I have a 2005 Mazda 3 5dr with 35K miles on it. About a month ago I noticed that when I filled the car up, there was a strong odor of gasoline inside the car and also if you walked around the outside of the car - strongest in the back on the driver's side. The smell would linger, slowly fading in intensity until the tank was nearly empty. Then fill it up again and it would start all over again.

My father's a mechanic and he checked it out. He could not find any leak in the gas tank, but he suggested I take it to the dealer. So off it went. The car was at the dealer for 11 days. They ordered a gas tank for it, replaced the tank, o-rings, straps, etc. I'm told it was an emissions venting related problem.

So we get that car back last night after all this time, and start our 45 minute drive home. The dealer gave me the car back with NO gas in it.
The light came on soon after we left the dealership. So I stop and just for kicks I go to full serve and let someone else fill it up. The problem was ten times worse than before it left for the dealer. The fumes started to overcome my son and I and we had to drive with the windows down. 12 hours later he still has a headache and nausea.

Now the car just left on a flat bed to go the 35 miles to the dealer to find out what the *bleep* is really wrong with it. There's no way I'm driving it with that gas smell.

Anyone have any ideas? Similar experiences? I'm kind of at my wits end with this. Thanks!

 

Could be a possible hole in the gas fill line. Maybe near the top. Do you notice that you don't get as many MPG's or do you get the same? Did you see any puddles or anything? I would think since the smell lessens with the amount of gas you have in your tank that it would be something like that somewhere. I couldn't be sure.

 

Oops. I probably should have mentioned that. There is no fuel pooling up anywhere. If anything is leaking out, it's evaporating.

The mileage is definitely suffering since this problem started. MPG has probably dropped about 25%.

My father suspected that one of the fill/supply hoses along the top might be the problem.

We'll see what the dealer says this time. Thank goodness we have a spare vehicle in the family!

 

According to the dealer, one of the O rings didn't seat properly. Of course if they had filled the tank, they would have seen that, but at this point I just want the car back.

I'd be very curious to see if any other 3 owners had a similar problem. A very freaky failure.....

 

One of the mods should move this to the MZ3 section so winning3 can get some feedback from other MZ3 owners.