Gas Filling Problems

[ImprezaRose]

The 2002 WRX is having problems.

When we go to fill up the gas tank it ALWAYS overflows. We aren’t topping it off at all ever. We don’t top of our cars.

Aaron has replaced the Valve inside and it’s still overflowing. We generally pump the gas until the pump shuts off. At this point the gas tank will spill gas all over the side of the car and the ground.

What could be causing this? Besides the valve?

I know this is not normal behavior ‘cause my car doesn’t do it and neither does the SVX. I’ve never owned a car that would spill over like that. Aaron has only owned Subaru’s and he’s never had this happen with a car either.

It appears the gas tank was replaced at a NH dealer at some point.

Any suggestions you have would be helpful. Thank you.

[Hero]

Have you tried going to a different gas station?

I've always been under the impression that the automatic overflow shut off mechanism was in the gasoline pump nozzle once it senses a "low vapor return".

also - push the nozzle way in and angle it downwards next time - see if that helps

...thinking of what else it could be but my mind is just drawing a blank...:confused:

[ImprezaRose]

Yea it happens at every station we go to. I think i've only had One incident where it didn't happen. It's a normal occurance. and we have gone to Mobil, Valero, Sunoco, Hess, Zebra, etc.

[ImprezaRose]

anyone? *bump*

[Oscar_Meyer]

just on the outside chance.. what is the temperature like out when it happens? perhaps there is a piece of ice in the way making things bitter...I dunno I'm reaching here...

& how do U get gas from a Zebra?

[legacygt]

just on the outside chance.. what is the temperature like out when it happens? perhaps there is a piece of ice in the way making things bitter...I dunno I'm reaching here...

& how do U get gas from a Zebra?
Gasoline has a tendacy not to freeze. Its freezing point is well below -120F. Just thought i would throw that out there.

[Oscar_Meyer]

I was thinking more along the lines some localized moisture from rain and or snow causing a blockage somewhere...

[legacygt]

^^ i cant say for my subaru but i know somtimes when will fill the cruiser it overflows specially the crownvic. I just assume it has something to do with the pump.

[ImprezaRose]

It happens Year round Oscar. Also How do you think you get gas out of Zebra? You feed it Chili!

Legacy - I doesn't happen with my Impreza though. Why would it only happen with one car and not the other... same model? just a 2 year difference in age. Also it happens with ALL Gas Pumps.

I guess maybe I should ask other '02 WRX owners to see if they have the problem?

[Oscar_Meyer]

It happens Year round Oscar. Also How do you think you get gas out of Zebra? You feed it Chili!

Legacy - I doesn't happen with my Impreza though. Why would it only happen with one car and not the other... same model? just a 2 year difference in age. Also it happens with ALL Gas Pumps.

I guess maybe I should ask other '02 WRX owners to see if they have the problem?

thought I would take a shot at it: hope U get it solved... I am mostly impressed with the outcome and resolution of the zebra thing...

[abenson100]

do you have any check engine light. im thinking if the evap system was not functioning properly of leaking then when you fill the car there wouldn't be enough back pressure to turn off the pump. but im not exactly sure how gas pumps work either.

[GrassyKnoll]

just on the outside chance.. what is the temperature like out when it happens? perhaps there is a piece of ice in the way making things bitter...I dunno I'm reaching here...

I like the way you think! Not a bad guess at all.

Had a problem with filling gas in one of our Subarus. Would overflow if you didn't fill it nice and slowly (and would keep stopping). Kept the car in a heated garage for a night, then it was good to go :)

[afbeefcake]

do you have any check engine light. im thinking if the evap system was not functioning properly of leaking then when you fill the car there wouldn't be enough back pressure to turn off the pump. but im not exactly sure how gas pumps work either.

No, I have no check engine light, but the car came with an access port and tune so maybe the CE has been masked, but I dont think so.

[abenson100]

i was reading about how the gas pumps turn off and they use the back pressure in the fill novel. when gas covers a venturi inside it will turn off. so for some reason you are not building enough back pressure. you could have a shop do a smoke leak test on your gas and evap system. this would tell u if there was a leak. other wise for some reason your car is not back up the pump before it over flows.

