Problem:
When I refuel my 2001 Protege MP3 the pump clicks off every time I put approximately 1/4 gallon into my car at every gas station I have filled at.

Background:
I am the original owner of the vehicle. This has been an ongoing issue for approximately six months. The vehicle is mainly driven in the winter and sits the majority of the time during summer. Approximately one month ago I had a p0170 lean bank 1 engine code and determined that my accordian air intake hose had a tear in it. That has been replaced and I cleared the codes by disconnecting the battery and turning on the lights until all power was lost. MIL is no longer present.

Known:
The non-return valve at the end of the filling tube is/was not obstructed and moves freely. I recently removed it completely to determine if it was possibly seated incorrectly and it appears that this has increased the problem somewhat.

The air filter and evaporative check valve (FSM page 1-16-3) are functioning properly as specified in the FSM. The fuel filler neck was removed and it is not obstructed. All evaporative hoses that are visible near the gas tank appear to be in good condition and are not kinked.

There does not seem to be an audible vacuum leak under the hood and a quick visual check shows no signs of problems.

Unknown:
I did not test the catch tank. I also need to perform the charcoal canister and need to do the canister to fuel tank test and the canister to purge solenoid test found on page 01-03b-55.

I am unsure of how to test the canister drain cut valve (CDCV) and the purge solenoid valve as I am not very skilled with electronics.

I am unable to get a good view of the hoses that come off of the back-passenger side of the fuel tank but I could feel a few of them. Are there any simple things I could do to rule these components out as the cause of the problem?

Ideas/Solutions:
Does anybody know of any quick fixes or possibly a way to easily and safely eliminate the evaporative system?

How about any suggestions?

Sorry for the lengthy post and thanks a bunch for replies. Trying to sort this out in a cold garage is no fun so I really appreciate feedback!

 

Hi there,
Sounds like you have a very frustrating problem! That would drive me nuts!

I don't mean to sound like a smart-*** and stating the obvious, but when filling the tank, have you tried not putting the nozzle in the filler neck all the way? I had a simular problem but with an old Suzuki Swift I had. The pump would click off if the nozzle was shoved into the filler all the way. Something to do with allowing the filler neck to breathe so the pump doesn't think the tank is full.
Next time you are filling up, insert the nozzle and then withdraw it about an inch or two before pulling the handle. Also try turning the nozzle sideways slightly so the trigger is not pointing to the ground. This seemed to solve my problem for no $.
Just be careful that when the tank is getting full, that the pump will shut off automatically and not splash gas on your shoes!

Hope this helps!

 

I've had the same problem with my 2000 Mazda Protege (and NO- moving the position of the gas filler nozzle doesn't fix it).

I don't drive it that much and it annoys the snot out of me.

If you find a fix Quest, please post it.