Chrysler Repair: Fuel odor inside 2000 Plymoth Voyager, vacuum lines, grand voyager


Question
I have  a strong fuel odor inside my 2000 Plymoth Voyager. It is a 3.0L, V6 Grand Voyager.  It has 102,000 miles on it.  Odor started strong a few days ago and remains strong. It did not start and get worse.  Under the hood I smell exhaust/fuel odor which is strong also.  The odor comes right into the inside of the vehicle as soon as the engine starts.  I can't locate an exhaust leak or fuel leak anywhere. Haven't found any leak in other hoses or vacuum lines either.  The PCV valve has never been changed.  I was going to have that changed.  Can you give me any ideas of where the leaks would be that would cause this problem.  I can't use the vehicle in this condition.  Thanks for your opinion in advance.  I'd want to know where the problem is before I take it to a qualified repair person.  

Answer
Hi Brian,
It is good that you are looking into this issue as it can cause an engine fire that will cost a great deal to repair if not ruin the vehicle. That is a good reason to conclude as you have that "I can't use the vehicle in this condition."
It is likely that the fuel is leaking on the topside center of the engine where the piping that distributes the fuel to each of the 6 injectors is located. The fuel comes in a metal line from the fuel tank and travels along the right side of the frame under van and then up to the top front of the engine where there is a loop of piping that goes around underneath the intake manifold plenum, along one bank of fuel injectors, crosses over to the other side at the rear of the engine and then goes back in a return line to the front of the engine and then to the gas tank on the same pathway as it came. There is also a presure regulator in that piping line at the front of the engine. So there are a great many gaskets/joints in this entire system and because the engine is hot the leaking fuel will evaporate quickly if it is leaking at the top center of the engine, without dripping down on the ground. Unfortunately you can't see the fuel rail and injectors without removing the air intake plenum which covers the area. If you have the socket, extension and ratchet handle you could remove that manifold to inspect the rail. Otherwise, you need to go to a shop.
I would consider, if you have auto insurance that will cover a tow, having the van towed to a shop which you trust so as to avoid the risk of a fire. If that is not practical, then I would try to have a fire extinguisher on board in case a fire breaks out while you are going to a shop. If you can find the fuel lines (coming in  and going back) at the front of the engine then you can examine the connections of those to the fuel rail (that loop of piping that I described earlier) to those two lines, and the pressure regulator (a round brass object screwed in the rail) but from there on the rail will not be visible. There may also be welds in the rail which could become a source of leaky fuel if a weld cracked. It there were leaks in the lines between the fuel tank and the engine those would cause leaks to the ground which would be visible. But I suspect your leaks are on the top of the engine as I described, but where you can't see them without removing the air intake plenum (rectangular aluminum box on top center of the engine).
So get this resolved a.s.a.p.

Roland