Discussion
Nearly there ! The guys at Lotus have replaced the transfer pipe under the engine between the two tanks and the smell is 90% gone. Residual whiff seems to be coming from the fuel service port on the front of the right side fuel rail. When I take the dust cap off, all the threads are wet with petrol. This would explain why the pressure test is OK. The fault lies with the thing you use to test for faults! Either the Schreader valve is leaky or the rubber thing inside the dust cap is inadequate. In case the factory cannot help, does anyone know where I could get a new valve of the correct type!? Looks like a bog standard push bike valve to me.
Which reminds me.....Have you checked this pipe lately??? I had one of the hoses between the pipe and one of the tanks split due to degeneration. Loads of hot petrol right in front of a hotter turbocharger with little stones flying up and maybe sparking off the chassis! Death comes on swift wings to those who don't check their pipes !!!!
At last ! I think that I have finally solved the question of the fuel smell. As previously reported. I thought that corrosion of the fuel tank transfer pipe was responsible. The smell appeared to get 90% better after it was replaced. But no ! Within a week, the smell was as bad as ever. It was only after talking to the ever helpful technical line at the factory that I finally worked it out. For anyone who has never caqlled technical support at the factory, you have no idea what you are missing out on ! Those three guys are worth their combined weight in carbon fibre !
It was their idea that finally lead to my realising what the problem is.
Going back to the start, I had a smell of petrol which was worst below the fuel tank transfer pipe and above the right rear three quarter glass. I even went as far as a quote for new tanks !
Anyway, the mechanic at the dealership told me that the clips on the right hose were loose and that they had tightened them. The smell persisted and the pipe was corroded. They replaced the pipe and tested the system VIA THE SERVICE PORT and found that the pressure held. The smell was gone.
Within a week, it was as bad as ever! The mechanic was surprised when I called as the smell has been absent when they gave me back the car.
I was sure that the smell was coming from the service port and when I suggested using a more substantial dust cap to the technical guys at the factory, they pointed out that the pressure under the cap would eventually equal that in the fuel rail and would blow the cap off and would certainly bypass a coating of grease or mastic, which was my other suggestion.
I should point out at this stage why what might seem a trivial problem is actually a pain. The car lives in an integral garage for 80% of its time with the kitchen being the next room. For the last twelve months, the whole house has smelled of petrol and food was tasting of it also (not to mention any carcinogenic effects of eating food tainted with petrol). I am afraid that, despite the car being somewhat nostalgic (old carb. Esprits smelled of petrol and leather for any owners brought up on fuel injection) I was handed an ultimatum by the family!
Anyway, here is the explanation (and question):
The smell UNDER the car was fixed when the clips were tightened.
Despite the corrosion, the transfer pipe has no leak at all.
The smell appeared to improve because replacing the pipe had released the pressure in the system (and hence, under the service port dust cap) and this had to build up again before the fumes would bypass the dustcap.
The problem is, and 90% always has been, a slightly leaky service port.
The leak was not detected on pressure testing as the test is done via the leaky port itself.
The smell appeared to be intermittent because every time I removed the dustcap from the service port to look for spilt fuel, I was releasing the pressure under the cap. This pressure would then slowly rise as the car was used, until it reached a level high enough to force fumes past the threads of the dustcap.
I have tried several new valves and a new dust cap. I have tried generic valves from Halfords (UK bike and car spares shop) and GM valves from scrap yards. I have cleaned the valve seat and replaced the dustcap. I have drilled the centre of the dustcap seal to avoid pressure on the valve stem. All to no avail.
Guess what the solution is ??
Simple: I remove the dustcap once a week for about three minutes and this stops the smell for about a week.
Any better ideas? A new fuel rail (the only way to replace the valve) is about £400 ($750) pluss fitting !
Still, could be worse, at least I never got round to replacing the fuel tank !
Sorry that was a bit of an essay, but it might help someone and I had to get it off my chest !!
It was their idea that finally lead to my realising what the problem is.
Going back to the start, I had a smell of petrol which was worst below the fuel tank transfer pipe and above the right rear three quarter glass. I even went as far as a quote for new tanks !
Anyway, the mechanic at the dealership told me that the clips on the right hose were loose and that they had tightened them. The smell persisted and the pipe was corroded. They replaced the pipe and tested the system VIA THE SERVICE PORT and found that the pressure held. The smell was gone.
Within a week, it was as bad as ever! The mechanic was surprised when I called as the smell has been absent when they gave me back the car.
I was sure that the smell was coming from the service port and when I suggested using a more substantial dust cap to the technical guys at the factory, they pointed out that the pressure under the cap would eventually equal that in the fuel rail and would blow the cap off and would certainly bypass a coating of grease or mastic, which was my other suggestion.
I should point out at this stage why what might seem a trivial problem is actually a pain. The car lives in an integral garage for 80% of its time with the kitchen being the next room. For the last twelve months, the whole house has smelled of petrol and food was tasting of it also (not to mention any carcinogenic effects of eating food tainted with petrol). I am afraid that, despite the car being somewhat nostalgic (old carb. Esprits smelled of petrol and leather for any owners brought up on fuel injection) I was handed an ultimatum by the family!
Anyway, here is the explanation (and question):
The smell UNDER the car was fixed when the clips were tightened.
Despite the corrosion, the transfer pipe has no leak at all.
