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TBI leaking gas

Low87

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May 19, 2011
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Broken Arrow, OK
Truck won't start this morning. Tried to catch but failed. Turns over like no gas. Popped the hood and the intake is covered in gas. Can't see any one place that appears to be leaking. Seems like its low on the TBI though. Do I just have a bad o ring somewhere? Right now I'm thinking maybe grab a TBI rebuild kit and be done with it.
Any other ideas?
 
This has the potential to be really nasty, so you need to take certain precautions. Overkill is not a bad thing here.
First, if the vehicle is close to anything you like, house, other car, boat, move it.
Leave the hood open until all the gas has dried out.
Then, take a bright light and look for the obvious. Broken fuel line, something fell off, that sort of thing.

If you don't see anything, start rounding up some help. You really need at least one other person. And it needs to be someone who has fairly steady nerves.

Then get at least one fire extinguisher, more than one is nice. Depending on the type of engine and height above ground, I like a heavy blanket soaked with water that has some baking soda mixed in as well.

When everything is ready, have someone turn the key on for a second. Since its TBI, the fuel pump should come on for a second and you may see the leak.
The reason I want someone with good nerves, is in case something happens. Its not a big a problem with modern cars, since the fuel pump stops after a few seconds if the engine does not start.

On older trucks, you had to bump the engine or even start it to get fuel pressure. I had one crank and catch on fire at the same time.
I yelled turn it off, but the guy doing the cranking was already 20 feet away and moving fast.
I had to snatch the coil wire off, pick myself back off the ground and then put out the fire.

If you don't see gas squirting, look around for a wet spot before you try it again. The idea is to find the leak with minimum leakage.

If no luck at first, keep turning the key on and off until you find it.
While there are ways to bump the fuel pump from under the hood, the less chance of sparks the better.
Remember gas fumes will ignite quite a distance from the source of gas.

I know it sounds like I am being over cautious, but I have scars to tell why......
 
If it's on the intake, I'd be looking at fuel lines first, but I *have* heard if the pump is running and there is a leak on one of the injector seals, the throttle bore will fill up and overflow.

Should be pretty simple, pop the air cleaner off, have someone turn key to run (no reason to crank the motor, the fuel pump prime should take care of it) and watch what is happening. If nothing from the fuel pump prime, you can run 12V directly to the red wire hanging off the fuel pump relay, which will operate the pump until you disconnect the wire. No cranking needed.
 
I got a TBI rebuild kit, and the O-rings they supplied for the injectors were a little too big. I tried them anyway, and the spray pattern was all off. Truck ran, but horribly. Went back to the old O-rings and everything was fine. Not sure if any of that applies to you, but just be careful if you go the rebuild kit route.
 
Thanks guys - I was out there working on it while you all were replying. Had my boss calling bugging me to get to work. I love being a peon.

Fuel lines were secure & solid. Not to mention dry.

I pulled the TBI to check the injector o-rings. Everything looked good (I'd rebuilt it in Nov) except I had the rubber o-ring & the metal ring reversed (rubber on top of metal). I fixed that & bolted it back together. Also pulled the plugs to dry them off. #3 & 8 had serious deposits on them.

All back together & it fired right up, no leaks. However, it ran like hammered crap. A lot of dark grey smoke coming out the exhaust every other revolution. The driver's side injector (rebuilt injectors, less than 3 months old) was dripping heavy gas rather than a cone spray like the pass side.

Figured it ran, but not great, so I'd get to work and deal with the rest tonight. Well, I made it 1/2 mile when it died & wouldn't start (at an intersection naturally). Sat for about 10 minutes and got it started again. This was icing on the crap cake of my still young day, so I limped it to a trusted mechanic. Needed to wash my hands of it this time.

Got a ride to work, should hear from the mech tomorrow.
 
Meant to note that when I unplugged the vac line that goes to the charcoal canister, a little bit of gas came out. I read something about this a while back but can't remember what it meant.
 
My vote was originally for a ruptured fuel pressure regulator diaphram but now sounds like a bad injector.
 

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