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Old 04-20-2013, 08:02 PM   #1
randomhero199
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Join Date: Oct 2010
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2007 STI Limited
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Default HELP!! Fuel Smell - 07 STI (FOUND LEAK IN TANK)

I just picked up an 07 STI that was in a minor accident.... When we got it home we noticed a bit of a fuel smell in the cabin of the car, but didn't think much of it.... We just got it back today from body shop, drove the car for 30-40 minutes, towards the end of the ride began noticing raw fuel smell inside the cabin.

I got home, opened the hood to check all fuel lines, injectors & connections, NOTHING leaking, and NO odor.... I crawled under the car and noticed a faint fuel odor towards the mid-rear drivers side of the car. I can't see anything leaking, the smell isn't stronger anywhere in particular, but I'm puzzled.

The car had an e85 tune on it, and 1000cc injectors, which were put back to stock. The car currently has upgraded Walbro fuel pump, and generic cobb tune via AP.

Any help?? Is this normal, I would hate to be driving down the street and have the car go up in flames

I should preface by saying the car hit a fence post, and has some minor under carriage damage, but nothing I'd think would be causing these issues....

OK...... it's leaking pretty perfusely coming from the tank, but I can't see where it's coming from, any ideas. There's a 10" puddle of fuel after the car has sat.

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Last edited by randomhero199; 04-20-2013 at 08:19 PM. Reason: Update info
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Old 04-20-2013, 08:20 PM   #2
jayeeyee
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No, it is absolutely 100% not normal to smell any fuel vapor while driving. This should be an obvious. Check the fuel pump which is located under the rear seat if I remember correctly.. or it could be in the trunk (sorry.. I just can't remember correctly) to make sure it's sealed properly. You said the FP was upgraded to a Walbro, I do not know if you did this recently or was done before your ownership of the vehicle but go back and check it.

If the car hit a fence post and incurred damage to the underside, I'd check the fuel lines if I were you. Put the car on a lift and inspect the lines.

Does the fuel vapor smell stronger outside or inside the cabin? Follow the smell and start deducing the problem. That's all I can say with the limited info available to me. Oh yea, bring it to the shop where it was fixed.. make sure they didn't do some short-cutting or anything.
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Old 04-20-2013, 08:55 PM   #3
jaxscuby
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you have punctured gas tank..
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Old 04-21-2013, 03:07 AM   #4
randomhero199
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So I was in the garage under the car for almost 4 hours... here's what I've come up with. I had just filled the car up when the above picture was taken, since the photo I drove it around some to try and locate the source of the leak, but it only dried up. Below are a couple of pictures of the findings.

I pulled the fuel pump cover off (in the trunk, behind passenger seat) and found the entire setup covered in a black oily grime, smelled strongly of gas, BUT I couldn't see any fresh signs of fuel leaking. We cycled the ignition on/off multiple times, no luck seeing or hearing leaks. But it was covered in massive grime. Another strange sign was the fuel smell was strongest in the trunk, after taking off that lid cover, which makes me think that's the source of the problem.

The fuel filler hoses has zero signs of fuel leaking, and really the main amount of fuel saturation is on the bottom 1/2 of the tank, but there is signs of leakage from above. I'll install a new gasket Monday on the fuel pump.

Any other ideas?


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Old 04-21-2013, 07:03 AM   #5
A-man07
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I don't see how you're going to avoid pulling the tank to find the puncture.
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Old 04-21-2013, 03:19 PM   #6
randomhero199
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turns out the gasket was bad on the fuel pump, found the leak this am.
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