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Old 07-08-2019, 10:33 PM   #1
GHOST R1DER
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Member#: 144390
Join Date: Mar 2007
Chapter/Region: South East
Location: South Florida
Vehicle:
2002 WRX
PLATINUM SILVER

Default Issue pumping gas

Hello to all and thank you for reading,

I have had my 02 WRX parked for the past few years (3-4). It has always been parked indoors in my home garage or shop. I also turn it on at least once a month and run it.

Last year I went to add $10 of fuel and it started to trigger the safety at the pump causing pump to shut off but fuel level was on "E". I tried other gas stations and got the same issue. I didnt have plans to daily drive the car at the time so I filled it sloowly and put the issue on the back burner.

I am now thinking about getting the car back on the road and would like to know if anyone knows a proper way to diagnose the issue or knows what the issue is. Everything I have read points to the EVAP system but I don't have the money to do process of elimination and just start replacing parts... but I do have the time to try and figure this out.

CEL has not been triggered so I do not think I have any DTC's but I can't remember if Subaru's have "silent" DTC's that do not trigger CEL.

Any help is appreciated, thank you for your time.
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Last edited by GHOST R1DER; 07-08-2019 at 10:35 PM. Reason: typo
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Old 07-08-2019, 11:59 PM   #2
Blktrax
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Member#: 220971
Join Date: Aug 2009
Chapter/Region: South East
Location: West, NC
Vehicle:
2002 WRX 223K Mi.

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Fuel filler neck; from the cap to the tank. Itís old, probably rusted. Thereís a valve about 6in down the neck with 2 vent hoses going to it that follow all the way down to the tank. Itís common on the older cars ,the lines rot, get a hole or mice. If those small hoses are not connected to the valve or the valve isnít working. It wonít refuel properly.
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Old 07-09-2019, 09:44 AM   #3
GHOST R1DER
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Member#: 144390
Join Date: Mar 2007
Chapter/Region: South East
Location: South Florida
Vehicle:
2002 WRX
PLATINUM SILVER

Default

Thank you Blktrax, I'll pull it off today and inspect. Is there a way for me to test the filler neck valve in the event that the filler neck it self is not the issue ? My 1st instinct is to blow in one end and see if it comes out the other but I'm not sure if that is how the valve is meant to function. Thanks again !
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Old 07-09-2019, 05:09 PM   #4
GHOST R1DER
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Member#: 144390
Join Date: Mar 2007
Chapter/Region: South East
Location: South Florida
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2002 WRX
PLATINUM SILVER

Default

ok, I took apart filler neck with out removing it from the car and here is what I gathered.

Filler neck is in good condition, very minimal rust on brackets for hardware that secure filler neck cover. There was not any rust that I could see anywhere on the actual filler neck it almost looks like it's made out of aluminum but I'm not sure.



next I removed all rubber lines from filler neck and they where pristine on the inside no residue or restrictions in any of the lines.

I then moved on to the filler neck valve, it looked clean I pressed and depressed plunger on valve and felt no restriction or stick. I also blew in one port and had no restriction at all when blowing through either port I pressed in plunger while blowing through ports and it would seal ports in both directions. I then put a mirror to top of filler neck to inspect for any obstructions at the port on the filler neck where the valve mounts and that was also clean and unrestricted.



I continued to follow lines from this point and the next thing was the charcoal/carbon canister. I feel that this may be the issue but I don't have new canister to compare to. When I removed the canister I notice that it did not make any noise at all, in my mind I imagined a plastic canister filled with charcoal pellets that would make some sort of noise if the canister where to be shook but again I'm not sure if this is normal. The canister has a total of 3 ports, on the OEM canister the ports are labeled as "Fuel Tank", "Purge" and "Drain" with the Fuel tank and Purge ports on one half of the canister and Drain port on the other. I then proceeded to blow through the ports and noticed that when blowing through the Fuel tank ports air would come out of the Purge port and vice versa but when I blew through drain port there was no air flow. I then blew through Purge port and sealed the fuel tank port leaving the Drain port open and again no air flow. Should the Drain side of the canister be sealed or have no air flow? I also noticed mold spores in the drain port which makes me think that the Drain side may be clogged.