The smell appeared to improve because replacing the pipe had released the pressure in the system (and hence, under the service port dust cap) and this had to build up again before the fumes would bypass the dustcap.
The problem is, and 90% always has been, a slightly leaky service port.
The leak was not detected on pressure testing as the test is done via the leaky port itself.
The smell appeared to be intermittent because every time I removed the dustcap from the service port to look for spilt fuel, I was releasing the pressure under the cap. This pressure would then slowly rise as the car was used, until it reached a level high enough to force fumes past the threads of the dustcap.
I have tried several new valves and a new dust cap. I have tried generic valves from Halfords (UK bike and car spares shop) and GM valves from scrap yards. I have cleaned the valve seat and replaced the dustcap. I have drilled the centre of the dustcap seal to avoid pressure on the valve stem. All to no avail.
Guess what the solution is ??
Simple: I remove the dustcap once a week for about three minutes and this stops the smell for about a week.
Any better ideas? A new fuel rail (the only way to replace the valve) is about £400 ($750) pluss fitting !
Still, could be worse, at least I never got round to replacing the fuel tank !
Sorry that was a bit of an essay, but it might help someone and I had to get it off my chest !!
Just a thought. Maybe put a fitting where the dust cap goes and splice it into the line from the charcoal canister upstream from the one way check valve it is right near that spot anyway. That way the fumes are sucked into the engine and burned along with vent gases from the fuel tanks.
Edited by cnh1990 on Wednesday 3rd January 13:24
toyroom said:
Simple: I remove the dustcap once a week for about three minutes and this stops the smell for about a week.
Any better ideas? A new fuel rail (the only way to replace the valve) is about £400 ($750) pluss fitting !
Any better ideas? A new fuel rail (the only way to replace the valve) is about £400 ($750) pluss fitting !
Sounds pretty foolish to me. Would you prefer the car burn to the ground?
You don't need to replace the fuel rail, just the fuel pressure regulator. The regulator comes complete with a new cap.
toyroom said:
And another thing...the leak is not from the regulator, it is from the service port...and, a new cap would not help as the pressure would eventually bypass it.
The service port is part of the regulator. I am aware a new cap won't help, I just pointed out that you'll get a new one with the regulator. Which includes the service port. No replacement fuel rail required, as you stated before.
Don't you think a small leak now could turn into a bigger leak later? Whatever, it's your car.
Edited by sanj on Thursday 4th January 15:23
The service port I refer to is a small stubby appendage made out of the same piece of metal (all one piece, no joints) as the right hand cylinder bank fuel rail. As such, it is physically impossible to replace it without replacing the fuel rail. My car is a V8, by the way. Is the system you describe the one on the 4 cylinder engine ? Or am I giving the service port an incorrect name?
Whatever, the leak got slowly worse but has now been stable for months. It amounts to a smell rather than escaping liquid petrol. I have discussed this problem with many people (including the factory) and (until now) no-one ever said it sounded foolish. I published the story in case anyone else had the same problem and wanted to avoid the twelve month detective story I had to go through. I do appreciate your concern however and I can assure you that the car is cosseted in every way, especially safety.
Whatever, the leak got slowly worse but has now been stable for months. It amounts to a smell rather than escaping liquid petrol. I have discussed this problem with many people (including the factory) and (until now) no-one ever said it sounded foolish. I published the story in case anyone else had the same problem and wanted to avoid the twelve month detective story I had to go through. I do appreciate your concern however and I can assure you that the car is cosseted in every way, especially safety.
Actually spelling is wrong, its "John" 
How does everyone know I've got a stunning V8 ?? I mean it is stunning (I think all Esprits are. S1 to sport 350, there are no dogs at all. More than can be said for most other cars of this ilk. For example: the radiator covers of the Countach Anniversary were more Max Power than Bertone) Only my humble opinion, of course!
Regarding the fuel rail on the Lotus V8.
I know Johan melted his plastic fuel rail with a work light...
He ended up replacing it with this since Lotus wanted several hundred $$$ for "a little piece of plastic".
www.extremeesprit.com/Perf__Mods/FuelSystem/fuelsystem.html
I know Johan melted his plastic fuel rail with a work light...
He ended up replacing it with this since Lotus wanted several hundred $$$ for "a little piece of plastic".
www.extremeesprit.com/Perf__Mods/FuelSystem/fuelsystem.html
toyroom said:
How does everyone know I've got a stunning V8 ?? I mean it is stunning (I think all Esprits are. S1 to sport 350, there are no dogs at all. More than can be said for most other cars of this ilk. For example: the radiator covers of the Countach Anniversary were more Max Power than Bertone) Only my humble opinion, of course!
your right they all look great. I have seen some Esprits in bad shape, but they still look incredible. Its hard to peg down a favourite. [quote=lotusse89] ....
He ended up replacing it with this since Lotus wanted several hundred $$$ for "a little piece of plastic".
......
quote]
good looking fuel rail upgrade.
we often overlook that the esprit is a piece of plastic. i prefer the ones without toy-odor tail lenses. i'm always stunned by the price of parts; dare i call them lotus parts.
He ended up replacing it with this since Lotus wanted several hundred $$$ for "a little piece of plastic".
......
quote]
good looking fuel rail upgrade.
we often overlook that the esprit is a piece of plastic. i prefer the ones without toy-odor tail lenses. i'm always stunned by the price of parts; dare i call them lotus parts.
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