2001 4Runner Refueling Problem

[Unner]

Hi all,

I am having a problem with fueling my 2001 4Runner. V6, 4wd, A/T.
Yesterday I went to get gas, and the nozzle would click off after only a few seconds. It did this no matter how I held the pump. I could see the gas coming up the filler neck, causing the pump to click off. The only things I see that can cause this are 1) blockage of the fuel filler neck, 2) air not being able to escape the gas tank as the gas is displacing it. This pump worked perfectly with my girlfriend’s car, so it’s not an issue with the pump.

About 3 weeks ago I was at a gas station in New Mexico where the pump was running very very slow, and it overfilled the truck a lot. Gas came out of the top of the filler neck it was so full. After this the truck would start up, but die a few seconds later. It finally stayed running, but stumbled as I drove down the road. The stumbling stopped as some of the excess gas was burnt off, and I got back on the interstate where it ran fine for the next 1,500 miles. I’m sure the dying and stumbling had something to do with the extra gas going into the charcoal canister/EVAP system.

My starter was going out on my way home, so I was not shutting the truck off when I would refuel. Since I’ve returned and replaced the starter I’ve got gas twice, now shutting the truck off as you should. The first time everything went fine. The second time was the incident yesterday where it took 15 minutes to get gas. It was very cold last night, about 15*.

I’m leaning to something wrong with the charcoal canister from the station overfilling it. I’m thinking maybe with the truck running there is a valve that stays open and allows the tank to vent, but when it’s off this valve is closed and the traditional way of it venting is clogged from the station that completely overfilled it. Sound reasonable?

But first, I want to ask, does anyone with a 2001 4Runner have a little silver circle flap inside the filler neck, or is it just a straight hole into the tank once you take the cap off? Mine is just the hole, but I can’t remember if there used to be a flap. If there is a flap mine might be stuck in the filler neck causing a blockage.

Could the cold have anything to do with this? I don’t see how because it gets way colder up north. After I do some driving around today I’ll try to get gas again and see what it does.

Thanks for any help and input!

 

[YouInTheShirt]

No flap

Have 2001 SE and no flap on mine.

https://photos.app.goo.gl/oihlDactHW9fYGlD2

 

[4RunnerAquasport]

I had an 01' s10 blazer with the same problem. It would take quite awhile to fill it. It would only take a small stream and it would still click off. I would shake the truck to displace some of the air and it helped. But anyway I have heard of the charcoal overfill canister being contaminated as one of the causes for this. Which made sense because I always filled the neck in my blazer :redface: big dummy.

I think all vent tubes from the tank have to go thru this canister per EPA mandates years ago. Someone with more knowledge about this might check in, but I think that is your next step.

 

[octanejunkie]

I'm no expert, but 2001 fuel evap system is under the truck, as opposed to earlier models, so overfilling can flood the vent tube and gravity does the rest.

I would start with looking there, pulling the vent line and checking to make sure the evap canister is not full of gas

Luck

 

[6wheelin]

Same problem with my 2005 runner. Very annoying.

 

[Unner]

Thanks for the input guys. And thanks to [MENTION=92413]YouInTheShirt[/MENTION] for confirming there is no flap there.

I got gas just a minute ago. 4.2 gallons went in just fine...

Hopefully next week it is a little warmer and I can check the lines for any blockages or problems. Maybe it was just a freak incident last night, but it's never done that before so I'm inclined to think there's some problem somewhere.

 

[jgue467]

... 2) air not being able to escape the gas tank as the gas is displacing it.
...

On my 01 it is this issue and i've figured out it's caused by filling with the fill side facing 'downward' at a filling station that has an incline.

So pay attention where you fill for any hillside slant and point the fill side toward the higher side, makes a big difference for me. :cowboy:

 

[jsukey]

I believe the issue lies in the charcoal canister. There's a reason they say not to "top off" the fuel tank, once it's full. The overflow heads down that line, straight into the canister. It will eventually ruin the canister, and throw a CEL. You'll have a problem refueling from then on unless you replace it. Had that issue on my 2002.

 

[thezoltar]

I've had this issue before. Not convenient in the middle of winter. Turned out to be a clogged vent line down by the carbon canister. It got plugged up by some sort of mud using bug. I cleaned out the plugged end of the vent tube with a piece of coat hangar wire and all was back to normal.

 

[LittleCaesar]

My brother had a charcoal canister go bad on him in his Chevy truck, with the canister in the engine bay, and in the cold refueling was like watching a snail cross the road. If I remember correctly he said the problem only surfaced when the weather was below 40F.

 

[southTX4r]

I believe the issue lies in the charcoal canister. There's a reason they say not to "top off" the fuel tank, once it's full. The overflow heads down that line, straight into the canister. It will eventually ruin the canister, and throw a CEL. You'll have a problem refueling from then on unless you replace it. Had that issue on my 2002.

Yea, I had the same problem on my 02 recently. It kept throwing codes, I could smell fuel while driving, and could only put about 2 gallons in the tank. I pulled the evap canister, cut it open, and re-packed it using fish tank charcoal. 4 tanks of fuel so far and no problems.

Cutting it open was a real pain. I'm sure the EPA requires the manufacture make them impossible to get into.

 

[jsukey]

That's one way to do it!! Lol! Nicely done! You should've documented that so it could be made into a sticky!

Yea, I had the same problem on my 02 recently. It kept throwing codes, I could smell fuel while driving, and could only put about 2 gallons in the tank. I pulled the evap canister, cut it open, and re-packed it using fish tank charcoal. 4 tanks of fuel so far and no problems.

Cutting it open was a real pain. I'm sure the EPA requires the manufacture make them impossible to get into.

 

[HiLife]

One way to trash the charcoal canister is to keep fueling after the handle clicks off multiple times.

 

[KLiF1006]

I know this is a very old thread but it still shows up when searching and alot of folks still read them so...
I also had issue on my 2001 T4R 3.4L with starting and then stalling after a 10-20 minute warm soak or after a fill-up. After much troubleshooting and must testing, I found that the installer of a new EVAP canister had reversed the CCV air line and PURGE line connections back at the EVAP canister. What led my to suspect this was the obvious P0440, 441, 446 errors and the fact when warm or after fill-up there was fuel vapor and fumes in the intake hose from the air-box area. Disconnecting and removing the MAF had a very distinct fuel odor. I then pulled the CCV input line from the air-box and was about knocked out by the fuel vapor smell when warmed up and after fill-up. I knew that wasn't right. The ECU would interpret that as fuel and start warm or after fill-up and stall or severely stumble until it would pick and run, but upon second start would run fine after. So I chased both the PURGE line and the CCV air lines back to the canister and found them reversed.
Try looking in these areas for bad, crossed, reversed lines, defective canister or VSVs. your answer may lie in those areas.