Fuel is expensive, so a problem that causes fuel to spill on the ground is especially frustrating for drivers. SureTrack community member olivierm had a Kia Spectra in their shop that needed a new fuel tank due to corrosion. They replaced the fuel tank and checked the rest of the system, but fuel would spit out when filling the tank, They posed the question to the community, and with the help of fellow community member ericsautomotive, and others, they were able to resolve the issue quickly.
The following Real Fix summarizes the interaction between them in the community that led to the solution.
Vehicle
2007 Kia Spectra EX 2.0L
Title
Fuel spitting out when filling tank, replaced tank.
Complaint
Customer complains that fuel tank is leaking.
Diagnostic Steps Performed/Parts Replaced
Vehicle came in with fuel leak due to corrosion. After replacing fuel tank with aftermarket unit, OE from dealer is out of price at 1200$ CAD, when we fill the tank, the nozzle shuts when full, and gas spits back. Because it’s doing that after replacing the fuel tank, we took off the tank and took a look at every hose and pipe to see if everything is well connected. Everything is fine about that. Tested the canister to ensure it’s not clogged. If it was clogged, it would be hard to fill with gas. We also tried another fuel tank, and tried filling it ourselves at the gas station. It’s still doing the same thing. But, a symptom that we didn’t know of, was that it’s hard to start after it’s filled with gas. The purge solenoid failed open. I replaced it. Since the tank is now full of gas, I can’t really try filling it again. Do you think that the purge valve faulty can cause that?
Cause
We have a major issue with that aftermarket fuel tank supplier. On this Spectra, we replaced the purge valve. It have been tested multiple time since then and it’s better, but not like it was with the OE fuel tank. It still spits back. On another hand, we replaced a tank under a Kia Forte and it came back for the same problem. The problem for the customer is that an OE fuel tank is 3 times the price of the aftermarket one!
Correction
Customer agreed to pay for OE fuel tank. Installed in vehicle and filled with gas and it no longer spits back when full. Customer satisfied.
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