RESULT IN INJURY FROM FUEL BEING SPRAYED UNDER PRESSURE. ALSO, FUEL SPRAYED UNDER PRESSURE IS AN OBVIOUS FIRE HAZARD.

F-Series and Bronco vehicles are equipped with multiport fuel injection (MFI) engines (6007). Separate electronically controlled fuel injectors (9F593) are mounted in the intake manifold (9424) on the runner for each cylinder.

Each fuel injector is mounted so that it sprays fuel into the cylinder head intake port of its cylinder. The fuel injectors are supplied fuel under high pressure through an engine-mounted fuel injection supply manifold (9F792) which also has a fuel pressure regulator (9C968). The fuel pressure regulator controls the pressure of fuel going into the fuel injectors and returns excess fuel to the fuel tanks (9002).

For a description of the operation of the fuel injectors and fuel injection supply manifold, refer to Section 03-04A for 4.9L, Section 03-04B for 5.0L and 5.8L, or Section 03-04C for 7.5L.

On all vehicles, a fuel pump (9350) located in a fuel delivery module (FDM) in the fuel tank supplies fuel under high pressure to the fuel injection supply manifold.

All vehicles have an in-line fuel filter (9155) mounted on the frame rail under the vehicle.



Check (EZiest FIRST):

Fuel Tank Filler Cap; rubber seal may be cracked/damaged; if so, buy new Cap With tether @ Ford dealer or via Amazon)

Fuel Tank for Leaks; underneath or atop skid plat and rolling down around skid plate

tank leaks also from fill hoses as stated and from evaporative emission valve centrally located on the upper surface of the fuel tank and is installed using a rubber gasket seal.

in-line fuel filter mounted on the frame rail under the vehicle; under driver's seat

Fuel and Vapor Return Tubes from tank to filter and Fuel Pressure Regulator 0n driver side rail near firewall to injectors via fuel rail and pressure test Schrader valve on driver side rail

Fuel Pressure Regulator;

Pull the vacuum line on the FPR- any gas aroma or gas inside line, Replace FPR because its diaphragm is ruptured. if needed

Is attached to the fuel injection supply manifold downstream of the fuel injectors. It regulates the fuel pressure supplied to the fuel injectors. The fuel pressure regulator is a diaphragm-operated relief valve in which one side of the diaphragm senses fuel pressure and the other side is subjected to intake manifold vacuum. The nominal fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold pressure maintains a constant fuel pressure drop across the fuel injectors. Fuel in excess of that used by the engine is bypassed through the fuel pressure regulator and returns to the fuel tank (9002).

see diagram and more @ http://www.diesel-dave.com/vehic/manual/stj/stj34b08.htm

FPR, Injector & Rail pic



Source: by SeattleFSB (Seattle FSB)

fuel pressure regulator Replacement pics in a 94

Source: by 1994xlt (Cole R





Filter; Diagrams; Read More; Steve also shows Collar/clamshell tools

Source: by Steve

http://www.supermotors.net/clubs/superford/registry/2742/12737

===

94 FUEL PRESSURE

ENGINE RUNNING 30-45 PSI KEY ON,

ENGINE OFF 35-45 PSI

Note: Maximum fuel pressure is obtainable at WOT or the vacuum hose removed from the fuel pressure regulator.

Also, Is Check Engine Light ON while driving?

Nevertheless, Try a Self Test for Diagnostic Trouble Codes (DTC)s by my pal, BroncoJoe19

http://broncozone.com/topic/14269-code-reader/?pid=74587&mode=threaded

A helper is good to assist in reading Codes; best is to take a cell fone vid and replay it.

Some basics;

Visual Check

Battery is fully charged & connectors and grounds are clean

Inspect the air cleaner and inlet ducting.

