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 Post subject: Fueling problem
PostPosted: Mon Feb 01, 2010 4:44 pm 
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I've had my KJ for about 3 weeks now, and I noticed a problem like I've never had with any car before. Every single time I fill it at the pump, the fuel overflows right at the end. Like if the pump can't sense the tank is full and shut down in time, so it keeps pumping in the full tank. This is happening at all my regular pumps, which don't do it with any of my other cars. I even went to a couple of pumps I've used infrequently before and it happens there as well. Every time I get several ounces of gasoline spilled, sometimes squirting under pressure between the pump spout and the fill hole. Last night was the worst of all, with about 6-7oz spilled on the ground and another ounce or so on my clothes. I hate spilling gasloine like this, plus it creates a fire hazard. What could be the problem? I don't even know where to start looking.


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 Post subject: Re: Fueling problem
PostPosted: Mon Feb 01, 2010 5:09 pm 
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This has been discussed many times and I've never really seen a good universal solution. I seem to get this problem only when it is cold (under 35 degrees).

Basically I drive until the tank is near empty, and always put 17-19 gallons in when I fill up. Once I hit about 14 gallons on the pump I back off the automatic release to the slowest notch, and at about 16 or 17 gallons I back it off and just barely run it by hand. Once it clicks and stops I don't squeeze in another drop.

No it doesn't solve the problem, but it may save your shoes. I believe there have been some that got a new gas tank or vents or something, but I'm not sure. You should probably do a search for overflow or something, there have been at least 3-4 seperate threads on here in the past year about this.

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 Post subject: Re: Fueling problem
PostPosted: Mon Feb 01, 2010 5:37 pm 
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Oh so it's a known problem :( I frankly didn't even know what to search for. OK, I'll be minding my gallons then. This won't be too painful as I have a very regular pattern of driving, and I can already tell pretty much to the half-gallon the amount of fuel I'll have to put in every time. And if 'm a gallon short of a full tank it won't matter much.

Too bad there's not a definitive fix.


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 Post subject: Re: Fueling problem
PostPosted: Mon Feb 01, 2010 5:39 pm 
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Location: Hillsborough, NC / Corolla NC
could be a stopped up breather hose coming from the fill neck, those hoses degrade pretty quickly but usually they'll start throwin CEL's with an evap leak if thats the case

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 Post subject: Re: Fueling problem
PostPosted: Mon Feb 01, 2010 5:46 pm 
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Well I have no CEL on.


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 Post subject: Re: Fueling problem
PostPosted: Mon Feb 01, 2010 9:24 pm 
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That's funny, we have two 06 KJs at work, and now they both do it!! they never did it when new, then one started doing it while the other didn't. Now both do!!!! My wifes 04 doesn't do it at all, and it's got 130k+.

I've just started basically judging how much gas the vehicles need (say each quarter of the tank is rougly 4-5 gallons) and when I get within 2 gallons of full I throttle that gas pump back. I'm sure it has something to do with the vent lines and the factory should fix it but I doubt they're going to recall and fix it for free. They really should. I have filled up much older shitboxes and never had that problem!! ??????

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 Post subject: Re: Fueling problem
PostPosted: Mon Feb 01, 2010 9:42 pm 
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since the aging components in that section is the breather hoses, i'd start there, it's a time consuming, but worthwhile investment of just a few dollars

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03 Renegade (Black)
177k miles 3.7L gas - 45RFE
Command Trac / 4.10s
Lift: ft. 790+ rr. JBA4+
The last of the TrailReady Front&Rear Bumpers and TR Rock Rails
Jarhead Offroad light covers
31x10.5R15 RedLetter Grabbers on Blackrock Dunes
L.O.S.T #KD098632


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 Post subject: Re: Fueling problem
PostPosted: Mon Feb 01, 2010 9:50 pm 
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Both of ours do it. I watch the pump, and when it's nearing the tank capacity, I get out & listen to it fill. You can hear when it's almost to the top, right before the pump shuts off & your $$$$ goes all over the pavement.

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Purchased 12/28/09 with 53K miles
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 Post subject: Re: Fueling problem
PostPosted: Wed Feb 03, 2010 5:46 pm 
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I have the same problem with my '05 renegade. It has 60k on it an has done it since I purchased it. I just deal with it. Not worth the hassle to mess with my fuel system.


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 Post subject: Re: Fueling problem
PostPosted: Wed Feb 03, 2010 6:02 pm 
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Location: Hillsborough, NC / Corolla NC
must be an 05+ thing

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03 Renegade (Black)
177k miles 3.7L gas - 45RFE
Command Trac / 4.10s
Lift: ft. 790+ rr. JBA4+
The last of the TrailReady Front&Rear Bumpers and TR Rock Rails
Jarhead Offroad light covers
31x10.5R15 RedLetter Grabbers on Blackrock Dunes
L.O.S.T #KD098632


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 Post subject: Re: Fueling problem
PostPosted: Thu Feb 04, 2010 3:06 pm 
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Must be 05+, because the wife's 04 has 130k+ and has never done it!!

Luckily the company vehicles that I fill up, I'm not paying for the gas!!
I would imagine they would want to do a recall for this???

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 Post subject: Re: Fueling problem
PostPosted: Tue Feb 09, 2010 7:20 pm 
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Location: Ann Arbor, Michigan
Naw, my wifes '04 does it. It sprays gas everywhere. One time the pump never shut off and I was on the other side of the Lib washing the front windows. I almost crud my pants when I saw the gas shooting out of the filler neck :shock: . Seamed like a long time to get around the front of the lib to the nozzle. Who knows how long it was doing that. :oops:

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 Post subject: Re: Fueling problem
PostPosted: Tue Feb 09, 2010 7:36 pm 
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My 04 has never done it

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 Post subject: Re: Fueling problem
PostPosted: Tue Feb 09, 2010 7:38 pm 
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Well then Tom, I guess my wifes lib is special. :P Just don't tell here that.

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 Post subject: Re: Fueling problem
PostPosted: Tue Feb 09, 2010 9:54 pm 
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Location: Buchanan Mi
My 05 just started to do this 2 fill-ups ago!

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 Post subject: Re: Fueling problem
PostPosted: Tue Feb 09, 2010 10:20 pm 
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Never had this happen, but I always seem to get some on my jeans :x

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2003 KJ
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 Post subject: Re: Fueling problem
PostPosted: Tue Feb 09, 2010 10:55 pm 
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My 04 has always done it. From 90'000KM when I got it. never didn't shut down the pump but always sprayed out just a bit. I just pump by hand now and have gotten used to the sound of it almost full.


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 Post subject: Re: Fueling problem
PostPosted: Wed Feb 10, 2010 7:08 pm 
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I have 115K on my Renny and have never had a problem with this, thank goodness.

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 Post subject: Re: Fueling problem
PostPosted: Mon Feb 15, 2010 7:25 pm 
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My 05 Rennie has been doing it since 50k

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 Post subject: Re: Fueling problem
PostPosted: Wed Feb 17, 2010 12:46 pm 
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Update.
What I've been doing recently is: fuel up until I'm about 1-2 gal short of full per my calculations, then continue in 1/3 gal bursts until full. Have had no more spillage this way.


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