If your fuel pump smells of gasoline, this is typically because the fuel system leaks somewhere. A good Fuel Pump is sealed; meaning, there should not be a strong fuel odor present. Usual causes of this problem include a worn O-ring or gasket sealing the Fuel Pump to the fuel tank. In time, these will perish and leak out the gasoline vapors, very often very recognizably. For those cars that have been on the road for more than 10 years, or have driven more than 100,000 miles, these parts may be quite prone to wear.
Another potential culprit is a cracked fuel line. Fuel lines operate under high pressure, which can be within the range of 40 to 60 PSI, and sometimes, just a little crack or loose connection might cause gasoline leakage. If the fuel line at the vicinity of the pump is compromised, gas vapors could leak out even before the fuel reaches the engine. Many instances reveal that these cracks are small, and the fuel evaporates almost instantly without leaving puddles, but the smell remains strong.
Back in 2019, Volkswagen recalled over 280,000 cars due to problems with the fuel pump and line that have caused many odors of gas and, in some cases, fire hazards. This recall just goes to show how small leaks can be disastrous in terms of safety when they are not resolved in a timely manner.
Another probable cause of a gasoline smell could be overheating issues with the Fuel Pump. When fuel levels get too low, the Fuel Pump can overheat; in this case, the smell of burning plastic or rubber on the exterior can be mistaken for gasoline. Keeping a minimum of a quarter tank filled with fuel will prevent it and prolong the pump’s lifespan.
As David Vizard, a renowned expert in automotive systems, once said, “A fuel system leak isn’t just about wasted fuel-it’s about safety.” Obviously, the sooner the source of the gasoline smell is resolved, the fewer the chances that worse problems such as fire hazards or complete pump failure could be experienced.
For more detailed information about how to repair or service your Fuel Pump, see Fuel Pump.