Trouble Filling Fuel Tank

[jrodhotrod]

Hey All...

I have been having trouble getting fuel into my car for quite a while now. I NEVER overfill, always turning the nozzle off when the pump shuts off, but after starting to have problems with getting fuel into the tank I have come up with the following...

After initially being able to get in 1.5-2 gallons the nozzle shuts off, no matter how empty the tank was. This happened on a regular basis at several different stations.

I did some investigating and found that the charcoal cannister was filled with fuel. That's odd I thought...

I let it drain, and dry out for a day and then put it back in. I was able to put fuel in without problems after 2 tanks but then started having the same problem where the nozzle shuts off early and I am back to only being able to put in a small amount of gas.

So my question is, do I need to buy a new charcoal cannister instead of just drying the one I have?

And b, where do I look between the tank and the cannister to find out why it is being allowed to fill with fuel?

Anybody experienced anything like this?

The only modifications to my fuel system are the injectors, mental addiction fuel rail, and a walbro fuel pump. The mental addiction fuel rail removes the pulsation damper but that shouldn't have anything to do with this.

[jrodhotrod]

Hey All...

I have been having trouble getting fuel into my car for quite a while now. I NEVER overfill, always turning the nozzle off when the pump shuts off, but after starting to have problems with getting fuel into the tank I have come up with the following...

After initially being able to get in 1.5-2 gallons the nozzle shuts off, no matter how empty the tank was. This happened on a regular basis at several different stations.

I did some investigating and found that the charcoal cannister was filled with fuel. That's odd I thought...

I let it drain, and dry out for a day and then put it back in. I was able to put fuel in without problems after 2 tanks but then started having the same problem where the nozzle shuts off early and I am back to only being able to put in a small amount of gas.

So my question is, do I need to buy a new charcoal cannister instead of just drying the one I have?

And b, where do I look between the tank and the cannister to find out why it is being allowed to fill with fuel?

Anybody experienced anything like this?

The only modifications to my fuel system are the injectors, mental addiction fuel rail, and a walbro fuel pump. The mental addiction fuel rail removes the pulsation damper but that shouldn't have anything to do with this.

[Ken@ProtegeGarage]

i have never had a problem with a charcoal canister on any other car but a chrysler product - i would go to a dealer

[Ken@ProtegeGarage]

i have never had a problem with a charcoal canister on any other car but a chrysler product - i would go to a dealer

[BRIAN MP5T]

My Canister went into the Trash when the fuel system went UPDATE.

Nice info however!

[BRIAN MP5T]

My Canister went into the Trash when the fuel system went UPDATE.

Nice info however!

[NSNMotorsports]

I have the same problem.. and it annoys the daylights out of me. I removed the purge solenoid and all the hoses as well as the canister etc. I cut the vent line down at the firewall and capped it of... I thought that was the cause so I uncapped it, but it didn't improve... so no idea what causes it but the pump will shut off at least 10 or 12 times if not more when I try to fill.. it has gotten so bad that I have to hold the pump and trickel gas in.. a normal 10 gallon fillup takes about 10 minutes.

[NSNMotorsports]

I have the same problem.. and it annoys the daylights out of me. I removed the purge solenoid and all the hoses as well as the canister etc. I cut the vent line down at the firewall and capped it of... I thought that was the cause so I uncapped it, but it didn't improve... so no idea what causes it but the pump will shut off at least 10 or 12 times if not more when I try to fill.. it has gotten so bad that I have to hold the pump and trickel gas in.. a normal 10 gallon fillup takes about 10 minutes.

[vindication]

never happened to me but happens to my best friend in his 2002 ES. He has broughten it to the dealer and they did something but couldn't fix it. Then they tried saying it was due to his audio system in his car. crackheads they are. but the issue is unresolved.

[vindication]

never happened to me but happens to my best friend in his 2002 ES. He has broughten it to the dealer and they did something but couldn't fix it. Then they tried saying it was due to his audio system in his car. crackheads they are. but the issue is unresolved.

