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I've seen this before, mainly on diesel vehicles when hi flow browsers are used or when you fill up with the engine running.. What happens is the fuel foams up around the pickup and the engine sucks in air bubbles instead of fuel.
Wow that's awesome your car is making gasoline! I wish I had one that would do that...JK sorry couldn't help myself. Seriously, the tank is designed to allow for expansion so it should never be able to do this. You have an EVAP problem. the tank is supposed to vent to a charcoal canister so that the evaporating fuel doesn't go into the atmosphere. This does not sound like your average DIY fix, the fuel tank may have to come out. Alternatively, you could just not fill it clear full, at least until you get it fixed.
When you fill the car with gas if you dont stop when it is full and you continue to make the tank take more, you dont leave any room for expansion. The fuel expands and can cause orings to fail when it gets warm. If you have trouble filling the tank because of the issue that you stated, the problem might be due to a collapsed filler hose. If you are running the engine when you fill it, the noise is from the fuel return line.
sound like problem with the EVAP SYSTEM.HAVE CHECK OUT. trick to pumping gas dont stick fuel spout all the way in hold it back a little then pump gas the gas vapors stored in fuel tank stopping you from pumping gas.hold spout back pump gas.
Take off the radiator fill cap. Top off the radiator. Crank the engine.
Are there bubbles or is there water spouting out of the radiator fill hole?
Yes: likely cylinder head gasket failure or cracked header.
No: Pressure test cooling system after topping off with a pressure tester. Locate source of leak.
Assuming the water leak isn't anything to do with the non-starting situation, which it probably is though form the sound of it, also check the following:
1) Air filter 2) Fuel filter 3) Manifold Air Pressure sensor. 4) Mass Air Flow sensor.
In many vehicles 2000 and up, auto makers started putting a strainer type filter between the fuel door and fuel tank to help catch large particles before hitting the fuel, which could mess up the pump, sending unit, and clog your fuel filter quickly. It was also added, in my opinion, to help prevent siphoning. So I would try to look and see if that filter is plugged or clogged. Another thing it may be is sometimes at fuel pumps, the pumps themselves pump the fuel too quickly, making the fuel back up on itself.
The breether pipe located on the filling pipe can be blocked, it runs from the tank to the filling pipe . take it off at the top of the pipe and blow it to see if it is open.
There is a fuel tank vent tube that runs down the filler tube to let the air out of the tank as you fill it, these tubes get kinked, replace the tube, this is part of the filler neck assembly so the whole thing must be changed out.
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