When I fill my gas tank completely full, I get a VERY strong gas odor inside the cabin of the car. Just recently, I've been noticing that I can now smell it outside of the car, too. I've also noticed that after filling the tank full, there will be a large puddle of fuel left under the gas tank of the car. Once I use around 1-2 gallons of gas, the leak stops, and I no longer smell gas inside of the car. Ideas?

Like I said, it only leaks when the tank is full. Any other time, gas isn't leaking at all, and no odor is smelled. It seems to me if the gas tank was leaking, shouldn't I be getting a check engine light because of a de-pressurization of the tank? I'm not getting any codes at all. :?

Are you filling past the first click? If so..that might be the issue.

Otherwise..I'd think filler hose or the other little hose...vent I think.

It could be you are leaking around the fuel pump canister. Open the trunk, remove carpet and find the cover for the fuel canister. Remove that. Then, next time you go to the gas station to fill up, pop the truhnk and watch for fuel leaking around the ring that hold the canister in place. THe rubber gasket could be bad, or the fingers tha hold it in place are not holding it firmly in place.

Is this on the Aurora or SSEi?

Aurora, but before you move it, I can assure you 100% that the parts are identical for the fuel pump and fuel tank. There'* not a difference.

I'll try removing the cover and watching when I pump gas, thanks. I usually stop pumping gas when the pump shuts off. I always get gas at the same gas station though, so maybe I'll try a different one next time.

That'* a good question. I should think that at some point in time you would see a DTC for the Evap System. The tank is never pressurized btw. The PCM runs a routine to check fuel system integrity by applying vacum (via the purge valve up front) to the fuel tank. If the system can't hold vacum as measured by the fuel tank pressure sensor (it measures negative pressure), then a code is generated. But this code may not be an immediate action.

I'd pull the evap canister from under the car and see if there'* any fuel in it. If your tank is overflowing - it will drip into that. If you can jack the car, it'* pretty easy to pull this. It is under the rear driver'* side door approximately.

Evap codes take a few cycles to light the dash a lot of times. Couldn't hurt to check for codes if you haven't...

While you have the car jacked to inspect the evap tank you can take a look at the filler neck- that would also be my first bet.