Hard start after fueling up?

Tiny
PMAUGHN
  • MEMBER
  • 2008 KIA SPORTAGE
  • 6 CYL
  • AUTOMATIC
  • 111,000 MILES
When I go to the gas station to fill up the car won't start again until I try several times.
I have tried leaving the engine running while filling up but then the idling starts to falter and then it shuts off.
The check engine light is on constantly because of this.
All of my Oxygen sensors have been replaced.
My throttle body has been cleaned by a mechanic.
Smoke tests have been done and all subsequent tightening's where leaks showed up have been done.
Evap sensors by the gas tank and by the engine have been replaced.
Please help. I hate to fill gas now. My mechanic does not know what else to try.
Saturday, February 4th, 2023 AT 10:43 AM

8 Replies

Tiny
AL514
  • MECHANIC
  • 4,632 POSTS
Hello, what code is the engine computer setting? And exactly what Evap components have been replaced, theres the Charcoal canister, Canister vent valve, Fuel tank pressure sensor in the rear of the vehicle and the Purge valve in the engine compartment.
Another thing, do you stop filling the gas tank when the handle at the station clicks off? Some people will pull the filling handle out alittle more to try to get more gas in the tank. This causes and overfilling of the tank, and results in the Charcoal canister getting liquid gas in it. Its only designed for vapor not liquid gasoline. When the canister gets liquid gas in it the charcoal breaks up and pieces of it get sucked into the purge valve and the rest of the system. So a new purge valve can be put on and the same result will happen. The purge valve will have small pieces stuck in it. This will cause either a purge valve code, or a large leak code. So if you know the code number your mechanic is getting, we can go from there and try to help you out.

https://www.2carpros.com/articles/how-emission-control-systems-work

https://www.2carpros.com/articles/evap-system-code-repair
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Saturday, February 4th, 2023 AT 12:29 PM
Tiny
JIS001
  • MECHANIC
  • 3,411 POSTS
I agree with AL514. It sounds like fuel is spilling over to the charcoal canister. Trying to top off doesn't really help. What I recommend doing is removing the evap hose from the tank to the charcoal canister when you're about three quarters full. Fill up like normal and see if fuel spills out that hose. If it does you will need a new gas tank and charcoal canister. Update us with the results.
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Saturday, February 4th, 2023 AT 7:50 PM
Tiny
JIS001
  • MECHANIC
  • 3,411 POSTS
Just to update. What I meant is at three quarters full disconnect the hose and then drive quickly to a gas station to fill up. After the test have it resecured.
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Saturday, February 4th, 2023 AT 7:52 PM
Tiny
PMAUGHN
  • MEMBER
  • 4 POSTS
Thanks for the responses. The charcoal canister was not replaced. The purge valve by the engine was replaced. The Fuel tank pressure sensor was replaced. I also always try to top up and get extra fuel in when I fill up at the pump. So, I guess the next step is to replace the canister. Also, the gurgling in the tank is louder now.I can hear it even when the gas cap is in place.
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Saturday, February 4th, 2023 AT 9:02 PM
Tiny
JIS001
  • MECHANIC
  • 3,411 POSTS
Replacing only the charcoal canister is not going to help. You will need a new gas tank also. The valve in the tank that keeps it from overflowing is most likely damaged now from constantly trying to top off.
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Sunday, February 5th, 2023 AT 7:23 AM
Tiny
PMAUGHN
  • MEMBER
  • 4 POSTS
How does topping off with the gas destroy the tank exactly? I'm not a mechanic so I need a little more explanation before I spend money on a new tank and canister. Btw thanks for your response and advice.
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Sunday, February 5th, 2023 AT 10:03 PM
Tiny
AL514
  • MECHANIC
  • 4,632 POSTS
Because the tank is only made to hold so much fuel, when the handle at the gas station clicks off, that's full. When you try to add more there are valves and vapor lines that the extra fuel goes into, such as the charcoal canister, and vapor lines. There is also a rollover valve for when a vehicle is in an accident. There are a lot of components down there that can't get liquid fuel into them. The fuel tank pressure sensor cannot get gas into it either, that is for only measuring air pressure and tank vacuum. Here is a diagram with all the Evap and tank components. You can try just replacing the Charcoal canister and see if that takes care of the issue, but if pieces of the charcoal are now throughout the entire evap system. They will need to be cleaned out. They are going to be in the new purge valve as well. If you unhook it and tap out small particles of charcoal it needs to be replaced and the vapor lines cleaned out.
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Monday, February 6th, 2023 AT 7:12 AM
Tiny
PMAUGHN
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Oh, thank you very much. This clarifies a lot. The diagrams helped me to really see.
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Monday, February 6th, 2023 AT 10:31 AM

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