Other Fuel System Pump Problems of 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.

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

Fuel pump connector cracks.

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I was driving down the city highway - route 283 to get something to eat as I turned my car stalled out completely. Trying to turn over it would try to start but never start. Car has just over 17k miles on it. Thankfully I wasn't in heavy traffic as this could have caused an accident by someone rear-ending me because of the reduced speed and stall. I had to have someone push me up to a parking lot while I waited for a tow truck. A month later I am still waiting on a replacement fuel pump. The original bosch keeps blowing fuses and stalling out. My mechanic test drove it and he had to be towed back to his shop as well because of a stall/blown fuse because of the fuel pump issue. These fuel pumps seem to be on back order because lots of Smart cars are having the same issue at the moment with their bosch fuel pumps.

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.

Where do I begin? after about a year of owning my Smart car, I was driving on the highway doing about 70 mph when suddenly I feel my car pull to the right and start shaking. I pull safely to the shoulder to find the valve stem for my tire had detached and my tire was now flat. Not having a spare, I had to call a tow truck. The same issue happened to the remaining 3 tires in the following months to a year. While driving the valve stem would detach and all air depleting from the tires. I called the Smart dealer to be told this was impossible because the valve stems were bolted to the rim, well clearly not since it had happened to every tire. I have had multiple cylinder misfires with this car. I have had to replace the fuel pump. I have had to replace the alkaloid timing sensor. I have had to replace the blower motor for my heat and a/c. My headlights go out every other month. Car has stopped because a wire came loose in the battery. When I turn right or go on an onramp, I hear this awful clunking sound as if something is hitting a tin. When I go over bumps my car makes a squeaking sound. When going from park into reverse. . . Car will not go into gear. My car will read p and n. I have to turn my car off/on multiple times as well as mess with my shifter for about 5 minutes before I can go anywhere. The cherry on top happened today on my way home to akron from columbus. As I am driving on the highway with a semi truck behind me my car started losing speed, even when pushing the gas. I almost was struck by the semi due to the sudden decrease of speed but thankfully was able to pull off the highway. Once stopped, all lights came on and car shut off. Put my car in park to try to start my car again, nothing. My engine will rev but the engine will not turn over. Will find out what that is tomorrow hopefully. Car was brand new when purchased and bought the car 5yrs and 1 month ago.