[t3ase]

I havent had issues with that but I have had issues where the pump hasn't cut off while fueling and fuel went shooting out of the car on to everything around it. That's happened about four times now.

[t3ase]

I havent had issues with that but I have had issues where the pump hasn't cut off while fueling and fuel went shooting out of the car on to everything around it. That's happened about four times now.

[jaw307]

I havent had issues with that but I have had issues where the pump hasn't cut off while fueling and fuel went shooting out of the car on to everything around it. That's happened about four times now.
was the car running while you filled when it started spitting? it'll do that.

as far as the filling up prob, I had the same thing happen a year ago or so. it pretty common and I've seen it on other pros the I found out what was causing it by replacing a few things and now there should be a bulletin in the mazda tech support database that all the dealerships have access to so if they can't find whats wrong they are not looking hard enough.
replace the cannister, it will never be right again just drying. if you saw fuel in the cannister replace it all your trouble will be gone. just so we are straight with what is being replaced it is the black plastic box in the center of your spare tire well under the car.

[jaw307]

I havent had issues with that but I have had issues where the pump hasn't cut off while fueling and fuel went shooting out of the car on to everything around it. That's happened about four times now.
was the car running while you filled when it started spitting? it'll do that.

as far as the filling up prob, I had the same thing happen a year ago or so. it pretty common and I've seen it on other pros the I found out what was causing it by replacing a few things and now there should be a bulletin in the mazda tech support database that all the dealerships have access to so if they can't find whats wrong they are not looking hard enough.
replace the cannister, it will never be right again just drying. if you saw fuel in the cannister replace it all your trouble will be gone. just so we are straight with what is being replaced it is the black plastic box in the center of your spare tire well under the car.

[t3ase]

Yeah, it was. I never turn my car off while fueling.

[t3ase]

Yeah, it was. I never turn my car off while fueling.

[jaw307]

Yeah, it was. I never turn my car off while fueling.
yeah thats the prob, not sure why but they like to spit while you have them running. but that is unrelated to the problem he is having.

[jaw307]

Yeah, it was. I never turn my car off while fueling.
yeah thats the prob, not sure why but they like to spit while you have them running. but that is unrelated to the problem he is having.

[pdhaudio83]

weird problems. perhaps a problem with the Evaporative system?

[pdhaudio83]

weird problems. perhaps a problem with the Evaporative system?

[jrodhotrod]

Can somebody track down the technical bulletin on the problem? I am certain that the problem is with the evaporative system, but I don't want to replace the cannister without first knowing why it is being allowed to fill with fuel.

For obvious reasons I will not bring my car to the stealerships around me, but there are a couple of shops in my area that do good work on Mazdas that I trust.

[jrodhotrod]

Can somebody track down the technical bulletin on the problem? I am certain that the problem is with the evaporative system, but I don't want to replace the cannister without first knowing why it is being allowed to fill with fuel.

For obvious reasons I will not bring my car to the stealerships around me, but there are a couple of shops in my area that do good work on Mazdas that I trust.

[pdhaudio83]

perhaps boost related ?

wait, nm, you have a MSP not a turbo protege.

[pdhaudio83]

perhaps boost related ?

wait, nm, you have a MSP not a turbo protege.

[jrodhotrod]

Well, I have a MSP, but its been running high boost.

The first time I experienced the problem was when I tried to fill the tank right after a long track day.

But after driving the 200 miles home I was able to fill the tank normally and it worked normally for several months. Then it just started happening everytime like it is today. I am in the same situation as Steve as after getting in the initial 1.5-2 gallons it shuts off and the most I can put in is a tenth or 2 tenths at a time unless I am at a situation where I can trickle it in.

[jrodhotrod]

Well, I have a MSP, but its been running high boost.

The first time I experienced the problem was when I tried to fill the tank right after a long track day.

But after driving the 200 miles home I was able to fill the tank normally and it worked normally for several months. Then it just started happening everytime like it is today. I am in the same situation as Steve as after getting in the initial 1.5-2 gallons it shuts off and the most I can put in is a tenth or 2 tenths at a time unless I am at a situation where I can trickle it in.