Last edited by GHOST R1DER; 07-09-2019 at 07:44 PM. Reason: add images
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Old 07-09-2019, 10:28 PM   #5
Blktrax
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2002 WRX 223K Mi.

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Well good news is the filler isn't a rusty trombone. It's steel just painted silver. Unfortunately eliminated the cheaper part first.

The canister has a BAG inside with the charcoal pellets it in it, when it breaks or degrades due to overfilling with fuel (why they say; "don't top off when filling" as it saturates the canister.) All that can get sucked to the engine via the purge line.

Basically the canister works as a Desiccant like silica to remove moisture, but rather scrubs fuel vapor. So a blockage would definitely cause an issue. But the switch for allowing pressure to release is actually above the canister. Follow the drain hose to the valve. But if you can't blow into the fuel tank port and get air out both the drain and the purge, canisters busted.

Here's a good write up.
http://cars.natemichals.com/subaru-2...ment-write-up/
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Old 07-10-2019, 10:14 AM   #6
GHOST R1DER
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Join Date: Mar 2007
Chapter/Region: South East
Location: South Florida
Vehicle:
2002 WRX
PLATINUM SILVER

Default

Good deal, I am going to replace the canister for now as it is confirmed to be failing and hopefully that will solve the issue. Normally I would just replace it all since I'm already there but with the canister alone being about $100 +/- and the purge valve being another $100 +/- I am hoping that the canister solves the issue and that the valve gives me a little more time before it has to be replaced.

thank you very much blktrax, I owe you a cold one !
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Old 07-10-2019, 10:23 AM   #7
GHOST R1DER
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Member#: 144390
Join Date: Mar 2007
Chapter/Region: South East
Location: South Florida
Vehicle:
2002 WRX
PLATINUM SILVER

Default

for others that come across this thread in search of answers here is the some resources I came across that may help.

Charcoal canister Part#: 42036AC020 (confirmed for 02 WRX, should fit other years and models but its up to you to confirm)


Auto Zone part # (for Subaru OEM charcoal canister): VC4377 (images in next post)

filler neck removal vid:

Generic diagram of Charcoal Canister function:

Last edited by GHOST R1DER; 07-11-2019 at 06:36 PM. Reason: typo
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Old 07-11-2019, 06:30 PM   #8
GHOST R1DER
Scooby Newbie
 
Member#: 144390
Join Date: Mar 2007
Chapter/Region: South East
Location: South Florida
Vehicle:
2002 WRX
PLATINUM SILVER

Default

Picked up new canister today, after going from part store to part store I ended up ordering from Auto Zone they where not the cheapest but they where able to get it for me next day at no extra charge and it would come with a life time warranty as well which was also a plus. Another bonus was that when I picked up the canister and checked it to make sure it was the right one I was surprised to see that it was a SUBARU OEM canister !! I will add AZ part number above.





As for the issue I was having before it is now resolved I filled up today with no interruptions In my case all I had to replace was the charcoal canister.

Some other notes that may help determine the issue that I tried for good measure is as Blktrax mentioned, there should be air flow accessible from ALL ports. I tried the new one today and it was a clean unrestricted airflow from all ports and I also noticed that the new one was significantly lighter as well being that it wasn't saturated like the old one.

Last but not least I also applied a silicone based grease to all nozzles that connected to rubber hoses to ease re-installation, condition the hose ends a little and help prevent evap leaks. Same should be done with nuts and bolts a dab of anti-seize to prevent issues in the long run.

Last edited by GHOST R1DER; 07-11-2019 at 06:32 PM. Reason: typo
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