Other Fuel System Pump problems of the 2008 Smart Fortwo

2008 Smart passion, 116k miles, maintained at recommended service intervals: condition: vehicle in use, various driving conditions: "old gas" smell inside vehicle after a break from usage of ~4-8 hours. "fresh gas" smell outside vehicle near the rear, after vehicle is used. No smell inside or outside if vehicle is left to stand 2-3 days. Inspection: no fluid leaks observed under car. Condition is repeating/repeatable. Upon removing rh rear lamp inspection plate, gas smell was found to be greater. No visual evidence of overfill on the fuel filler tube observable inside inspection cover. No wet or moist dust/dirt found in or near same. Inspected under-car, forward of engine for evidence of leaking, none found. Inspected engine compartment fuel rail and fuel returns. No leaks/seeps found. No insulation degradation found, no modifications or foreign material found. Concern: similar year/model/mileage Smarts have been reported as having caught fire "in the engine compartment". One online resource has documented cracked/broken fuel pump outlet/inlet/bypass nipples (which resulted in an observed pool of gas under the car). Action: further investigation of the fuel tank, pump and vapor-recovery systems are planned.

Top of fuel pump crack after car hit bumpy roadways leaking fuel filling with gasoline fumes.

Fracture in the plastic nipple at the top of the fuel pump which connects the fuel pump output to the engine. This condition allowed gasoline to spray all over the bottom of the vehicle. The manufacturer's field representative who was present when the defect was discovered stated that this was due to normal wear and was not a manufacturing defect.