SureTrack Community Fix: Stop Overfilling

Sometimes you have to observe how a customer uses their vehicle to track down a problem. But sometimes you need a bit more help. SureTrack community member rockyridge2 had a Toyota Highlander in their shop that would stall after filling up, but not every time. 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 Community Fix summarizes the interaction between members of the community that led to the solution.

Vehicle
2016 Toyota Highlander XLE 3.5L

Title
Vehicle stalls after fill up, replaced EVAP canister and purge valve

Complaint
Customer states vehicle stalls after filling the fuel tank.

Diagnostic Steps Performed/Parts Replaced
Drove vehicle with customer to gas station and verfied problem after customer filled tank. When you come to a stop light it hesitates, runs rough, then turns off. It will restart and drive normal but when coming to a stop it will stall again, it only stalls like 3-4 times. Only does it when the tank is filled but not every time. And not with partial fill. It sets codes P0139, P1603, P1604 and P1605. Replaced EVAP purge valve under hood. What could be making this stall only a few times and only after refueling only to a full tank?

Best Answer from Community Member ericsautomotive
Have you made sure the canister isn’t contaminated with liquid fuel? Is customer over filling the tank? That alone can damage the canister!

Cause
EVAP canister filled with gas and was pushing fuel up to the purge valve.

Correction
Replaced EVAP canister and purge valve. Instructed customer to not overfill the tank. Stalling concern resolved.