2008 smart Fortwo: fuel pump failure

Filed May 15, 2025 · Fuel system · CA

The 90 degree fittings(integral to the fuel pump) on top of the fuel pump cracked and leaks gasoline leading to a potential fire that could cause bodily injury for the driver and passenger. It is noticeable because of strong gasoline smell inside and outside of the car. There are many of the same complaints from Smart Car drivers in various forum.

Filed Sep 1, 2017 · Fuel system · 116,000 miles · CA

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.

Filed Aug 25, 2017 · Fuel system · 81,000 miles · SC · 1 injury

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

Filed Jun 23, 2017 · Engine, Fuel system · 32,500 miles · CA

As my wife was filling the gas tank it failed to build back pressure that would normally shut off the gas pump. This has occurred twice. Then on mon. The 19th of june after work my wife complained of a strong gas oder inside the vehicle. She drove the car to work on tues. Morning and had the same strong gas smell. She thought that it might be due to overfilling the tank. When she got home on tues. Night we noticed a steady stream of gas pouring out of the vehicle under the car near the passenger side of the vehicle. The gas only streamed out when the engine was running. Once we shutoff the car it would dribble out for a few more minutes then eventually stop. When I turned the car on it would begin flowing fuel onto the ground immediately. I had the car towed to the mercedes benz\smart car dealer located nearest to me. After the car was towed I started to do some research online to determine if this is a common issue. I was surprised to find that there have been many complaints posted to chat room boards regarding a fuel leak and a broken discharge line from the fuel pump to the engine. What I was even more startled to find was literally hundreds of different videos of smart cars catching on fire. I soon discovered that there is an open investigation with the federal safety agency for engine fires on model 2008-2009 fortwo smart cars. The investigation number is pe-16-016 the dealership called me today and stated that the fuel pump is leaking gas on top of the tank and that the fuel pump will need to be replaced. They have not dropped the fuel tank yet. They witnessed the fuel leak using a mirror. It is now friday at 2:15pm pst, and to late for them to start repairing the fuel pump today. The dealership plans to drop the tank and replace the fuel pump on tues. Morning. I will be there to photograph the location of the break on the fuel line and update this complaint after that.

Filed Sep 1, 2014 · Fuel system · 41,179 miles · AL

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.