Fuel gushes out every time I fill up!!

OK, I bought my 08 Highlander in Feb. 09. It was used with 22,000 on the odo. Here's whats happening:

About 2 out of 3 times I put gas in, it gushes out when the tank gets full. I dont stand there holding the pump, I just set the automatic thingy on the pump nozzle and wait for it to click off.



The first time I put fuel in the car this happened and I just figured the fuel pump was messed up, but it has happened again and again and again.



About 6 weeks ago I took the truck to the dealer and had them look at it. The mechanic told me there was a valve or flap in the filler neck that is there to prevent someone siphoning fuel from my tank. He said the flap was out of place and he corrected it. Later that day I filled up and no problem.



Well..... about a week later I filled up and it happened again. So I went back a few days later and another mechanic said he couldn't find any problems with the filler neck or tank. I even took him to the gas station and filled up but nothing happened.



Then the next time I filled up it happened again, but this time I had my camera and video'd the incident. I showed the video to the mechanic and he tells me that the new Highlander has a bladder in the tank and that if the fuel pump pressure is too much, or the pump nozzle isnt in all the way that fuel will gush out when the tank gets full.



I have had many vehicles and several Toyotas, and this is the first one that has a problem like this. Is anyone else experciening this? Thanks for any help.

Reply 1 : Fuel gushes out every time I fill up!!

to TN.



I have had my 09 HL since end of March and have never had that happen to me.



Up here in Cda, at least in my area, its been quite some time since any of the gas stations have had the clip that allows you to lock in the position of the trigger on the pump. You need to squeeze the trigger by hand, and when gas reaches the nozzle, the pump shuts off.



You may want to try avoiding the locking clip and try filling by hand until the pump auto shuts off. Not sure why it would make a diff between hand held or clip, but who knows....

Reply 2 : Fuel gushes out every time I fill up!!

Had my 08 HL for over a year and never had that problem. In NY, they prohibit those clips at the pumps. Is even illegal to have something like your gas cap to hold it for self pumping.

Reply 3 : Fuel gushes out every time I fill up!!

Probably not the case but are you filling up with the HL's passenger side next the pump and taking the hose across the back and have inserted the nozzle upside down??



If so the nozzle will not shut off properly.



The nozzle has to be inserted with the handle/hose pointing downward to work properly.

Reply 4 : Fuel gushes out every time I fill up!!

I have never had any problems with fuel gushing out! I have, however, over filled the tank by trying to top it off. I have since stopped trying to top it off.

Reply 5 : Fuel gushes out every time I fill up!!

Quote:

Originally Posted by summerwind Probably not the case but are you filling up with the HL's passenger side next the pump and taking the hose across the back and have inserted the nozzle upside down?? If so the nozzle will not shut off properly. The nozzle has to be inserted with the handle/hose pointing downward to work properly.

Thanks for all the replies but no, I am not filling up from the passenger side. I just wanted to see if anyone else has been having this problem. I've been looking all over the internet for something similar and haven't found anything. That tells me its not a model-wide problem but specific to my vehicle. I guess I need to contact Toyota's South East division and see if they can help me.

Reply 6 : Fuel gushes out every time I fill up!!

I have an 08 Sport and havent had that happen. Ive only driven it 3300 miles though.

Reply 7 : Fuel gushes out every time I fill up!!

Quote:

Originally Posted by mdwebby Thanks for all the replies but no, I am not filling up from the passenger side. I just wanted to see if anyone else has been having this problem. I've been looking all over the internet for something similar and haven't found anything. That tells me its not a model-wide problem but specific to my vehicle. I guess I need to contact Toyota's South East division and see if they can help me.

There is emissions control equipment to recycle gasoline vapor and controls venting the gas tank. The problem lies in that area and the dealer needs to address the problem. Any chance you try to pump the maximum amount of gas into the tank by restarting the nozzle after it shuts off? I have been advised not to force gas into the tank but to simply stop filling then the gas nozzle turns off else the gas can be forced into the vapor recycling cannister affecting the tank venting.

Reply 8 : Fuel gushes out every time I fill up!!

Quote:

Originally Posted by jeffs3820 There is emissions control equipment to recycle gasoline vapor and controls venting the gas tank. The problem lies in that area and the dealer needs to address the problem.

+1



One other thing I can add. I don't know about the 08 as I have an 09. In the manual there was a blurb about refueling. When you push the button to open the fuel door, the display (if you have it) will say something like "Ready to refuel". In the manual it says that under some conditions, the door will not pop open until the truck relieves the pressure in the tank. It will display something like "Please wait to start refueling" or something along those lines. I never saw that message yet. I don't have the verbage exactly right.



I wonder if your display shows anything interesting during refueling?

Reply 9 : Fuel gushes out every time I fill up!!

08 and 09 models are exactly the same. Yes, I recall that same comment in the manual but I have never experienced any delay...the fuel filler door has been opening immediately.

Reply 10 : Fuel gushes out every time I fill up!!

Quote:

Originally Posted by adamscl I have never had any problems with fuel gushing out! I have, however, over filled the tank by trying to top it off. I have since stopped trying to top it off.

I do the same thing, but practice makes perfect and I rarely overflow my Highlander. Funny thing is that with both my Avalon and Highlander the pump will shut off early, and when I pump the remainder in "by hand" to the brim I always get in an extra 1.3 gallons.