[jaw307]

Well, I have a MSP, but its been running high boost.

The first time I experienced the problem was when I tried to fill the tank right after a long track day.

But after driving the 200 miles home I was able to fill the tank normally and it worked normally for several months. Then it just started happening everytime like it is today. I am in the same situation as Steve as after getting in the initial 1.5-2 gallons it shuts off and the most I can put in is a tenth or 2 tenths at a time unless I am at a situation where I can trickle it in.

I am not sure of the bulletin of hand but I had the exact same problem last year sometime and I narrowed it down to the cannister being replaced and haven't had a problem since. exact prob as you guys(fill click fill click fill click fill click) I mean seriously it was annoying to be with people on a drive and take a half hour to fill your tank.

[jaw307]

Well, I have a MSP, but its been running high boost.

The first time I experienced the problem was when I tried to fill the tank right after a long track day.

But after driving the 200 miles home I was able to fill the tank normally and it worked normally for several months. Then it just started happening everytime like it is today. I am in the same situation as Steve as after getting in the initial 1.5-2 gallons it shuts off and the most I can put in is a tenth or 2 tenths at a time unless I am at a situation where I can trickle it in.

I am not sure of the bulletin of hand but I had the exact same problem last year sometime and I narrowed it down to the cannister being replaced and haven't had a problem since. exact prob as you guys(fill click fill click fill click fill click) I mean seriously it was annoying to be with people on a drive and take a half hour to fill your tank.

[jrodhotrod]

hmmm....

If someone can hunt down the tech bulletin that would be awesome. I just would love to know why the cannister is filling with fuel so a new cannister that I put in doesn't get filled and ruined the way this one is. If it is just the cannister, great, thats something I can do myself, but if there is a check valve that also needs to be inspected/replaced I would love to know that too.

[jrodhotrod]

hmmm....

If someone can hunt down the tech bulletin that would be awesome. I just would love to know why the cannister is filling with fuel so a new cannister that I put in doesn't get filled and ruined the way this one is. If it is just the cannister, great, thats something I can do myself, but if there is a check valve that also needs to be inspected/replaced I would love to know that too.

[TheMAN]

possible two-way check valve (near charcoal canister) failure, or check valve failure (near purge control solenoid)

return your fuel system back to stock and take it to the dealer to diagnose the fuel filling problem... the evaporative emissions system is covered under the emissions warranty

there is NO reason to ditch this system because it does NOT reduce performance

[TheMAN]

possible two-way check valve (near charcoal canister) failure, or check valve failure (near purge control solenoid)

return your fuel system back to stock and take it to the dealer to diagnose the fuel filling problem... the evaporative emissions system is covered under the emissions warranty

there is NO reason to ditch this system because it does NOT reduce performance

[TheMAN]

hmmm....

If someone can hunt down the tech bulletin that would be awesome. I just would love to know why the cannister is filling with fuel so a new cannister that I put in doesn't get filled and ruined the way this one is. If it is just the cannister, great, thats something I can do myself, but if there is a check valve that also needs to be inspected/replaced I would love to know that too.

if such a TSB was available, I would've told you to stfu and look at it already

[TheMAN]

hmmm....

If someone can hunt down the tech bulletin that would be awesome. I just would love to know why the cannister is filling with fuel so a new cannister that I put in doesn't get filled and ruined the way this one is. If it is just the cannister, great, thats something I can do myself, but if there is a check valve that also needs to be inspected/replaced I would love to know that too.

if such a TSB was available, I would've told you to stfu and look at it already

[SandmicaMP3]

I've had the same prob, to go along with what jrod was saying has anyones gas guage needle acted strange aswell? when the car does this not wanting to fill up crap the needle only will read to half a tank when full, theres been times i thought the car was completly empty but there was still half a tank of gas in there..if that makes sense?

