Hey so this has been plaguing my car for a couple years now, but it hasn't been getting driven much so I haven't made too much of an effort to find the problem.
Basically, the cabin fills with a strong smell of gas after I've been driving on the highway for more than an hour. Its strong enough to give you a headache after a few minutes and I can almost guarantee I've lost a few brain cells because of it, lol.
It doesn't seem to be be affected by how much gas is in the tank, or whether or not I'm beating on the car. The smell isn't especially present outside the car, or in the engine bay.
I have had a shop check for exhaust leaks, and have checked under the rear seat and its all dry. No obvious gas leaks under the car. The cabin air intake filters are removed and I've taped over the holes in the engine bay just in case but that did nothing.
Any help is appreciated! I don't really know where to go from here.
I would remove the rear seat the two inspection plates and inspect the fuel pump/sender on the passenger side and the left fuel tank sender sniff around down there, you have seal rings and the various hose and electrical conections. Look for staining also
Have the evap system smoke tested for leaks, for that too will take time for the vapor to build as you indicate.
Darin
Current:
16 220i Active Tourer Platinsilver MET (C08)/Dakota Black (PDSW), P7ACA, P7LDA, P7LHA, P9BDA, 6sp Manual - Wife's new toy!
05 325it Electric Red(438)/Gray(N6TT) ZCW, ZSP 5sp Manual Back set cover, trunk mat, Euro Infra-Rot front windshield, and mud flaps! Mr. Wagon My new Winter car.
05 M3 Imolarot II(405)/Gray(N5TT) ZCW, ZPP 6sp Manual C.F. Lip, CSL diffuser, SSK, Euro Infra-Rot front windshield and a trunk liner! Mr. Go_Fast Stored for the Winter
Past:
95 318is Montreal Blue Met (297)/Beige(K1SN) RIP, killed by an Idiot.
84 M535i gray market Burgandy Rot Met/Black Leather Lowered by Intrax on bilies, poly everywhere, B&B cat back system, K&N, and a hitch! Da Beast - Still running w/400k+!
91 316i euro Tizianrot/Gray cloth - E-36 w/M-40 RIP, but great on gas! Best was 38 MPG
82 528i euro Saphire Blue Met/Blue Leather RIP
79 525 euro Green/Green RIP
79 318 Silver/Black - The first one that got it all started
M-Flight Member
With the windows up and the climate control system operating you have a very slight positive cabin pressure due to the fan running so I think the fumes emanating from the tank senders is unlikely but still worth looking.
Your fuel lines in the engine compartment pass almost directly in front of the driver's side air intake. You mention the cabin filters are removed(why?)and the openings taped over.
My suspicion is fuel weeping in the engine compartment and being drawn in, taped openings or not. Check carefully for any stains around the fuel line connections.
If you can leave two black stripes from the exit of one corner to the braking zone of the next, you have enough horsepower. - Mark Donohue
Hey sorry for the late reply, so the blower motor doesn't work and is never running. The cabin filters were removed because the filter housings became so warped over the years there was no seal around the filter and they were basically doing nothing besides looking awful, and at one point we figured that could be the source of the smell. I just checked the fuel lines and there are no visible leaks in the engine bay, however next time the smell comes back I'll give it another quick check just in case.
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