BTW, to mdwebby, do you set the clip on the nozzle to the first notch (lowest setting)? I've found over the years that when pumps overflow it's invariably when someone has the nozzle set to the lowest/slowest setting.

Reply 11 : Fuel gushes out every time I fill up!!

Quote:

Originally Posted by TrailDust BTW, to mdwebby, do you set the clip on the nozzle to the first notch (lowest setting)? I've found over the years that when pumps overflow it's invariably when someone has the nozzle set to the lowest/slowest setting.

Its funny you ask that. I was always putting the nozzle on the top notch (highest flow rate) and it was gushing out. Now the mechanic told me to fill up on the lowest setting. Also, people asked if I am adding more fuel after the nozzle shuts off. No I am not doing that. The only thing I do is round it to the nearest 10 cents, i.e. if shuts off at $20.46 I then put in 4 cents to make it $20.50 (dont ask its just something I've always done).



Anyway, after my 3rd dealer visit, about 10 days ago, the mechanic told me that all 08 & newer Highlanders have a bladder in the tank, and that if you fill up on the highest flow setting that it causes too much air pressure in the bladder and that it will cause fuel to burp out when it gets full.



So I called Toyota's 800 number last Friday and opened a case with them. I got a call just a bit ago from a rep and she told me that she is not aware of any bladder on the Highlander . She said the only tank bladder she knows of is in the Prius. I'm supposed to get a call back on Thursday to see what the next step is. I guess its a good thing I had the service advisor give me a service ticket with the mechanics tank bladder explanation.



I'll give updates here as they progress. Thanks again for all the input.

Reply 12 : Fuel gushes out every time I fill up!!

Thanks for the update. Let us know if there really is a bladder or not.



Interesting that the problem happens on the highest flow settings. The main reason I never use that setting is since the flow rate is so great when the nozzle clicks off on some car it will be enough for to "eject" the nozzle out of the fill spout. Way back in high school when I worked as a gas jockey I learned real quick about that. Certain cars were more susceptible to nozzle ejection because of the angle/fill opening. Anyway, never had an issue with my Highlander other than the early shutoff, but I can live with that since I always brim the tank at each fill up.

Reply 13 : Fuel gushes out every time I fill up!!

Here is the latest and maybe last update. I was supposed to get a phone call from my Toyota case manager last Thursday (28 Mar 09), but instead got a call from someone else saying my case manager was unavailable and would call me by the end of business yesterday ( 2 June 09). By 4 pm yesterday I hadnt recieved a phone call so I decided to call and was told she was busy and would get back to me later. Around 5:30 pm the case manager finally called and told me that she had talked to the service manager at my dealership and has decided that because the dealer could not duplicate the fuel gushing out, that there was nothing they could do at this time. She recommended that I bring the car in anytime I need to refuel and ask for a techinician to ride along with me to see if I can duplicate the fuel filler problem. This will probably not happen anytime soon as I am leaving the country today and I'm sure my wife wont drive the 1 hour round trip to go to the dealer just to see if fuel will come out. So when I get back home I'll deal with it again.



About the fuel bladder, my case manager again said that the only Toyota vehicle with a fuel bladder is the Prius (and there have been reports of fuel gushing out on refills). She also told me that all the mechanics at that dealership will be told about the fuel bladders so as not to misinform the customer. I'm not holding my breath on that one.



I'm a bit disappointed that nothing was resolved but I can understand the lack of evidence on Toyota's part. When I am home I will continue to video tape my refills and if I'm in the area have a technician ride along to the gas station.



I'd like to thank you all again for your replies, I will continue to visit this site when my job allows.

Reply 14 : Fuel gushes out every time I fill up!!

Quote:

Originally Posted by mdwebby Here is the latest and maybe last update. I was supposed to get a phone call from my Toyota case manager last Thursday (28 Mar 09), but instead got a call from someone else saying my case manager was unavailable and would call me by the end of business yesterday ( 2 June 09). By 4 pm yesterday I hadnt recieved a phone call so I decided to call and was told she was busy and would get back to me later. Around 5:30 pm the case manager finally called and told me that she had talked to the service manager at my dealership and has decided that because the dealer could not duplicate the fuel gushing out, that there was nothing they could do at this time. She recommended that I bring the car in anytime I need to refuel and ask for a techinician to ride along with me to see if I can duplicate the fuel filler problem. This will probably not happen anytime soon as I am leaving the country today and I'm sure my wife wont drive the 1 hour round trip to go to the dealer just to see if fuel will come out. So when I get back home I'll deal with it again. About the fuel bladder, my case manager again said that the only Toyota vehicle with a fuel bladder is the Prius (and there have been reports of fuel gushing out on refills). She also told me that all the mechanics at that dealership will be told about the fuel bladders so as not to misinform the customer. I'm not holding my breath on that one. I'm a bit disappointed that nothing was resolved but I can understand the lack of evidence on Toyota's part. When I am home I will continue to video tape my refills and if I'm in the area have a technician ride along to the gas station. I'd like to thank you all again for your replies, I will continue to visit this site when my job allows.

We'll be looking forward to your return. Best of luck while you're away, and if we turn anything new up we'll bump this thread.