[SandmicaMP3]

I've had the same prob, to go along with what jrod was saying has anyones gas guage needle acted strange aswell? when the car does this not wanting to fill up crap the needle only will read to half a tank when full, theres been times i thought the car was completly empty but there was still half a tank of gas in there..if that makes sense?

[jrodhotrod]

all right.

The main reason I went with the upgraded fuel rail was one of my stock fuel lines got pinched against the block and had a hole melted into it and I wanted an adjustable FPR to deal with the walbro intank pump and the MAM fuel rail was also a nice appearance mod. So to return to stock I would have to purchase factory fuel lines go back to my old injectors, undo or remap the haltech, and so on and so forth. It's just not worth it.

I don't plan on ditching the evaporative emissions system in any way, I just want to be able to fill my car with gas.

So it looks like I'll need to find and purchase a new charcoal cannister along with an inspection of the two way check valve and check valve. Thanks for the help guys.

[jrodhotrod]

all right.

The main reason I went with the upgraded fuel rail was one of my stock fuel lines got pinched against the block and had a hole melted into it and I wanted an adjustable FPR to deal with the walbro intank pump and the MAM fuel rail was also a nice appearance mod. So to return to stock I would have to purchase factory fuel lines go back to my old injectors, undo or remap the haltech, and so on and so forth. It's just not worth it.

I don't plan on ditching the evaporative emissions system in any way, I just want to be able to fill my car with gas.

So it looks like I'll need to find and purchase a new charcoal cannister along with an inspection of the two way check valve and check valve. Thanks for the help guys.

[jrodhotrod]

if such a TSB was available, I would've told you to stfu and look at it already
Thanks. I would have expected nothing less from you. ;)

[jrodhotrod]

if such a TSB was available, I would've told you to stfu and look at it already
Thanks. I would have expected nothing less from you. ;)

[BRIAN MP5T]

So this canister improves, Emmisions and/or Economy?

[BRIAN MP5T]

So this canister improves, Emmisions and/or Economy?

[pdhaudio83]

its stock. its for the evap system, which yes, aides in emissions

[pdhaudio83]

its stock. its for the evap system, which yes, aides in emissions

[jrodhotrod]

So this canister improves, Emmisions and/or Economy?
Yes, the theory behind the cannister is it acts as a purifer to absorb the fuel vapors so they don't escape to the atmosphere. If it gets filled with fuel it can't do it's job and there is no where for the vapors to go so pressure builds in the tank causing the nozzle to shut off early in this case.

These aren't the best articles, but they describe what the charcoal canister was designed to do:

http://www.findarticles.com/p/articles/mi_m3102/is_6_123/ai_n6083390#continue

"..... Our automobiles are evaporating right before our eyes. Emissions from the fuels, oils, rubber, and plastic parts that are used in the manufacture and operation of today's vehicles are continually dispersing into the atmosphere. While there isn't much we can do to control the emissions from our tires and plastic interiors, most of the fuel emissions can be controlled using a charcoal canister-based fuel evaporative system.

The charcoal canister was first introduced in California for use on 1970 model vehicles. It was developed to collect raw fuel vapors from the fuel tank and carburetor bowl before they could escape into the atmosphere. Air is drawn through the canister by engine intake manifold vacuum, and the hydrocarbon fumes are burned inside the engine instead of being released into the atmosphere. The beauty of the charcoal canister is that it can release the fumes when fresh air is pulled through the charcoal, efficiently allowing the canister can be used over and over again.

For the most part, the emission system is fairly trouble-free but problems can develop when the air inlet to the canister becomes plugged. This air inlet acts as a vent for the fuel tank. When fuel flows out of the tank, air must be allowed to enter. If air can't enter, a vacuum develops and eventually the fuel pump cannot pull any more fuel out of the tank. The vehicle will seem like it ran out of gas, but the gauge may indicate that there is still plenty of fuel....."

