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In general, a smelly Fuel Pump usually means that there is a leak somewhere, either at the pump itself or at the fuel lines or related parts. A properly working Fuel Pump is always sealed and should not allow fuel to leak out, which indicates that any smell of fuel means something is not right. Many times, this can be due to a worn or damaged O-ring, sealing the Fuel Pump to the fuel tank. Over time, the O-rings may become brittle or even crack. Fuel vapors then can leak out and cause a strong smell. Other potential sources of the problem include fuel lines, responsible for carrying the fuel from the Fuel Pump to the engine. The fuel lines are under pressure-regularly between 40 and 60 PSI in most modern vehicles-and a small crack or loose connection can cause a fuel leak. These leaks result in an odor that often appears well before any trace of visible signs could manifest. For example, if the leak is small enough, fuel can immediately evaporate, leaving only an aroma as evidence of some sort of trouble.
Some recalls have been issued because of fuel system issues that led to odors. In 2019, Ford recalled upwards of 90,000 vehicles because the fuel lines were defective and leaked easily, causing distinct fuel odors; these, in some incidents, even caused fire hazards. This recall indicates how alert one needs to be for any unusual odors of fuel because it may point toward grave issues beyond mere inconvenience.
Overheating is yet another catalyst for odors within a Fuel Pump. The temperature of the Fuel Pump is sustained through the flowing gasoline within the pump. While the levels of fuel get low, there is less fuel to cool the pump, and that may cause overheating which could burn and build smells. This overheating could also burn and ruin the plastic and rubber pieces inside the pump, which contributes to causing the smell and lowers the efficiency of the pump itself.
Fuel leaks, whether from the pump or lines, become potentially dangerous. Vapors from fuel are highly flammable, and a small spark from an engine component can create a fire in these fumes. As David Vizard so aptly put it, “Fuel systems need to be sealed and secure-leaks aren’t just an inconvenience; they’re a danger.” The sooner fuel odors are caught, the less likelihood of costly repairs and dangerous situations will occur.
Regular maintenance of the Fuel Pump, O-rings, and fuel lines prevents many leaks and may well extend the life of the fuel system. Also, recommended periodic replacement of parts and keeping the fuel tank at least partially full will avoid some of these problems. For other information about maintaining your Fuel Pump, see Fuel Pump.