Well yesterday prior to reading the latest postings this morning I found it is a fuel injector leaking.  Problem, this is my only vehicle and I need to know is it possiable to change out all the injectors in a late afternoon after work.  Also do I need to pull the upper intake to acheieve this.  i had a hydro lock up this morning but luckly was able to get to turn over.  i am aware of the very high and dangerous hazards of driving this truck like this.  I have not had an engine light on as of yet, i have an extinguisher on hand and  I am trying to source out some injectors today.  Now i wish it was the filler hose that was leaking versus this.  any advice would be appreciated. thaks

yo G,

See

Section 03-04B: Fuel Charging and Controls, 5.0L and 5.8L Engines

Vehicles Equipped with 5.0L and 5.8L SFI V-8 Engines Workshop Manual (PARTIAL)

REMOVAL AND INSTALLATION

Fuel Injectors

http://www.diesel-dave.com/vehic/manual/stj/stj34b18.htm

Rebuild in a 94 5.8

Source: by joelb23 http://fullsizebronco.com/forum/showthread.php?t=42535

==========

Injector Removal, Testing & Cleaning

Source: by Ryan M (Fireguy50) at http://web.archive.org/web/20110920233959/http://www.fordfuelinjection.com/?p=82

==========

make sure you;

relieve fuel pressure by using Inertia Fuel Shutoff (IFS) Switch...

WARNING: IF YOU SEE OR SMELL GASOLINE AT ANY TIME OTHER THAN DURING FUELING, DO NOT RESET THE INERTIA FUEL SHUTOFF SWITCH.

CAUTION: Do not reset the inertia fuel shutoff switch until the complete fuel system has been inspected for leaks.

In the event of a collision, the electrical contacts in the inertia fuel shutoff switch open and the fuel pump (9350) automatically shuts off. The fuel pump will shut off even if the engine (6007) does not stop running. The engine, however, will stop a few seconds after the fuel pump stops. It is not possible to restart the engine until the inertia fuel shutoff switch is manually reset.

To reset the inertia fuel shutoff switch, depress the button on top of the inertia fuel shutoff switch.

Switch Location

The inertia fuel shutoff switch is on the right cowl panel just forward of the door below the instrument panel.

Inertia Fuel Cut-Off Switch Location in a 92-96 the inertia switch is behind Passenger side kick panel...

Location pic in a 94



socket for intake manifold *****

Removal, Upper Intake Tip & Tool; "...This is the Torx T-40 you're going to need to get that pesky inner center ***** out with to remove the EFI's upper intake. Trouble is you'll never get that 3/8" drive socket between the runners, with the space the way it is. I just drift the center part of the T-40 out. It happens to be 1/4" hex. Now it's seperated from it's 3/8" host housing. I use contact cement to glue the T-40 bit into a 1/4" drive 1/4" sized socket and then work with several 1/4" rachet extensions, which pass through the intake runners no trouble at all..."

Source: by Sixlitre (Malcolm H, Eddie Bauer)

http://www.supermotors.net/registry/4970/20145

Removal, Upper Intake, T40 Socket Overview & pic; "... This tool is made to help remove the upper intake from your vehicle. It is not needed for all Ford intakes. Some intakes have longer bolts that are easier to reach. But if you can only see 4 or 5 of the bolts holding the upper intake on the engine, you’ll probably need one of these. The bolt that you can’t see way down in the middle has a torx 40 head. It is possible to make a chain of 3/8 or 1/4 drive socket pieces to reach these bolts. But this page is about all the cool tools you don’t have yet..."

Source: by Ryan M (Fireguy50) at http://web.archive.org/web/20110707142544/http://www.fordfuelinjection.com/?p=12

=======

have O rings etc,

manifold gasket, etc.

vacuum hose to replace brittle sections

===========

Fuel Injector Replacement for your 1994 Ford Bronco

by Chilton;

AT DEALER -- 1.7 hours

SEVERE (not defined, but may mean DIY at home) -- 2.6 hrs

--

http://repairpal.com/estimator/results

Parts Included:

Fuel Injector

Fuel Injector Seal

$185-$236

Best Practices

•Using lower quality gasoline can result in recurring fuel injector problems, even after a fuel injector replacement.

•Fuel injector seals should always be replaced along with fuel injectors.

Common Symptoms

•Failing fuel injectors can cause engine misfiring and hesitation. The Check Engine Light may come on and set diagnostic trouble code(s).

yo Grizz.,

Sorry, was rushed and did not 'splain how to reduce/eliminate fuel pressure;

disconnect the battery

most trip the inertia fuel shutoff, then start engine until it shuts down; crank it over again

others take cap off of Schrader Valve on fuel rail and depress pin, but this is not safe.