[shtbxr22]

pull the neck, and see about the condition of the little plastic flapper at the end of the neck.

[Bu11dogg2]

the only way the evap system on the pump can fail is if you have a bend/dent in your filler tube or a hole.

You need to replace the fuel filler neck.

[javasti2004]

is the line kinked when from when the tank was replaced or a line not hooked up properly like a overflow line in the filler neck? i believe there are 3 lines on the filler neck the fill line very big. and two smaller lines both equalsize. possibly could these lines be switched causing the tank to over flow?

[mdungelman]

It wouldn't always happen if you didn't fill it up to the top, would it?

[shtbxr22]

Imprezarose.....call me. I hopefully have good info for you. may fix your fuel issue easier than previously thought. Eric- (603)943-3114

[afbeefcake]

pull the neck, and see about the condition of the little plastic flapper at the end of the neck.

There is no plastic flapper. I looked in the service book and asked a dealers parts department.

[afbeefcake]

is the line kinked when from when the tank was replaced or a line not hooked up properly like a overflow line in the filler neck? i believe there are 3 lines on the filler neck the fill line very big. and two smaller lines both equalsize. possibly could these lines be switched causing the tank to over flow?

I checked the lines that connect to the filler neck and they were not kinked. I don't think it really maters which of the two smaller ones goes where. The valve in one position connects the two and disconnects them in the other.

[javasti2004]

well if theres two small lines on it ones for evap ones for overflow i believe that could be the solution to your problem

[tC2WRX]

My car has the Exact Opposite issue. I squeezing the trigger all the way makes it think the tank is full. No matter what station I go to.

[ScrapinSti]

The vent tube isn't working correctly. Have you tried just pumping slower?

[shtbxr22]

I did some more research. pull down your evap canister, disconnect all the hoses, see if you can dump crap out of it, or see if the element inside has come apart. then check the hose that comes out of the evap vent valve(little cylindrical valve w/ electrical connector on it) where it vents into the frame, see if it's clogged. after this if all looks ok, hook up the D-check connector under your dash(green unplugged connector), then feel the Evap vent valve to make sure it is clicking on and off. it could be stuck closed, or the wires going to the valve could be corroded. you should find something after this. any questions? call Eric 603-943-3114

[Hero]

I did some more research. pull down your evap canister, disconnect all the hoses, see if you can dump crap out of it, or see if the element inside has come apart. then check the hose that comes out of the evap vent valve(little cylindrical valve w/ electrical connector on it) where it vents into the frame, see if it's clogged. after this if all looks ok, hook up the D-check connector under your dash(green unplugged connector), then feel the Evap vent valve to make sure it is clicking on and off. it could be stuck closed, or the wires going to the valve could be corroded. you should find something after this. any questions? call Eric 603-943-3114

I'm getting a P0457 CEL code and I'm wondering if it has to do with this. I already replaced the gas cap with a new one from Subaru and I erased the code but it came back. :spin:

[shtbxr22]

test the vent valve/check the condition of the wires going to the connector. they also have been known to short to the body under the right side of the rear seat. P0457 is an EVAP code.

[shtbxr22]

Here is the best I can show you without doing it for you.

Canister: (remove w/ 12mm)

http://i104.photobucket.com/albums/m194/star91281/Canister.jpg

Vent valve:

http://i104.photobucket.com/albums/m194/star91281/VentValve.jpg

[afbeefcake]

OK, I tried all of that. All of the hoses were clear. Both Canisters looked clean and intact inside. With the test connector connected I did hear the valves cycling and all of the wires looked OK.


Counld it be a hose on top of the tank that is kinded or installed wrong?

[shtbxr22]

It must be. if everything on the neck is ok, and the canister is ok, and the vent valve is ok. pull the two little access doors off at the front of the trunk are. see what the hoses look like.

[afbeefcake]

Ok, ill have to try that maybe tomarrow. Its dark out now.

[ScrapinSti]

I'm getting a P0457 CEL code and I'm wondering if it has to do with this. I already replaced the gas cap with a new one from Subaru and I erased the code but it came back. :spin:
Done a fuel pump recently? If the gasket isn't seated correctly it can throw this code.