I was out changing the thermostat in my LHS, and when I went to start it, I noticed a strong fuel smell coming from the engine. I looked under the car and saw fuel spots! Then I looked up under the car and I saw fuel just dribbling all over the pavement. I quickly shut the car off and tried to find what was leaking. It looks like fuel is coming out of the fuel rail. I have not had this replaced due to the recall yet. I have tried to think what could cause this fuel spilling out all over and what I may have done to cause it but I cant figure out anything that I did. I didnt bump anything. After I changed out the thermostat, I worked some more on my air intake box to add more air flow. I had drilled quite a few holes underneath of it, but today I went ahead and took out the bottom of it (no I did not work on the airbox in the car, I took it completely out). Could the computer sense this extra air and try to pump more fuel and cause the lines to overpressurize? This sounds improbable but I am trying to figure out what I did since yesterday when I last drove it and it was fine. The only thing I can think of is I added a strong fuel additive last night before filling up and driving home. Could this fuel additive have something to do with my fuel leak this morning? Nothing makes sense. If it is the fuel rail, how long do I have on the recall to get it replaced for free? It really seems like that is where the leak is coming from. I lightly touched the rail and it seemed that there was fuel coming out of it towards the engine side of it.
The fuel rail bends around the front of the engine near the thermostat on the 3.5L. There is a schroeder valve on the rail near the thermostat. Did you bump it?
My fuel rail leaked like crazy earlier this year (I bumped it when I changed out my inner tierod bushings). It leaked so much that I had it towed in to the dealer. They performed the recall procedures and the repair was free of course. I wouldn't recommend starting the car anymore until the recall work is done.
I took my vehicle into the dealership yesterday to have them look at my car due to it overheating. I am fairly confident that I did not bump this rail. I am wondering if they could have bumped it when they did diagnostics on it for an hour yesterday. Regardless, can they say they did not do it and make me pay for it, or can they just do the recall repair and fix it that way. Either way, if they try to accuse me of it, Im going to be royally t'd off. That rail is not even supported adequately.
Still, it leaks badly from both sides. How could this happen to both seals from a bump? I am wondering if this has something to do with my fuel system cleaner or the fact I opened up so much more air to the engine causing the PCM to send out more of a fuel mixture increasing the fuel pressure. I know it sounds crazy but I am trying to make sense of it all. If a fuel line is overpressurized, will it just go out the o-rings of the rail or what?
One more thing, if your car is inside a garage, I would shut off the breaker for it, and leave the garage door open. You dont want it filling up with gas fumes.
Here’s a pic of where mine leaked. It’s the outlet of the passenger side fuel rail where the fuel has a return running to the tank. Don’t worry, you did nothing wrong. The original fuel rail was poorly designed (poorly supported) and prone to cracking near where the arrow is on the pic. The dealer should also replace the injector o-rings (upper, lower, or both—I can’t remember).
It was horrible. I had it running for five minutes like that before I knew. The whole driveway and front of the house reeked of fuel. I turned off the LHS and got out the hose and rinsed the engine off and the driveway. I didnt know what to do about the garage door and powering it so I left it. Its just that my water heater and furnace were close by. I went back out a few minutes ago and put the car in neutral and rolled it down the driveway closer to the street and away from the house. I did start it one more time to make sure it was leaking from the rail and it was from both sides. This seems to me it wasnt bumped but perhaps over pressurized.
I thought the fuel rail was that U-shaped line by the thermostat. This is where it is leaking. The Haynes manual calls it a fuel pressure test port and it is leaking not at the port but at the clips on both ends of it.
The manual also mentions to check the air intake duct to the intake manifold for air leaks which will result in an excessively lean mixture. This didnt happen until I took out the bottom of my airbox and opened it up. Why would the manual say this unless too much air is not good?
I suppose the fuel rail could leak up front too, although, I haven't heard of one leaking up there. I'll try to find a better pic so maybe we can pinpoint the problem.
Tow it to the dealer. My 2002 Stratus had a failed o-ring and the whole front of the car went up in flames and was totaled out. The O-ring blew out the night before and the gas leaked all over the intake manifold the next day i get in and start it and bam it starts on fire and dies in the garage. I had to push it outside the garage on fire. The fuel lines are like under 65 to 80 psi.
Ok thanks. I did some research on the net and I have found quite a few places that state that too much airflow into your engine can wreak havoc on it. I have heard of other people opening up their airbox with no problems. So who knows. I would think that if the fuel rail was bumped, it would leak only on one side for the most part. But my U-shaped fuel rail next to the thermostat (3.5 engine) leaks badly from both sides and this didnt happen until I took out the bottom of my airbox. Could be related...
Yeah I am going to probably tow it there tomorrow. I just hope that I can get them to replace the fuel rails within a reasonable amount of time. Last time I called (over a year ago), they said they had to order them. I cannot wait forever to get these fixed.
Now I am leaning towards perhaps the fuel additive I used might have caused it (dont I sound confused). I cant see now how too much air flow can cause a fuel line to leak. Fuel lines cannot be so cheap that a little more pressure would blow them or their seals. The fuel additive I used I got at O'Reillys called Greased Lightning and it is fairly new on the market and is good for every 12,000 miles versus some of the other ones. Apparently it is supposed to be a strong cleaner. I put this stuff in over night. If my o-rings were already compromised due to the recall, perhaps this strong cleaner which was in constant contact overnight with the orings could have been the orings demise. This would make sense as to why they leaked on both sides and not just one.
Here’s a pic of the fuel rail and associated components:
Btw, it looks like the recall replaces a lot more stuff than I originally thought. Here is what is included in the recall kit (P/N CAXJ7901, Fuel Rail O-Rings and Reinforcement Package):
Also, if the outlet fuel rail is cracked and leaking, they will replace the fuel rail as apposed to reinforcing it. They had to on my car.
If the fuel injector O-rings leak after pressure testing, the injector o-rings will be replaced as well. (I would highly encourage the dealer to replace the injector o-rings, although technically they don’t have to foot the bill for those unless they are leaking.)
Once again, your air intake mod shouldn’t be a problem-- it’s just a coincidence. Even if you completely remove the intake tubing and air filter (i.e. minimal vacuum), our fuel pressure regulator will still only allow a max of 49PSI.
Thank you argus for all your help. That diagram gives me a good idea of how it looks. That crossover tube is the only thing leaking. The only problem now is to hope that the dealer has this in stock and I do not have to wait weeks for it. They should have these in stock but who knows. The last time I called which was awhile back, they didn't have anything. If they give me the same runaround, I will go threw the roof as this is my only mode of transportation.
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Related Threads
?
?
?
?
?
DodgeIntrepid.Net Forums
2.2M posts
41.9K members
Since 2001
A forum community dedicated to Dodge Intrepid owners and enthusiasts. Come join the discussion about performance, modifications, specs, parts, classifieds, troubleshooting, maintenance, and more!