HYBRID ONLY Fuel line issue

[rclee]

Hello MTC members. I just had an interesting day today. I started my Maverick this morning and started running some errands. While pulling out of my driveway I noticed a strong gasoline odor. We had a tree company doing work a house away, so I thought someone had spilled gas in the area. I went down the street a bit and the smell didnt go away even after rolling my window down. I pulled into a church parking lot to see if it was my truck. Oh Boy it was me! I opened the hood to see fuel all over the top of the engine, and some of it had mist like boiling water coming off of it. I am glad I stopped to check because if I went much further I bet it would have ignited.

I found the source of the leak. It is the main line going to the fuel rail. The line is solid on both ends and has a plastic line in between. I guess that is to help with vibration etc... Well, it had a little split in the plastic linesection and that is what was spraying the engine bay. The repair doesn't look too bad, so I thought I would do it myself and not get involved with the dealer. I called the parts department and asked if they had the fuel line. He replied that they don't have one and neither do any dealers around have one. He said he would have to order it and it would be about 4-5 days. That is when I changed my mind and had a tow truck take it to my dealer (Germain Ford Beavercreek Ohio) I talked to Jade and told her it was on it's way there and she set up an appointment for me at the dealership. I explained that the truck was going to be there for at least 4-5 days and asked if she could arrange a loaner for me. At first she said they had a line waiting for a loaner and I explained that my Maverick is four years old and I might be thinking about getting a new one She said they had a Bronco Sport courtesy car I could use. I snapped up that loaner car as fast as I could, because my only alternative was asking my mother-in-law to borrow her car. So now I am rolling in a new Bronco Sport with 2K miles on it. I get to experience what all the EcoBoosters love about that little turbo and I also get to see what its like using the push to start and the BIG screen.

Big shout out to Jade at Germain Ford for making my bad day much better with the loaner SUV!

The fuel line is the one with the orange part label on it.

EDIT: The orange label part is the protective cover for the plastic fuel line. The cracked line is underneath it.

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[ScottyC]

The Bronco Sport courtesy vehicle is likely a 1.5L 3 cyl EB motor so you will not get the "full effect" that the 2.0L 4 cyl EB motor in the Maverick has, but that aside, glad you got a loaner and quickly into the dealer for service.

 

[OleFordGuy]

The Bronco Sport courtesy vehicle is likely a 1.5L 3 cyl EB motor so you will not get the "full effect" that the 2.0L 4 cyl EB motor in the Maverick has, but that aside, glad you got a loaner and quickly into the dealer for service.

Yep think it has to be a Big Ben’s? If I remember correctly to have the 2.0turbo

 

[Tailender]

Glad you caught that before it became a fireball!

 

[SafetyGuy]

Good day, @rclee

Wow, I am wondering if this is something to report (I have seen much less hazardous incidents reported, here on MTC) to see if this is a widespread issue and is this plastic line under engineered for its potentially catastrophic consequences if it fails!

You may save lives if there is a problem with the quality of the line and its designed purpose.

I think it is reported to your NHTSA? I checked via my "search assistant" and it seems legit.

I personally think this is a reportable incident.

Andy

 

[rclee]

The Bronco Sport courtesy vehicle is likely a 1.5L 3 cyl EB motor so you will not get the "full effect" that the 2.0L 4 cyl EB motor in the Maverick has, but that aside, glad you got a loaner and quickly into the dealer for service.

It's a big bend, so 2.0

 

[Timothyd]

Hello MTC members. I just had an interesting day today. I started my Maverick this morning and started running some errands. While pulling out of my driveway I noticed a strong gasoline odor. We had a tree company doing work a house away, so I thought someone had spilled gas in the area. I went down the street a bit and the smell didnt go away even after rolling my window down. I pulled into a church parking lot to see if it was my truck. Oh Boy it was me! I opened the hood to see fuel all over the top of the engine, and some of it had mist like boiling water coming off of it. I am glad I stopped to check because if I went much further I bet it would have ignited.

