The smell of gasoline is very strong both inside and outside of the vehicle every time it is filled.

• There are no visible leaks on the driveway or underside of the car.
  
• Gas cap is tight, but original.
  
• Tank is not overfiilled.
  
• Smell goes away as fuel level decreases.
  

Any suggestions where to start?


2010 HHR LT 2.2L

185,000 miles

CheckEngineLight?

No CEL. No codes have been recorded.

Check the insulation part of the fuel lines, it runs up behind the driver’s side rear tire and across, it could be the vapour line has pin holes in it.

Maybe something rusted out at the filler.

I will check those things. Thanks.

I did some looking thru the archives, is it possible that there’s rodent damage up on top of the fuel tank? A chewed hose or loose fitting?

The system should detect a noticeable vapor leak and complain with a P0442. A liquid fuel seepage, not so much. Maybe someplace where it’s not making it to the ground?

I have had the identical problem ever since I bought this 2011 2.2L car a few years ago with 100k on it
A lot of times I fill it to a bit over 3/4 full level and it is fine. over that and it smells inside .
If I do fill it all the way it stops smelling when the gas gauge goes a bit below the full mark.
Previous owner said the lines were replaced at the dealer.
No codes ever and just have not looked into it yet.

Found the leak!
 

This morning the fuel tank was pulled and we found fuel seepage around the vapor hoses on top of the tank. Decided to swap tanks. The salvage yard had hosed off the replacement just before we arrived. Back at home with the replacement tank, now dry, we saw the same signs of seeping fuel. We then discovered all of the yellow plastic caps on the "roll over" valves were cracked. Went back to the original tank for a closer look and confirmed it also had the same cracks. We thoroughly cleaned the surfaces then liberally applied RTV over the yellow caps, seals and cracks. That should solve it!