Fuel System - Fuel Odor Noticed In Passenger Compartment

DIVISION: AUTOMOTIVE

CATEGORY: TECHNICAL

SECTION TITLE: ENGINE

TSB NO.: TS 19 05028

SUBJECT:
HARD TO FIND FUEL ODOR; DIAGNOSTIC INFORMATION

MODEL(S):
FORENZA, FORENZA WAGON, RENO (RQ420)

YEAR:
2006-2007

CONDITION:

A fuel smell/odor noticed in the passenger compartment while driving.

CAUSE:

Fuel injector(s) may have a very small amount of seepage where the electrical terminals exit the injector housing for the electrical connection. The leak, if present, is small and may be difficult to detect by visual inspection without removing the injector electrical connector.

CORRECTION:

First inspect vehicle for visible fuel leaks to eliminate any other issues not covered in this bulletin. If no visible fuel leak is found, inspect for leak/seepage from the fuel injector connectors. Follow the instructions below for specific diagnostic procedure.





PART(S) INFORMATION





WARRANTY CLAIM INFORMATION

Diagnostic Procedure:





WARNING:
The fuel system is under pressure. If the fuel leaks out under pressure, there is a risk of fire and severe personal injury. Carefully follow the procedure in the service manual; Section 1G - FUEL SYSTEM.

1. Disconnect the negative battery cable.

2. Disconnect all fuel injector electrical connections.





3. Inspect all injector connectors inside for evidence of fuel exposure. If any signs of fuel leakage are found in one injector, replace four(4) fuel injectors. See above picture.

4. Inspect all female connectors of wiring harness for dust seal swelling. If the dust seal is swollen, replace the affected wiring harness.





5. Inspect the fuel injector wiring harness for evidence of fuel exposure. Signs of fuel exposure include:

A. Unfurled electrical tape.

B. Damage to the wire insulation. Usually nearest to the injector electrical connection.

^ If condition "A" exists, carefully inspect the wiring harness insulation for further damage and if no damage is found, replace the affected electrical tape.

^ If condition "B" exists, replace the affected wiring harness.

Correction:

WARNING:
The fuel system is under pressure. If the fuel leaks out under pressure, there is a risk of fire and severe personal injury.

Carefully follow the procedure in the service manual; Section 1G - FUEL SYSTEM.

Replace four(4) fuel injectors if fuel leakage is detected in one injector and replace the affected wiring harness if needed. Refer to the service manual for replacement procedure.

CAUTION:
Pay special attention to fuel injector installation procedures. Failure to follow proper fuel injector installation procedures may result in severe fuel or vacuum leakage and/or fuel injector damage.

^ Properly lubricate injector O-rings. Apply a small film of clean engine oil to the upper and lower injector O-rings, prior to installation. Lack of lubricant may result in O-rings damage during installation. Improper lubricant usage may result in fuel flow restrictions or internal injector damage.

^ Carefully inspect all fuel system connections upon completion of the repair. Pressurize the fuel system and inspect all O-ring interfaces and fuel rail connections for leakage.





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