[bimbo2011]

When I fill the tank, I got a strong smell of gas outside, around the car. only outside and only when the tank is full...What do you think? Anibody having same problem??

[ricx]

There is a o ring seal on the fpr and fp that seals in fumes, it could be leaking.

[BimmerG0d]

Pull up the rear set and you’ll see two round covers, unscrew both and see if there’s a pool of gasoline, if so, the plastic housing on the fuel pump regulator or the fuel pump is developing hairline cracks and leaking gasoline.

[RealJ22]

Like Ricx said, FPR usually causes this issue or the top of the pump assembly cracks.

[mecheng77]

Do people use rtv gasoline sealant or just replace them?

[ricx]

No sealant please. If o rings are leaking replace them. You need the fuel tank spanner wrench to get to the o rings. But before you do any thing pop up the back seat to verify it is in fact leaking from that area.

[Welcome to NBA Jam]

Originally Posted by mecheng77

Do people use rtv gasoline sealant or just replace them?

It's worth a try using gasoline RTV if the pump housing is cracked. I haven't seen any success stories yet though.

[lowrydr310]

I have the same exact issue. I only smell fumes when I fill the tank more than halfway.

I don't understand how a cracked fuel pressure regulator or fuel pump housing would only leak fuel when the tank is filled higher than halfway. Can anyone please explain that?

I have heard the issue could also be caused by a crack in the fill neck vent hose. Apparently the diesel guys discovered it here first because it was leaking diesel on the ground. For us gasser E90s the fuel evaporates and we smell it before it can leave visible drips on the ground. If this is the problem, then how am I not getting a evap leak code? The tiniest leak from the fuel cap would trigger a minor evap leak code, so I don't understand how a cracked vent hose leaking fuel wouldn't trigger an evap code.

The only reason I haven't inspected either of these in detail is because I have other things on my car that need attention (thrust arms, tie rods, new tires, and alignment are due).

[freakystyly]

https://www.e90post.com/forums/showthread.php?t=817634

Breather hose rubbing is likely if only smelt outside on fill up.

My car had this when I bought it, let an indy take care of it. Not sure how necessary all of these steps are.

[smass]

Originally Posted by lowrydr310

I have the same exact issue. I only smell fumes when I fill the tank more than halfway.

I don't understand how a cracked fuel pressure regulator or fuel pump housing would only leak fuel when the tank is filled higher than halfway. Can anyone please explain that?

I have heard the issue could also be caused by a crack in the fill neck vent hose. Apparently the diesel guys discovered it here first because it was leaking diesel on the ground. For us gasser E90s the fuel evaporates and we smell it before it can leave visible drips on the ground. If this is the problem, then how am I not getting a evap leak code? The tiniest leak from the fuel cap would trigger a minor evap leak code, so I don't understand how a cracked vent hose leaking fuel wouldn't trigger an evap code.

The only reason I haven't inspected either of these in detail is because I have other things on my car that need attention (thrust arms, tie rods, new tires, and alignment are due).

A cracked vent hose or evap tank can throw a code but a bad pressure regulator will not. The pressure regulator is the most common gas smell issue for 06 E90. When the plastic cracks, it is a spiderweb of cracks from old age. The cracks are on higher parts of the assembly so gas sloshing around the tank seeps out and falls to the lower nooks where it is caught until it evaporates. A bad pressure regulator will smell strongest in the drivers side rear wheel well. A pad fuel pump will smell stronger in the passenger side wheel well.

When changing the regulator (drivers side), the pump (pass side) is also partially removed. A hose from the regulator runs across the inside of the tank and hooks to the pump. Old pumps have very brittle plastic. It is very difficult to remove this hose without breaking off the nipple on the pump. Youtube has many videos on how to change regulators and pumps.

And finally all of this is nor applicable for the N51 which has an odd tank that is not as serviceable but sometimes covered by the extended warranty.

[ElMarino825]

I had this same issue. My FPR has bad cracks and was leaking a lot of fuel. I replaced my FPR but now my fuel gauge isn’t 100% accurate. I opened everything back up to check both floaters and wiring but they seem okay. Does anyone know what’s causing this?

[lookalikehuuh]

Originally Posted by ElMarino825

I had this same issue. My FPR has bad cracks and was leaking a lot of fuel. I replaced my FPR but now my fuel gauge isn’t 100% accurate. I opened everything back up to check both floaters and wiring but they seem okay. Does anyone know what’s causing this?

Whats funny is I have the same issue on my car after replacing the FPR as well. Car things its "full" but its not actually full. I bought the OEM parts as well so I think the calibration is just different on the new parts.

My other friend also has the exact same thing on his car.

From my calculation is seems like the new FPR seems to allow about 1.5 gallons less than my original part allowed somehow.