Some time ago, there was an overfill situation. Ever since then, if tank is filled till pump auto clicks off there is a fuel smell. Otherwise, all is well. No codes, no drivability issues. Wife took over the car and I didn't say anything. CLICK.

Q: What is the most likely or common cause?

The goal is to limit the time spent outside messing with it due to heat. Its hot! That an I'm not getting younger. :) Not apposed to dropping the tank, but maybe that isn't the most likely cause. Would be a shame to do all that without replacing worn bits "while in there" but if it doesn't solve the issue then its a waste of time and money. This is a secondary vehicle with only real transport duty twice a week... REAL tempting to just keep the fuel level at 3/4 tank

Links for myself:
https://www.chevyhhr.net/forums/how-...t-44780/page2/
https://www.chevyhhr.net/forums/gene...k-64786/page3/
https://www.chevyhhr.net/forums/prob...k-63571/page3/
https://www.carparts.com/details/Che...C22719581.html

 

I doubt you would have rusty fuel lines , but



https://www.chevyhhr.net/forums/how-...follies-62310/

 

I have the same issue until the fuel tank level drops below 3/4.
From what I've read the vent lines on top of the tank are prone to loose there seal.
Especially in hotter climates.

 

If it started immediately after the overfill, my guess is some fuel spilled into the vent and contaminated the charcoal.

 

In a odd way, I'm hoping for that. lol.

 

No check engine light? No codes?

 

Nothing. Zip. Zero.

 

Fuel line wet just at the bottom of the insulation, above the front of the driver’s side rear tire?