And a definition from AutoZone:

http://www.autozone.com/servlet/UiBroker?ForwardPage=/az/cds/en_us/0900823d/80/04/b7/52/0900823d8004b752.jsp

"Charcoal Canister Operation:
A container, usually located in the engine compartment, containing activated charcoal. The charcoal absorbs or traps vapors from a vehicle's sealed fuel system, generally when the engine is turned off. This is a basic component of evaporative emissions control systems."

[jrodhotrod]

So this canister improves, Emmisions and/or Economy?
Yes, the theory behind the cannister is it acts as a purifer to absorb the fuel vapors so they don't escape to the atmosphere. If it gets filled with fuel it can't do it's job and there is no where for the vapors to go so pressure builds in the tank causing the nozzle to shut off early in this case.

These aren't the best articles, but they describe what the charcoal canister was designed to do:

http://www.findarticles.com/p/articles/mi_m3102/is_6_123/ai_n6083390#continue

"..... Our automobiles are evaporating right before our eyes. Emissions from the fuels, oils, rubber, and plastic parts that are used in the manufacture and operation of today's vehicles are continually dispersing into the atmosphere. While there isn't much we can do to control the emissions from our tires and plastic interiors, most of the fuel emissions can be controlled using a charcoal canister-based fuel evaporative system.

The charcoal canister was first introduced in California for use on 1970 model vehicles. It was developed to collect raw fuel vapors from the fuel tank and carburetor bowl before they could escape into the atmosphere. Air is drawn through the canister by engine intake manifold vacuum, and the hydrocarbon fumes are burned inside the engine instead of being released into the atmosphere. The beauty of the charcoal canister is that it can release the fumes when fresh air is pulled through the charcoal, efficiently allowing the canister can be used over and over again.

For the most part, the emission system is fairly trouble-free but problems can develop when the air inlet to the canister becomes plugged. This air inlet acts as a vent for the fuel tank. When fuel flows out of the tank, air must be allowed to enter. If air can't enter, a vacuum develops and eventually the fuel pump cannot pull any more fuel out of the tank. The vehicle will seem like it ran out of gas, but the gauge may indicate that there is still plenty of fuel....."

And a definition from AutoZone:

http://www.autozone.com/servlet/UiBroker?ForwardPage=/az/cds/en_us/0900823d/80/04/b7/52/0900823d8004b752.jsp

"Charcoal Canister Operation:
A container, usually located in the engine compartment, containing activated charcoal. The charcoal absorbs or traps vapors from a vehicle's sealed fuel system, generally when the engine is turned off. This is a basic component of evaporative emissions control systems."

[BRIAN MP5T]

So there is no reason to have one...

[BRIAN MP5T]

So there is no reason to have one...

[TheMAN]

don't be a dumbass and read how that shit works

there IS a reason to have one... first of all, it reduces pollution, which its obvious to me you don't care about, but second of all, so you don't let that gas boil away... it's like flushing money down the toilet... and third of all, the fumes get collected, and get BURNED anyway...

so if you want to ditch that shit, go ahead, because all you're doing is spending some marginally more money on gas and making yourself and everyone else harder to breathe in the long run

[TheMAN]

don't be a dumbass and read how that shit works

there IS a reason to have one... first of all, it reduces pollution, which its obvious to me you don't care about, but second of all, so you don't let that gas boil away... it's like flushing money down the toilet... and third of all, the fumes get collected, and get BURNED anyway...

so if you want to ditch that shit, go ahead, because all you're doing is spending some marginally more money on gas and making yourself and everyone else harder to breathe in the long run

[jrodhotrod]

Well, tracking down a replacement canister and will have a trusted mechanic inspect the rest of the system to find out why the canister is being filled with fuel.

I haven't read anything about this previously on the protege boards so I am glad to hear it's not an isolated incident

[jrodhotrod]

Well, tracking down a replacement canister and will have a trusted mechanic inspect the rest of the system to find out why the canister is being filled with fuel.

I haven't read anything about this previously on the protege boards so I am glad to hear it's not an isolated incident

[Ken@ProtegeGarage]

part number on the canister is KLG4-13-970, i can price you out on one tomorrow

[Ken@ProtegeGarage]

part number on the canister is KLG4-13-970, i can price you out on one tomorrow

[Aric]

check the purge valves and canister close valves too.

