Pancakes

Here's what we're working with

The HHR smells strongly like fuel in and around the cabin when the gas tank is full - this is something noticeable just walking around the outside

A mechanic diagnosed this about a month ago as a leak on top of the gas tank.

I did not speak to him directly and am only being relayed this information 2nd hand, however I'm being told the mechanic mentioned that a riveted flange has a crack.

Right now we have the gas tank dropped - no signs of any leaks that we can see and can't figure out what they mean by a riveted flange. Unfortunately I have no additional details on the location.

Does anyone have an idea what I should be looking for? We've inspected the tank all around and can't seem to locate any issues.

Pancakes

I should mention that there are no CELs and the smell is 24/7 even after the car has been sitting over night

donbrew

Purge vent. The one on the charcoal canister next to the gas tank, is the most likely culprit unless you can identify liquid gas somewhere.

Pancakes

thanks we're checking that out now

Snoopy

If you have the gas tank dropped, the only flange you probably can see is the fuel pump hole/access. Just make sure the gasket is intact.

But I agree with donbrew relative to the charcoal canister. You probably over fill your tank by "squeezing or rounding" the gas fill. That sometimes causes the problem you describe and causes damage to the charcoal filter, which would need replacement. Especially if you smell gas fumes all the time (the flange on the top would probably only leak when the tank is full).

Are you getting any codes on the dash read out?

Pancakes

It only seems to smell like gas when the tank is topped off - we're not over filling it intentionally but we do wait for the pump to stop .

We spoke to the mechanic today and were told that they had completely removed the tank and did some sort of smoke test - and only then they were able to find the leak.

Tonight isn't looking like a good night for me but I'll hopefully have time tomorrow to get back under there and figure out whats going on.

I'll post updates - next up are the front wheel bearings

Pancakes

Shouldn't a crack in the fuel tank cause a CEL? This issue has been going on for months and so far no CEL..

firemangeorge

I'm a little confused by your previous posts. You said the mechanic had the tank out to find the leak?
So, why wasn't it fixed at that time? And they reinstalled a leaking tank back into the car ?

Oldblue

yeah my question exactly, and as for the CEL and crack enough to allow fuel vapors out of the tank would be big enough to allow pressure out and trip a code, I believe this issue to be the one Don mentioned in post #3, please keep us posted

Disc1

I had fuel leaking (dripping) in front of left rear tire and had no codes popping up that I saw unless I had to be looking for them.