I found the source of the leak. It is the main line going to the fuel rail. The line is solid on both ends and has a plastic line in between. I guess that is to help with vibration etc... Well, it had a little split in the plastic linesection and that is what was spraying the engine bay. The repair doesn't look too bad, so I thought I would do it myself and not get involved with the dealer. I called the parts department and asked if they had the fuel line. He replied that they don't have one and neither do any dealers around have one. He said he would have to order it and it would be about 4-5 days. That is when I changed my mind and had a tow truck take it to my dealer (Germain Ford Beavercreek Ohio) I talked to Jade and told her it was on it's way there and she set up an appointment for me at the dealership. I explained that the truck was going to be there for at least 4-5 days and asked if she could arrange a loaner for me. At first she said they had a line waiting for a loaner and I explained that my Maverick is four years old and I might be thinking about getting a new one She said they had a Bronco Sport courtesy car I could use. I snapped up that loaner car as fast as I could, because my only alternative was asking my mother-in-law to borrow her car. So now I am rolling in a new Bronco Sport with 2K miles on it. I get to experience what all the EcoBoosters love about that little turbo and I also get to see what its like using the push to start and the BIG screen.

Big shout out to Jade at Germain Ford for making my bad day much better with the loaner SUV!

The fuel line is the one with the orange part label on it.

"4 years old, time for new?!" Even if you wanted new you still have to fix the old.

 

[rclee]

"4 years old, time for new?!" Even if you wanted new you still have to fix the old.

I agree, really don't want to have to pay the 8K for what I already have. And they dont have Eruption green anymore

 

[HeyBales]

Does that look chewed - or a rub point on the hood?
Seems like a weird chew spot - with so much tasty soy wrap nearby.

Sure would have thought the plastic was just a protector to rubber hose underneath.

 

[ScottyC]

Yep think it has to be a Big Ben’s? If I remember correctly to have the 2.0turbo

It's a big bend, so 2.0

2.0L 4 cyl EB starts in the Badlands model - 1.5L 3 cyl EB is standard fare for Big Bend.

 

[rclee]

Does that look chewed - or a rub point on the hood?
Seems like a weird chew spot - with so much tasty soy wrap nearby.

Sure would have thought the plastic was just a protector to rubber hose underneath.

That part is the protector for the fuel line. It is split so it can be installed on the line.

 

[rclee]

2.0L 4 cyl EB starts in the Badlands model - 1.5L 3 cyl EB is standard fare for Big Bend.

I just looked again and it is an Outer Banks model. I know nothing about Bronco Sports.

 

[rclee]

Does that look chewed - or a rub point on the hood?
Seems like a weird chew spot - with so much tasty soy wrap nearby.

Sure would have thought the plastic was just a protector to rubber hose underneath.

I edited my post.

 

[ScottyC]

I just looked again and it is an Outer Banks model. I know nothing about Bronco Sports.

Only Bronco Sport Badlands has the 2.0L 4 cyl. EB motor.

Looking at Germains website - they list 12 BS Outer Banks with 10 being in the "courtesy or FCPT program" and the other 2 being for sale new but all have the 1.5L 3 cyl. EB motor.

 

[SafetyGuy]

That part is the protector for the fuel line. It is split so it can be installed on the line.

Good day

Yes, the plastic oversleeve is split and is around the black plastic fuel line (where I peeked under my sleeve to check it was a rigid black plastic line, anyways).

I believe @HeyBales was referring to the damaged point to the right of the orange tag.

So, I am wondering what possibly may have caused the fuel line to split or be weakened sufficiently that the pressurized fuel system was able to suddenly/eventually allow fuel to escape.

If it has never been removed/installed at any point in the trucks life (sometimes stuff happens where unseen damage can be caused and then appear sometime down the road), did something happen to it when you had the hood up, maybe someone lost their balance and their hand landed on it, is an example (that wouldn't explain the damaged outer sleeve, but you get the idea)...or maybe something was dropped which damaged the outer sleeve and was enough to also damage the line underneath?

Was the leak in the area of that outer sleeve damage is an important question...was that the area the fuel mist was emanating from?

I am very interested in this incident and would like to eliminate conjecture as to the root cause of the fuel leak.

If the line ruptured on its own, a report should be made to the NHTSA to potentially save others from the same occurrence but possibly a much worse outcome then having a 1.5 litre loaner vehicle.

Andy

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