I have a 2002 2dr 2wd Blazer. Last Saturday the fuel pump went out at 145k miles, and I spent Sunday replacing it. As I've read from others the Haynes was useless, and I had a very hard time getting the oring to seat properly, but I did manage to finally get the new pump in after struggling with the o ring for about an hour.

Over the last 2 days my wife has been complaining of a strong gas smell when driving the vehicle. I drove it this morning and sure enough there is a strong gas smell.


Is it possible the o-ring is crimped and allowing fumes and/or gas to escape? That's the only thing I can think it could be at this point. I hate to have to drop the tank again, but it looks like that's what I'll be doing.

Has anyone else had an issue like this or any suggestions on what else it could be? If anyone has a how to on the 2dr Blazer fuel pump install I would greatly appreciate it. I've searched high and low, and all I can find is the 4dr install...which is completely different. As the Haynes was useless I think I might not have the o ring even installed right.

Edited To Add:
I already know about the smell of fumes when filling the tank, and this is not the same issue. It is happening with half a tank of gas, and only when driving on a road that is bumpy or curvy...or when the gas could be sloshed in the tank. Neither of us are smelling anything on the interstate and straight aways.

Update:
On the way home the check engine light came on, and it's now throwing a P0440 code, so I now have a place to start. I'm going to run through the checklist of what can throw the code. Has anyone had any problems with a not seated well o ring throwing the code? I hate to think I may have to drop the tank again if it's none of the many other P0440 code issues.

 

Ben,
Is the front small vent tube re-connected. Mine went on no problem though in some instances I've used lubricants to avoid the kinking of a gasket.

 

Well you already pulled the tank so it should not be so bad to pull it again your gasket is leaking I know it is not fun but they are good trucks so it is worth it to fix it. You can use a very little bit of Vaseline on the gasket to install it.

 

just a thought, is the fuel pressure sensor installed?

 

That is exactly what happened to me.. I smelled gas after i replaced the pump then i had an experience when i went to the pump and left the nozzle unattended thinking the handle would pop when it was full.. Guess what it didnt and gas was everywhere... fire dept, and all.. quite embarrasing.. anyways vaseline did the trick and all is good.