Probably seepage around the fuel sending unit flange. Check for any signs of seepage as well as around the hose connections. Could also be a leak or plugging up of the evaporative control hoses.

It only takes a tiny bit of seepage to create a pretty strong smell.

What year Spider is it?

 

The S3 Spiders have a vapor recovery system. There is an 'expansion' tank plus hoses and a one-way valve & air vent - all located in the compartment just forward of the trunk. (I assume other models are similar.) Then there is a hose that runs along the inner sill (beneath the passenger side carpeting) to a cannister in the space behind the right side wheel well. From there a pair of hoses go up to the engine bay - one to the intake duct and the other to the intake plenum.

The hoses must all be in good condition. The one way valve and air vent must not be clogged. You can clean the valve and vent by removing them and squirting some carb cleaning spray into them. Make note of which way they are attached.

Greg Gordan at Hi Performace Store sells kits for replacing those hoses.

Finally, make sure the filler hose is in good shape and the tank doesn't have any rust holes in it.

 

Why 2 fuel pumps?

Why are there 2 fuel pumps on my spider? The wiring diagram shows a submerged one inside the fuel tank and the other up the line.

To prevent vapor lock we would put the electric fuel pump in the back nearest the fuel tank and make sure the fuel line steers clear of hot items like headers and such. But I never thought I might need 2 pumps!

 

The in tank one simply acts as a 'pusher' for the main pump so it doesn't have to siphone fuel up through the sending unit and then through the hoses til it gets to said main pump.

The main pump is the one that does the real pushing and pressurization up to the rail.

 

Hmmm....

Thanks. It still sounds odd though.

Why not submerge the powerful one and push the fuel up the line. Then there would be no real siphoning.

Oh well, they must have had pretty good reason for doing it. I would like to have been an Italian fly on the wall in that engineering meeting!

 

For all I know, they went with the little one in tank and the big one underneath so they didn't have to retool the great honking pile of fuel cells that they had out in the warehouse to allow a big one to fit in that little sending unit hole.

 

Lol

Now that makes sense!!!!!!!!!!

 

Found a pin hole in my tank once,up above, v near the weld with the 3 tubes coming out, pressurized the tank (carefully!) with air, then brush on soap bubbles, and watch for bubbles. Had it repaired, BUT still gas odor plagueing me. Have to live with it. I tried everything in the book!! Nothing worked! Spent 2 yrs off and on chasing it. Forget it.

 

Thank you everyone, i will do my research, but i assume it is a normal aspect of owning an S3......

 

It is absolutely NOT a normal aspect of owning an S3. They didn't smell when they left the showroom floor and if properly maintained, they shouldn't smell now. My 85 used to have a terrible gas odor whenever I filled the tank. I ended up getting Greg Gordons kit. I replaced all the gas lines and the filler hose. My car no longer has the gas odor and it is much more enjoyable to drive. These are great vehicles and we are passionate about them. Don't settle on this issue. With diligence, it can be fixed.

 

Greg Gordon's kit?

Can you tell me more about it and where I can get one?

 

My Spider smelled of fuel when I first had it. My problem was the filler hose clamps had come loose. You could see small amount of gas weeping out between the hose and the fill neck. I retightened and all is well.

Dave

 

Dave, you are one big lucky guy.....seems like you nailed the problem first time around.

 

I would get it fixed on health grounds. I think petro fumes are carcinogenic...even though they smell nice.

 

LOL....Right, along with vinyl shower curtains, and all vinyl products, grilled steak/chicken, well done toast, well cooked bacon, fatty foods, etc etc.

For real, gas smells should be avoided.

 

Well, I know you guys mean well, and that you are trying to cheer me up (wiping the tears from my eyes, snifling), cuz I have had it bigtime with this gas smell troubleshooting. You dont know what lengths I have gone through to chase it. I have done way more than yous describe from above posts. checked the check valves, new clamps, new filler neck tube ($50 for that stupid thing), pressurized the system repeatedly, thinking I missed something, new high grade fuel injection tubing, NO soap bubbles showed up after sealing off everything AND pressurization.

