2008 Smart Fortwo Fuel System Problems

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.

DURING ROUTINE DRIVING, GRADUALLY SMELLED STRONGER GASOLINE ODORS. ODOR REMAINED WITH CAR WHILE PARKED & UNUSED FOR SEVERAL DAYS. SMELLED STRONG GASOLINE ODOR WHEN ENGINE RUNNING WHILE PARKED IN DRIVEWAY. OBSERVED GASOLINE IS SLOWLY DRIPPING UNDER CAR, FORWARD OF THE REAR-MOUNTED ENGINE COMPARTMENT, FROM HOLE LOCATED IN PLASTIC UNDERCAR SHIELD. HAVE READ THIS IS A COMMON PROBLEM LIKELY WITH FUEL TANKS THAT SMARTUSA OR MERCEDES REQUIRED TO BE MODIFIED BY G&K FOR AN EMISSIONS SYSTEM UPDATE PRIOR TO RETAIL SALE, MANY OWNERS REPORT GAS TANK CRACKS WHERE MODIFICATION HOSE FITTING ADDED, OR LEAKS AT THE MODIFIED FITTING DUE TO ADHESIVE OR SEALANT FAILURE. WORST-CASE, RAW GASOLINE OR GASOLINE VAPORS DRIFTING REARWARD ONTO HOT ENGINE COMPONENTS LIKE EXHAUST MANIFOLD REPRESENT A SERIOUS FIRE HAZARD. I DON'T YET KNOW THE EXACT SOURCE OF GASOLINE LEAK. THERE ARE MANY REPORTS OF THE SMART FORTWO CATCHING FIRE DURING OPERATION. PRAY THIS DEFECT WILL RECEIVE ATTENTION PRIOR TO FATALITY.

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

FUEL LEAK

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. *TR

INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) VEHICLE INFO 2008 SMARTCAR STYLE: PURE COLOR: SILVER VIN: [XXX] PURCHASE DATE: SEPTEMBER 20, 2008 PURCHASE PRICE: $17,000.00 BEGINNING MILEAGE: 417 DEALER INFORMATION [XXX] DESCRIPTION/EXPLANATION OF EVENTS BEGINNING IN JUNE 2008 TO SEPTEMBER 20, 2008, I SPENT TIME DOING MY DUE DILIGENCE REGARDING THE NEW SMARTCAR AND THE PERFORMANCE POSSIBILITIES IT WOULD HAVE IN MY FORESTRY CONSULTING BUSINESS. I TYPICALLY DRIVE 4,500 TO 5,000 MILES PER MONTH AND MY FORD F-150 WAS USING APPROXIMATELY 26 GALLONS OF FUEL PER DAY AT A COST OF $4.25 PER GALLON. THIS DUE DILIGENCE INCLUDED MEETING WITH THE GENERAL MANAGER OF SMART CENTER SEATTLE AND GIVING HIM A FULL DESCRIPTION OF WHAT WORK I WOULD BE DOING AND DETERMINING HOW I THOUGHT THE CAR WOULD HOLD UP. WE EVEN MEASURED THE CLEARANCE OF A SHOWROOM CAR WHICH WAS ACCEPTABLE. I WAS SCHEDULED FOR A TEST DRIVE AND WAS COMPLETELY SOLD ON THE CAR AND THE BENEFITS OF UTILIZING THIS VEHICLE IN MY PROFESSION. I ORDERED A CAR AND WAS TOLD IT WOULD TAKE UP TO 15 MONTHS BEFORE MY CAR WOULD BE BUILT AND DELIVERED. THERE IS A PROGRAM WHERE THE DEALERSHIP CAN SELL CARS THAT WERE ORDERED AND NOT PURCHASED FOR ONE REASON OR ANOTHER. THE CAR I EVENTUALLY PURCHASED WAS ONE OF THESE CARS. I WAS CALLED TO SEE IF I WOULD LIKE TO BUY THIS ONE INSTEAD OF WAITING THE MONTHS FOR MY CAR TO BE MANUFACTURED. WITH THE CURRENT COST OF FUEL AT THE TIME, I DECIDED TO PURCHASE THE CAR AND SURPLUS MY ORDERED CAR WHEN IT CAME INTO THE DEALERSHIP. THE COST OF THE VEHICLE WAS $17,000.00 PLUS THE DEALER PREP, TAX AND SO ON, FOR A TOTAL PRICE OF $19,000. THE VEHICLE HAD A STANDARD 24,000 MILE WARRANTY AND I WAS GIVEN THE OPTION TO PURCHASE AN EXTENDED WARRANTY FOR AN ADDITIONAL FEE, APPROXIMATELY $2000 IF I RECALL CORRECTLY. BECAUSE OF THE HIGH MILEAGE I DRIVE EACH YEAR, APPROXIMATELY 70,000 MILES, I DECIDE. *TR

GAS GAUGE ON 2009 SMART FORTWO WILL NOT REGISTER FULL ON FILL UP. CAR HAS BEEN TO THE DEALER 3 TIMES TO HAVE REPAIRED AND THEY HAVE REPLACED EVERYTHING ASSOCIATED WITH THIS ISSUE. STILL CANNOT FIX. *TR

GAS GAUGE DOES NOT REGISTER FULL ON FILL UPS. *TR