Lets all remember that useless name calling should be left on MsProtege
We are all adults here and we should treat each as such.

[Aric]

check the purge valves and canister close valves too.

Lets all remember that useless name calling should be left on MsProtege
We are all adults here and we should treat each as such.

[BRIAN MP5T]

don't be a dumbass and read how that shit works

there IS a reason to have one... first of all, it reduces pollution, which its obvious to me you don't care about, but second of all, so you don't let that gas boil away... it's like flushing money down the toilet... and third of all, the fumes get collected, and get BURNED anyway...

so if you want to ditch that shit, go ahead, because all you're doing is spending some marginally more money on gas and making yourself and everyone else harder to breathe in the long run

Ok, Well I did and it dosen't seem to have a "Good" use.

On the whole Pollution thing... I took a N/A car and run twice as much air and fuel in it when I accelerate so, it's obvious that whatever minimal economy/green hugging factor is the least of my concerns.

Thanks for clearing it up Edwin, you all did answer my question, I was not trying to be an ass, it simply serves no purpose in my car for me.

[BRIAN MP5T]

don't be a dumbass and read how that shit works

there IS a reason to have one... first of all, it reduces pollution, which its obvious to me you don't care about, but second of all, so you don't let that gas boil away... it's like flushing money down the toilet... and third of all, the fumes get collected, and get BURNED anyway...

so if you want to ditch that shit, go ahead, because all you're doing is spending some marginally more money on gas and making yourself and everyone else harder to breathe in the long run

Ok, Well I did and it dosen't seem to have a "Good" use.

On the whole Pollution thing... I took a N/A car and run twice as much air and fuel in it when I accelerate so, it's obvious that whatever minimal economy/green hugging factor is the least of my concerns.

Thanks for clearing it up Edwin, you all did answer my question, I was not trying to be an ass, it simply serves no purpose in my car for me.

[jaw307]

Well, tracking down a replacement canister and will have a trusted mechanic inspect the rest of the system to find out why the canister is being filled with fuel.

I haven't read anything about this previously on the protege boards so I am glad to hear it's not an isolated incident
I have a huge thread from last year on msprotege about it probably titled problem refueling or something.

there is a check valve in the fill tube at the bottom of the rubber part, there is a breather filter up behind the bumper, and the cannister. thats really about all to check.

[jaw307]

Well, tracking down a replacement canister and will have a trusted mechanic inspect the rest of the system to find out why the canister is being filled with fuel.

I haven't read anything about this previously on the protege boards so I am glad to hear it's not an isolated incident
I have a huge thread from last year on msprotege about it probably titled problem refueling or something.

there is a check valve in the fill tube at the bottom of the rubber part, there is a breather filter up behind the bumper, and the cannister. thats really about all to check.

[jrodhotrod]

yeah, I already checked the filler tube because that was easily accessible and that one is still working fine. But there are valves before the charcoal canister but they are closer to the tank and behind the rear subframe so they are much more difficult to get at.

[jrodhotrod]

yeah, I already checked the filler tube because that was easily accessible and that one is still working fine. But there are valves before the charcoal canister but they are closer to the tank and behind the rear subframe so they are much more difficult to get at.

[pdhaudio83]

Lets all remember that useless name calling should be left on MsProtege
We are all adults here and we should treat each as such.

Agreed. Noted. Thanks.

[pdhaudio83]

Lets all remember that useless name calling should be left on MsProtege
We are all adults here and we should treat each as such.

Agreed. Noted. Thanks.

[Ken@ProtegeGarage]

dealer price is $124.95, i sell it for $82 shipped

[Ken@ProtegeGarage]

dealer price is $124.95, i sell it for $82 shipped

[jrodhotrod]

dealer price is $124.95, i sell it for $82 shipped
Ken you have a PM.

I <3 ProtegeGarage.

[jrodhotrod]

dealer price is $124.95, i sell it for $82 shipped
Ken you have a PM.