When I found that pin hole, I shouted Yahooooooo. But I was the big fool. It did minimize it , of course, but that low level stink is still there. Shame Shame, Alfa engineers, taking to many espresso coffee breaks!!!!! Ford shoulda bought out Alfa, not Fiat.

 

Ouch!

Don't start a flame war around leaking gas tanks! I empathize with your trouble. Take a coffee break or an entire weekend and forget about it for a while. When you return reenergized, the solution will reveal itself.

Stiff upper lip. Nothings ever as bad as it seems. Silver lining, and all that.

Good luck with it!

 

Don't start a flame war around leaking gas tanks! I empathize with your trouble. Take a coffee break or an entire weekend and forget about it for a while. When you return reenergized, the solution will reveal itself.

Stiff upper lip. Nothings ever as bad as it seems. Silver lining, and all that.

Good luck with it!

LOL!! Thanks for the laugh, bud.....Really, This is just funny as he**. Flame war....LOL!

Really, I put it behind me (I think??). Man, though, I believe you are right in that it eventually reveal itself, although, probably not v soon.....

Thanks.

 

Busted knuckle club

All members of the BKC have been there and done that. We feel your pain brotha'!

 

[war story]

I once owned a honda civic which made a HUGE gas smell when i first filled it, and every time i turned a hard corner... so I ended up dropping the tank and found the previous owner had tried patching it repeatedly. It was the ugliest pile of gas tank sealant I'd ever seen! I wondered greatly how a gash like that could get into the *top* of a tank like that...

One gas tank later, smell is gone, and gas mileage is up. Who woulda thought?

[/war story]

 

Sometimes life is cruel. Try replacing the gas cap gasket and make sure it's on straight and tight.

 

My 84 spider stinks of gas (occasionally). My 82 did the same. I think the cars DID come from the factory with the smell as a no cost option.

My 84 has new fuel lines from the tank to the rail (and back). New fuel hose from the rail to the injectors, New fuel filler hose, new gasket at the sending unit, check valve checked, vapor canister checked and every line Greg Gordon sells and I still get the stinks (last week).

 

Yep, now you're talkin my tune.....Did all that, plus pressurizing, which is not as easy as it sounds.....

Look, I like the car...Its like that over used cliche...you cant live with em, and you cant........

 

My car also came from the factory with driveshaft 'thumping' and exhaust rattles and stupid oil sending unit and no (initial) cost options.

Have you noticed how new cars come with roadside assistance? My Alfa came with the polar opposite...the ability to strand me on the roadside with no warning.

 

Is this the valve that may need cleaning? The Yellow thingy on the far left.
Thanks

 

Yes.

also check the other check valve (black and white part). You should be able to blow through one end but not the other. That part should not be just sitting there either. It should be up above the vapor canister mounted (kind of) on the inner side of the panel between the trunk and the covertible top.

 

One source of gas fumes in my car is the rubber shield between the body and the filler neck. In Jersey you're not allowed to fill your own car, and gas attendants are never prepared for the small volume. They also like to round up to the next whole dollar or $.25. I really don't relish the idea of changing that puppy.

 

Yup, and Yup. Did both those things. Still stinks. Odor seems to be coming from gas tank metal tubes area, NOT vapor canister/check valve area.

 

Joe, have you removed the trunk floor section to inspect the top of the tank for holes (rust)? Are all the hoses & clamps tight? How about the gasket on the in-tank pump'gauge sender opening?

Really, your Spider shouldn't stink.

 

Thanks for your concern, Eric. And sorry for delay in my reply......but yes, I checked all you mentioned. Pressurized the tank and brushed on soap bubbles (the best Ive found is the kid's play bubbles at the toy dept). Other checks too. Pressurized all then soaped up. Nothing. You see? time to pull my hair out!! (and Im not bald, so its gonnna hurt....LOL)

Im gonna disconnect the evap expansion tank "tube to charcoal canister" line, temporarily, to eliminate that as a source. Thinking if the car still smells, it cant be that tube (going through the cab, you know). Then go from there.

 

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