Cannot fill car with gas?

Tiny
LOOZWAIT
  • MEMBER
  • 2004 CHEVROLET MALIBU
  • 3.5L
  • V6
  • 2WD
  • AUTOMATIC
  • 283,000 MILES
Had the car a year. The car runs good. No misfires. But gas mileage is suffering. Fuel level never worked. Pulled tank 1/2 way down. Disconnected entire Evap system except purge line. Still won't take gas. Brand new vent valve is still connected to electricity, but not to canister. The Evap line from fuel module to canister is disconnected. I blew air through it watched the tank expand. 1 minute later that Evap hose started dripping gas. The canister had 20 ounces of gas, but air can go through it - maybe it's toast from overfilling filler neck 100 times. All Evap lines and filler vent tube are clear. The only things left to mess with is the module and tank inlet, and a smoke test. 1)I need to know what the Evap hose is doing inside the tank. 2) Is there a check valve in the pump module? Gas pools heavy around the tank inlet. It's like something is stopping gas from going in the tank. 3) Do you know if my tank has vents connected to that in tank Evap hose. Just recently seen this in someone's tank. Gas gauge always says full recently, I'm thinking it tells a tank check valve to close - the tank is full. But only 1-2 gallons are in it. Thanks for your help.
Sunday, July 23rd, 2023 AT 9:06 AM

1 Reply

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 48,363 POSTS
Yep, the canister should not have any gas in it so I would replace that and check the vent valve operation by connecting it to a battery, if you have problem after that I have seen the filler tube go bad or get something stuck in it. Here is how to remove the filler pipe so you can see if it will flow outside of the car. Use water then let it dry out. This guide may help as well:

https://www.2carpros.com/articles/comprehensive-guide-why-your-cars-gas-tank-wont-fill-up-and-how

Check out the images (below). Let us know what happens and please upload pictures or videos of the problem so we can see what's going on.

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Monday, July 24th, 2023 AT 12:07 PM

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