I <3 ProtegeGarage.

[pdhaudio83]

u <3 this site

im sure ken just doesnt hand out lolipops at msprotege (at least not ANYMORE, right ken (stare) )

[pdhaudio83]

u <3 this site

im sure ken just doesnt hand out lolipops at msprotege (at least not ANYMORE, right ken (stare) )

[jrodhotrod]

I second that on the big <3 for this site.

It's nice to go straight to the source with a community of knowledgeable folks and know it will be discussed like adults with real answers.

Thanks for putting this together guys. I hope it's the beginning of a long run for this community.

[jrodhotrod]

I second that on the big <3 for this site.

It's nice to go straight to the source with a community of knowledgeable folks and know it will be discussed like adults with real answers.

Thanks for putting this together guys. I hope it's the beginning of a long run for this community.

[jaw307]

another happy flyinprotege member thanks to the mid-west boys;)

[jaw307]

another happy flyinprotege member thanks to the mid-west boys;)

[pdhaudio83]

haha, i dont know about going THAT far ;)

[pdhaudio83]

haha, i dont know about going THAT far ;)

[NSNMotorsports]

possible two-way check valve (near charcoal canister) failure, or check valve failure (near purge control solenoid)

return your fuel system back to stock and take it to the dealer to diagnose the fuel filling problem... the evaporative emissions system is covered under the emissions warranty

there is NO reason to ditch this system because it does NOT reduce performance


Hell of a lot easier switching out alternators and pulling the intake manifold without it in the way... few less wires and solenoids and hose too..

I just can't understand how the heck I can have trouble fueling with no restrictions on that line... I should be pouring out fumes when pumping without issue... But I have major fueling issues. I'll probaly tear apart the fill tube and so forth this spring when I start re-prepping the car for the new year... but I don't intend to put the canister back in... just to figure out how to fuel the thing without issue.

[NSNMotorsports]

possible two-way check valve (near charcoal canister) failure, or check valve failure (near purge control solenoid)

return your fuel system back to stock and take it to the dealer to diagnose the fuel filling problem... the evaporative emissions system is covered under the emissions warranty

there is NO reason to ditch this system because it does NOT reduce performance


Hell of a lot easier switching out alternators and pulling the intake manifold without it in the way... few less wires and solenoids and hose too..

I just can't understand how the heck I can have trouble fueling with no restrictions on that line... I should be pouring out fumes when pumping without issue... But I have major fueling issues. I'll probaly tear apart the fill tube and so forth this spring when I start re-prepping the car for the new year... but I don't intend to put the canister back in... just to figure out how to fuel the thing without issue.

[CasopoliS]

I read through most of the thread... but not all.
This just happened with our Accord and it was a solenoid. I am not sure what it does. But yea that was really annoying.

[jrodhotrod]

Just an update...

Still having awful problems, but I have a replacement cannister from Ken ( I <3 Protege Garage) and the car goes to a mazda specialist next week. After talking with him on the phone we agreed that the things mentioned here could likely be the cause. He will be inspecting the vacuum source that goes to the canister along with the valves/solenoids that sit between the canister and the fuel tank. He hasn't seen this in any proteges but said he has seen similar problems on miatas.

Hopefully it will get figured out and the new filter can go in and I can resume filling my fuel tank properly again.

The 1/10 or less of a gallon at a time is really starting to get old.

[jrodhotrod]

So what I hope is a final update (knock on wood)

After taking it in and having a shop check things out all the evap system components, solenoids, and check valves tested ok. They then followed the lines to under the hood and found a pinched vacuum line. It was the only thing that could explain the problems so the vacuum line was replaced and re-routed. I then drained the fuel from the stock canister one more time, and today was able to fill the tank normally. If all continues to work smoothly, I'll put in my new canister from Ken and we should be back in business.

Thanks for the all help, hope this info helps anyone else experiencing the same kind of problems.

[bazooka joe]

vacuum problems seem to be at the root of a lot of issues!