Overfilling Problem At The Gas Station

[evox786]

I have a concern here about filling up my gas tank that I am hoping others might have experienced (and solved!). I own a '99 Legacy Outback and every time I fill up, gas always overflows out of the filler neck into the little gas door compartment. I've been to several gas stations throughout PA and it's always the same deal. There is then a strong smell of gasoline around my car for several days afterwards until I use up about 1/8 of the tank. Has anyone ever heard of this before? Thanks.

[Huffer]

The filler nozzle is supposed to have a vapor lock where it automatically shuts off.

Remedy for this is for you to stand there while it's pumping gas. And you should probably never totally fill the tank. Put $40-50 from empty at most.

Even at today's prices, that should be 12.5gal max. You have a 16gal tank.

[evox786]

Thanks for the fast reply! I'll definitely try that next time. I was thinking that maybe it was an issue with the filler neck being too narrow and the pump doesn't have time to cut off before it overflows.

[jey]

I wonder if it's an issue with your EVAP system, especially since you're smelling gas.

[evox786]

Actually yeah I was wondering if that system could have something to do with the gas smell since the smell seems strongest near the front left rather than by the gas cap. Do you know how to check this system? If not, I'll just take it in to the shop to have them check it out.

[jey]

Sometimes if there is an issue with the EVAP system you'll get a CEL code - but I'm well aware that that is not always the case because I have disconnected my EVAP solenoid and it didn't create any codes...

The actual solenoid itself is bolted onto the intake manifold, and has two vacuum hoses attached to it (one going to the intake manifold, the other goes back to the gas tank). There is also an electrical connector. Since you think the smell is coming from the front I'd start checking there for any leaks in those hoses.

[LegacyRob]

Sound like maybe the purge control solenoid valve may be stuck open causing no back pressure to stop the fuel flow. My only question is, Do subaru's have a pcsv? I work at a hyundai dealer and the hyundai cars have these. Usuaully the hyundai ones get stuck closed causing the fuel pump to keep shutting off when trying to fill the tank.

[evox786]

A stuck open solenoid makes sense, since that would allow the gas to evaporate from the gas tank straight into the intake manifold. If you could help me out again, which one is it? I found two solenoids each with two hoses, one of which appears to run to the manifold. The first one is closer to the throttle body and the second is near the edge of the manifold.
http://evox786.googlepages.com/DSCF3913.jpg

https://sl-i.net/FORUM/images/imported/2008/07/DSCF3915-1.jpg

[evox786]

Well I figured out that the red solenoid in the first picture is for the EGR, so it looks like I'll be checking out the solenoid and hoses in the second picture. It's looking pretty old and worn out to me...

edit- I tested the solenoid and it's working fine, so I'll have to check the hoses next.

[immortal1kon]

both solinoids pictured are for the egr system they should not effect. sounds like you need to drive your car till it is completely empty adn find out if you gauge is just messing with you. could also be a charcol cansiter issuse. gl

[AkumaMax]

It doesn't sound like a problem with the car but a problem with the pumps itself. They seem to not have an automatic shutoff? I could be wrong but you never know

[jey]

Yeah you've got it that second valve is the purge control valve.

[evox786]

I was able to access some professional repair website and from what I could tell, the second one was the purge control. But I just realized that even though it tested ok, it could still be stuck open if there is a short to ground in the circuit...


sounds like you need to drive your car till it is completely empty adn find out if you gauge is just messing with you. could also be a charcol cansiter issuse. gl

The gauge is fine- reads full when the tank is full and shows empty when I'm on empty. Could it be that the charcoal canister is just fully saturated and can't absorb any more vapor? Do they ever go bad or wear out?

[jey]

But I just realized that even though it tested ok, it could still be stuck open if there is a short to ground in the circuit...


You can just unplug the solenoid and see if that changes anything. You will get a CEL for the unplugged solenoid though.