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Fuel Filling Problem

Discussion in 'Gen 4 Prius Care, Maintenance and Troubleshooting' started by eric1234, Feb 6, 2017.

  1. eric1234

    eric1234 Active Member

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    I've searched the threads, and I think Post #30 in this thread provides some insight:

    Won't take much gas | Page 2 | PriusChat

    Today, as I was filling my tank in my 2016, the gas immediately shut off and spilled gas all over the outside of the car. I've had the 2016 for almost 1 year now, and put 25,000 miles on it.

    I tried again and again to no avail. I didn't understand why. What I did notice was that I was moving the pump handle around a bit, and I saw that a part of the pump hit the fuel door "latch" - i.e. as if to indicate that the fuel door was closed.

    I was becoming desperate - it was early AM, and I had to get to work. So, I tried to re-press the "Open Fuel Door" button on the dash panel, and - voila - I was able to fill up the tank.

    So, what it seems like (and I'm just guessing here) is that when you close the fuel door, it makes some change in the fuel system (maybe closes off a valve?). At any rate, it seems like if that change occurs, you can't put the fuel in. The way to overcome the issue is to press the "Open Fuel Door" button, which seems to reset the change in the fuel system so that the tank can be filled.

    At least, that's what seems to have happened to me today.

    If this is the case, you'll want to be careful to make sure you don't accidentally depress the fuel door "latch" while fueling.

    Is there anyone out there that knows more about the evap fuel system and the function of the "Open Fuel Door" button?? (Note that after pressing the button - there is a message on the screen that says something like "Refuel Ready").

    Anyone else that has (perhaps accidentally) tested and confirmed my suspicion)??

    Best,
    Eric
     
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  2. jerrymildred

    jerrymildred Senior Member

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    Not sure about the Gen 4, but the PiP has a pressurized fuel tank. If you hit that switch, it might think that you closed the door. However, it would also know that the door didn't stay shut, so you'd get an alarm if you tried to drive it like that. I wonder if it may be the computer's way of saying, "We ain't doing nuthin' till you tell me what's up with that door."
     
  3. eric1234

    eric1234 Active Member

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    Thanks Jerry. I don't know if it knows whether the door is open or closed. The latch (from the little I looked at it) is just a spring-loaded pawl. That is, (I think) the latch in the same (extended) position when the door is open or closed - but - it is depressed as part of the transition from open to close.

    That's my guess, anyway... maybe I'll try again someday and see what happens. I should probably be looking for a carwash to wash the spilled gasoline off of the paint...
     
  4. Prodigyplace

    Prodigyplace Senior Member

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    Likely that is what happened. The pump hit the latch and the car thought the door had been closed.

    The documentation states that you must complete refueling within 30 minutes or fuel may spill. It states you can press the button again to get additional time.

    I suspect the car closes off the filler neck to reduce evaporation as part of the emission system.
     
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  5. RCO

    RCO Senior Member

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    I think when you press the fuel cap release button you need to hold it for 2 or 3 seconds and the tank then balances the pressures between the atmosphere and the tank interior before refueling begins.
     
  6. hsminolta

    hsminolta New Member

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    I just went through the exact same thing last week. I took it to Toyota service and they had never seen this problem before and wanted to see it happen. On the way to the gas station we received a call from the service manager and there is a bulletin addressing this problem. If you do not open the fuel door all the way, you will not be able to fuel the car. The spring on the fuel door has been redesigned to open the door fully and is much larger than the original. They ordered the spring and installed it a couple of days ago. I have not needed to fuel the car since but I hope this fixes the problem. My Prius 4 just hit 6000 miles so it took a while for it to show up.
     
  7. Prodigyplace

    Prodigyplace Senior Member

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    Welcome to Prius Chat!
    Thank you for the information. I have not had this issue but some others here have been frustrated by it. Did the dealer mention the service bulletin number? It may be helpful to others with the issue.
     
  8. hsminolta

    hsminolta New Member

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    Not sure of the service bulletin number but the part number is 1 77366-47030 spring, fuel filler. There are a couple of references to 531991 Replaced Fuel Door Spring and 7049 Fuel Door Spring Weak 53199. Hope this helps someone else.
     
