[Maj]

Loving my GS! But there's something bugging me.

I sometimes get a very strong smell of fuel in the cabin and boot (trunk). This seems to happen mostly when I have a full tank. The smell can be quite strong even when I haven't driven the car for a few days.

The fuel cap is tight and theres no visible signs of a leak. Someone mentioned that it could be the charcoal filter needing replacement - but I figure that might me responsible for fumes when the car is running, not when the car is off.

Any thoughts?

[Tubber273]

I recently had my fuel cell repaired after the technicians noticed a strong fuel smell (I have diminished olfactory senses - so I didn't notice). They performed a smoke test and discovered I had bought the car with a damaged fuel cell. Apparently, I was leaking fuel through cracks!

Here is what they (FM of V) stated on the invoice (total cost was close $4500):

GROSS EVAP LEAK FOUND.SMOKE TEST FUEL SYSTEM.FOUND R/S FUEL PUMP
CAP CRACKED (SIGNS OF FUEL LEAKING ON FUEL CELL). FOUND ONE FUEL ROLL
OVER VALVE LEAKING. HAD TO RE AND RE FUEL CELL. REMOVE SUB FRAME AND
TRANSMISSION ASSEMBLY. REPLACE R/S FUEL PUMP AND ALL SEALS AND ROLL
OVER VALVES.REPLACE FUEL FILLER GASKET. RE INSTALL ALL COMPONENTS AND
TORQUE TO FACTORY SPECS.ROAD TEST. NO MORE FUEL LEAKS FOUND AFTER
REPAIR.

Best bet is to have the dealership do a smoke test to be sure!
Hope yours isn't this bad!

[Maj]

Originally Posted by Tubber273

I recently had my fuel cell repaired after the technicians noticed a strong fuel smell (I have diminished olfactory senses - so I didn't notice). They performed a smoke test and discovered I had bought the car with a damaged fuel cell. Apparently, I was leaking fuel through cracks!

Here is what they (FM of V) stated on the invoice (total cost was close $4500):

GROSS EVAP LEAK FOUND.SMOKE TEST FUEL SYSTEM.FOUND R/S FUEL PUMP
CAP CRACKED (SIGNS OF FUEL LEAKING ON FUEL CELL). FOUND ONE FUEL ROLL
OVER VALVE LEAKING. HAD TO RE AND RE FUEL CELL. REMOVE SUB FRAME AND
TRANSMISSION ASSEMBLY. REPLACE R/S FUEL PUMP AND ALL SEALS AND ROLL
OVER VALVES.REPLACE FUEL FILLER GASKET. RE INSTALL ALL COMPONENTS AND
TORQUE TO FACTORY SPECS.ROAD TEST. NO MORE FUEL LEAKS FOUND AFTER
REPAIR.

Best bet is to have the dealership do a smoke test to be sure!
Hope yours isn't this bad!

Wow, thanks Tubber. I'm hoping mine's not that bad too.

[FlyinBrian]

Maj- the fuel tank is actually INSIDE the passenger cabin in these cars, in the area between the rear seats and the trunk. Therefore, any leak in that part of the fuel system will be smelled in both the cabin and trunk.

It could be as simple as a leaky line -- or a more complicated repair like a leaking fuel cell. The fact that it seems to only occur with a full tank points to a few specific areas, but nothing you can diagnose more fully until the interior bits on either side of it are fully removed.

[Tubber273]

Keep in mind also that I have a Spyder not a GS.
I believe (but not positive) the same job on your car would be a lot cheaper as I doubt you'd have to remove the transmission to get at your fuel cell if necessary.
Good luck!

[FlyinBrian]

That explains a lot, Tubber- I was curious why your bill listed charges for removing the transmission, but it makes sens with your car being a spyder.

[FlyinBrian]

Any updates, Maj ?

[Maj]

I wanted to test my own theory that it only happens when the tank is full. So I'm going to do a few half fills over the next few weeks and see if the smell goes away. Then it's probably off to the mechanics for a deeper look.

[Saturn]

Originally Posted by Maj

I wanted to test my own theory that it only happens when the tank is full. So I'm going to do a few half fills over the next few weeks and see if the smell goes away. Then it's probably off to the mechanics for a deeper look.

I get this only when I fill up to full and some of the gas spills outside of the filling area. It normally drains out of the small hole below the cap(in the gas cap area) through a tube to the outside underneath the car. Unfortunately some of gas lines up this tube and eventually evaporates.
When I wash the car some of the water falls into the hole and washes the gas remnants away.

[Maj]

I've found the problem. Looks like the breather hose that allows fuel vapour to vent has become detached from the fuel union. This means that the vapour is venting into the boot/trunk cavity instead of to the outside.

It appears that the fuel union is broken at the point it attaches to the hose. Eurospares has these for sale at $27 for the US/CDN version, but for the rest of us... $409 !! :(. Anyone know what's so different about the fuel system used in the US?

[elambo]

Good find! You saved yourself a lot of cash.

[lcdave]

Originally Posted by Maj

I've found the problem. Looks like the breather hose that allows fuel vapour to vent has become detached from the fuel union. This means that the vapour is venting into the boot/trunk cavity instead of to the outside.

It appears that the fuel union is broken at the point it attaches to the hose. Eurospares has these for sale at $27 for the US/CDN version, but for the rest of us... $409 !! :(. Anyone know what's so different about the fuel system used in the US?

Without taking the liner out I can't be certain, but looking through the battery access hole it looks like the picture of yours (more attached of course). If it were me, I'd gamble the $27+shipping.

[Maj]

I've ordered and fitted the US fuel union and problem solved! It was identical in every way to the one I removed from the car, so I'm still not sure why there is such a price difference between the US & UK part.

No more wondering whether the car is going to spontaneously combust!

[lcdave]

Yea.

[Silverback]

I have an 03 Maserati Coupe. Looking to see if anyone has a write up for DIY Fuel Filter replacement. Don't know if it is hard or something a dealership should do, but figured I would ask on here first. Thanks!!