On the subject of the Schrader valve.  That is what is leaking.  i wanted to look closer at the injectors to see what kind of shape they are in and how bad is the leak.  Well as i was poking around i notced the gas bubbling out of the valve.  I dont have a valve stem tool but I am sure there is one here at work.  Fingers crossed to that being the problem.  On reliving fuel pressure I usually pull the fuse for the pump and turn the motor over a couple times.  Keep everyone posted on the progress of this.  And again thanks for the help.

Great.., & good you found that..!  Saved a lot of unnecessary disassembly labor.

Auto parts will have the tool.., prob. the same as is used for all wheel valve stems.

They'll have the valve as well.

And, thanks for the "updates" ...!   Somewhat rare these days.

yo G,

GREAT!

On the valve; I heard from a Ford tech 10 yrs ago that the fuel sys valve is Not same as used on tires/ or AC

Here is some info;

"...Do not attempt to use a Schrader valve designed for air or refrigeration for test port applications on fuel injection systems as neither of these types of valve cores are rated for the engine temperatures found underhood or the corrosive actions of fuel compounds. The non-fuel rated types of valves will leak and will potentially cause a fire hazard under your hood!

WARNING: Do not use the Schrader valve when connecting a permanent fuel pressure gauge under the hood. This fitting is designed for temporary test port connections only..."

http://www.dieselorings.com/1999-2003-ford-7-3l/fuel-bowl-parts/schrader-valve-fuel-injection-rated-1-8-mnpt.html

by SeattleBronco; "...The Schrader Valve is 1/8" NPT and has threads on both sides, double male if you will. The valve itself appears to be easily replaceable except for the fuel rail port which is an integral part of the OEM fuel rail. I am headed for the JY today and I will look for one.

Personally, I installed a BBK Mechanical Fuel Pressure Gauge which came with adapter fittings to be used on Ford EFI Schrader valves. I tapped the gauge into an existing port located in the end of my aftermarket Fuel Rail.

http://www.supermotors.net/getfile/782906/fullsize/fpr--gauge.jpg

Without the Schrader Valve, you will have to release fuel pressure by activating the inertia switch with the engine idling when changing your fuel filter or working on the fuel system..."

MiesK5, so what your saying is if i were to replace the valve a standard tire valve wont work.  I work in a machine shop, so i am thinking then i will make a metal cap for that port with a gasket in it to seal the port.  I may just go to the junkyard and pull an old valve too.  thanks

yo,

Here is the info re the difference between tire and fuel Schrader Valves;

The fuel sys one has; Continuous Operating Temp - 0 to 450 F

System Pressure rating: 0 - 500 PSIG

Viton Cup Washer for gasoline or diesel fuel

The non-fuel rated types of valves will leak and will potentially cause a fire hazard under your hood.

Check

MOTORCRAFT Part # CM3461 {#E0AE9H321AB, EOAY9H321A} FUEL INJECTION FUEL RAIL PRESSURE RELIEF VALVE

Category: Fuel Injection Auxiliary Air Supply $5.64

http://www.rockauto.com/catalog/raframecatalog.php?catalog=48&partnum=CM3461&a=r.search.yahoo.com%2BSearch%2Bfor%2BMOTORCRAFT%2BCM3461&blanktemplate=true

http://www.oehq.com/oeparts_motcm3461.htm Call local Ford Dealer

http://www.oreillyauto.com/site/c/detail/MOT0/CM3461.oap?pt=06684&ppt=C0024

etc.

So $11.56 for the valve from the dealership, a 9mm wrench and ten miniutes and now I am not leaking gas.  A lot better than roughly spending a couple hundred and losing my vehicle for a couple days for an unessacary repair.  I was trying to be hopefull and upgrade the injectors to a better flowing injector.  That will come when i can upgrade the throttle body and ignition as well.  Thank you all for the advice and clarity in the matter. 

yo Grizz,

VG!

BTW, some have been known to say that I leak gas too!

yeah, i get that too, but you and i know there is no fixing it