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Old 10-13-2011, 01:12 PM   #1 (permalink)
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Gas Smell on Fill Up (1995 Prizm)

1995, 1.8l auto, 138,000 miles

Yep, I am posting about a 1995 Geo Prizm, the red-headed step-brother...

I recently started driving this car (it was my fiancee's car, she now has a newer Focus) and discovered that every time I fill the car up (I stop the first time the pump clicks off) I have a terribly strong gasoline odor for a day or so afterward. I have to drive at least 50 miles before it disappears. The smell is primarily outside the vehicle and is not there when the vehicle is being driven, but I cannot localize it and there is never a puddle or any dripping which I can see.

Any ideas on where and what to look for?

Another (possibly related) problem...this car loves to idle at 25 mph when cold, and will hunt for an idle speed when it is just warming up and in neutral. I.e., about 5 minutes after starting in cold whether it will attempt to kick the idle down, then immediately rev back up again, cycling that way about once every 2 seconds. I have been unable to find a vacuum leak, but begin to wonder if the two problems are related or not.

Thanks for any suggestions.

Randy
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Old 10-13-2011, 03:14 PM   #2 (permalink)
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As far as the high idle and hunting, I've seen that behavior when the catch can on my PCV hose has the drain valve open, IE, a vac leak. Try replacing the PCV and hose (a couple bucks at most) and see if that resolves the issue.

For the gas smell, have you checked the fuel filler neck? It could be that rotting/tearing away slightly, it could be a bad spot in the very top of your gas tank, it could even be a fuel line.
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Old 10-13-2011, 07:11 PM   #3 (permalink)
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Quote:
Originally Posted by Piloter View Post

For the gas smell, have you checked the fuel filler neck? It could be that rotting/tearing away slightly, it could be a bad spot in the very top of your gas tank, it could even be a fuel line.
I was gonna mention a rotted filler neck, check for gas leaking out or something.

get it on a lift and look elsewhere too.
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Old 10-17-2011, 08:53 AM   #4 (permalink)
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Thanks for the suggestions...still looking into this, so I have not resolved it yet. I replaced the PCV valve last year and at the time did not find a problem with that hose, and it also did not resolve the high idle/idle hunting at that time. Is it possible the EVAP line(s) are damaged?

As for the gas smell, it is so strong it is hard to localize. The fact I can't find liquid gasoline when it smells that bad is just weird to me. I will take some more time this week to look.
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Old 10-17-2011, 07:12 PM   #5 (permalink)
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....When you drive until the fuel light comes on, then pop the cap, do you notice a hiss of escaping air? That's a sign of a clogged/plugged charcoal canister, if it were backed up enough it might be flooding with gasoline and taking a while to pull it back out again...
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Old 10-17-2011, 10:27 PM   #6 (permalink)
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fuel tank is leaking, gotta be. I'm willing to bet your tank is leaking bro. Need to get under there and look good, on the sides, feel on top, feel around the tank. If you still have that protective black paint on the tank, the leak may be hard to spot. But if you have a gas odor as you described...theres def a leak, and my educated guess is fuel tank. Notice any unusual pressure built up in the tank before?
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Old 10-25-2011, 12:21 AM   #7 (permalink)
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Whoa. Sure hope it isn't a fuel tank leak. Car sat from November last year until mid October this year in my garage when I decided to start driving it. It had a 3/4 full tank when parked, and I started noticing the smell when I went into the garage in late summer. Wonder if the heat caused fuel expansion and eventually a leak somewhere??
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Old 10-26-2011, 06:48 AM   #8 (permalink)
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Update on this...Put the car on ramsps yesterday and got under it after filling the tank. Finally noticed a drip of gasoline on a VERY rusty line coming down from the top of the tank. Wow. what an absolute maze of pipes and hoses emanate from that tank. And rust like everywhere. (Michigan...what should I expect?) Now I am beginning to wonder about how crazy I am in trying to fix this car and keep it on the road.

Anyway, can't tell if the leak is from a bad hose or from a rusted steel line. Sheesh, why didn't they use stainless on those fuel lines????

Hate to think it, but I am guessing this means dropping the tank and replacing ALLLLLLLLL the hoses and fuel lines...they all looked pretty dicey...

Suggestions?
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Old 10-26-2011, 05:51 PM   #9 (permalink)
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As posted before its the filler neck thats rotted out. Happens on almost EVERY rusty corolla! If you work carefully you shouldnt break any of the other connections and hoses.

Idle problems on fuel injected cars are 99% of the time from an idle control valve. Most just need cleaning some of the electronic ones short out or go open.

Theres a DIY on here for cleaning.

-SP
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Old 10-27-2011, 07:29 AM   #10 (permalink)
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Could someone give me a link to the IAC valve cleaning? Tried but either don't understand the search function or entered the wrong terms.

Thanks.
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Old 10-27-2011, 11:16 AM   #11 (permalink)
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Just had the same problem with a 96 Corolla I bought a few weeks ago. Fuel smell only with a full tank: found out the filler tube and vent holes on top of the tank were pretty much rusted through.

Last weekend I replaced the tank, straps, filler tube, and pump strainer. I got all 4 on rock auto for ~$200. The fuel lines were rusty, just like yours, but the only one that looked particularly worrisome was the vent line. Worst case scenario is that it rusts out and slowly leaks vapors. Luckily, the OBD2 codes on my 1996 don't provide data on the evap system. And since yours is a 1995, you don't have to worry about passing emissions testing (if it's even required in your area).

Replacing the tank isn't too difficult. Took me about 3-4 hours. The Haynes manual instructions are good. You'll probably want to jack up all four corners. The rusted bolts might be tough to get out: I used an impact wrench. Make sure to wear eye protection, there will be plenty of rust flaking off. You'll have to drop the center exhaust pipe/heat shield as well. I just unbolted it at the muffler to give myself enough room to get the tank in/out.
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Old 10-27-2011, 01:29 PM   #12 (permalink)
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Unfortunately I waited until almost November to discover this (I am in Michigan). SO, not sure what I am going to do yet. Thanks for the suggestions...luckily I have the actual Geo Prizm workshop manual. Picked it up on eBay for $15 for the 2 volume set, and so far it has been pretty detailed and helpful...
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Old 10-27-2011, 06:49 PM   #13 (permalink)
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Quote:
Originally Posted by hancockr View Post
Could someone give me a link to the IAC valve cleaning? Tried but either don't understand the search function or entered the wrong terms.
Search doesnt work well for me either but people seem to find things!

I didnt find the thread but I did find a good pic kiwi corolla posted.



That should help a bit.

-SP
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