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  9. Elektroingenieur

    Elektroingenieur Senior Member

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    The service bulletin is T-SB-0220-17, “Difficult to Refuel Vehicle Due to Fuel Filler Door Switch Interference,” issued May 23, 2017, which at this writing seems to be available only by subscription to techinfo.toyota.com.

    The bulletin is applicable to 2016 and 2017 model year Prius cars with VINs earlier than JTDKBRFU#H3038680 (Tsutsumi Line 1) or JTDKBRFU#H3552934 (Tsutsumi Line 2), and also to 2017 model year Prius Prime cars with VINs earlier than JTDKARFP#H3012455, but only if the fuel filler door does not open completely when the fuel door open button is pressed, which can cause the fuel vapor containment valve to close prematurely. The bulletin links to videos showing examples of complete and incomplete door opening.

    As @hsminolta kindly reported, the countermeasure is to replace the Fuel Filler Opening Lid Hinge Spring, original part number 77366-52010, with a spring of a new and “much larger” design, part number 77366-47030. The bulletin includes illustrated work instructions and allows 0.2 labor hours for the job.
     
  10. eric1234

    eric1234 Active Member

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    IMG_0125.JPG Since a picture may be worth a thousand words, here is the fuel filler inserted. You can see the part of the fuel pump (the large black "disc") that may interfere with the latch (to the right of the disc), and thus trigger the problem previously described.

    If I were an experimental guy, I'd intentionally depress the latch whilst filling with fuel and see what happens. I'm not quite so adventurous.
     
  11. randomwalk101

    randomwalk101 DYI'er

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    Can someone with access download this T-SB-0220-17 pdf and post it here? Thanks.
     
    #11 randomwalk101, Jun 27, 2017
    Last edited: Jun 27, 2017
  12. ATHiker

    ATHiker Senior Member

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    Add me to the list of owners who have experienced this.

    In my case, at about 50k and 18 months of ownership.

    If not for Prius Chat, I would have freaked out.
     
  13. Prodigyplace

    Prodigyplace Senior Member

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    @Tideland Prius
    Please sticky this with a reference to post 9. I just had to search to find this TSB for another user.

    EDIT: Is it possible to gather all TSBs in one forum? Most of the others are in the Main Gen 4 forum
     
  14. Tideland Prius

    Tideland Prius Moderator of the North
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    #14 Tideland Prius, Aug 24, 2017
    Last edited: Aug 24, 2017
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  15. randomwalk101

    randomwalk101 DYI'er

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    Can we have the actual TSB PDF posted?
     
  16. Prodigyplace

    Prodigyplace Senior Member

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    If you find it post in the thread. I suspect it cannot be legally posted by those with direct access though. I think @Elektroingenieur would know.
     
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  17. JennSH

    JennSH New Member

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    Same thing happened to me today filling up my 2016. Gonna try again later today and see what happens after reading this thread
     
  18. randomwalk101

    randomwalk101 DYI'er

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    Tsb is not copyrighted. It's posted everywhere if you do a quick search. Other manufacturers have it too not just toyota.
     
  19. CoolPrius

    CoolPrius Active Member

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    Toyota Tech Tip T-TT-0445-17 May 15, 2017

    Subject Market
    Fuel Filler Nozzle Splash Guard Interference USA
    Service Category Section
    Engine/Hybrid System Fuel System
    Applicability
    2016-2017 MY Prius & 2017 MY Prius Prime

    Expires on 05/15/2018 © 2017, Toyota Motor Sales, USA Page 1 of 1
    Ver. 2.8 01/01/2017 T
    APPLICABLE VEHICLES
    2016-2017 Prius 2017 Prius Prime

    CONDITION
    Some fuel filler nozzles are equipped with splash guards that may interfere with the fuel filler door
    switch. The fuel filler door switch is normally closed by the fuel filler door, which will close the fuel
    vapor recovery valve.

    RECOMMENDATIONS
    When refueling, please ensure that the fuel filler nozzle is positioned in a way that does not allow the
    fuel filler nozzle splash guard to interfere with the fuel filler door switch.
     
  20. Prodigyplace

    Prodigyplace Senior Member

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    That is Toyota acknowledging the photo in Post 10.
     
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