Overfilling the fuel tank during refueling can lead to several engine performance issues and possible damage to the fuel system. If the fuel station fill nozzle automatically shuts off (clicks off), and the customer continues to try to add more fuel beyond three clicks, liquid fuel can enter the vapor lines of the evaporative emissions (evap) system. The fuel may block the recirculation line and cause issues with the fuel tank pressure sensor readings.
On some 2019-2023 XT4 and 2021-2023 Envision models equipped with the 2.0L engine (RPO LSY), the fuel tank overfill may illuminate the Check Engine MIL and set DTC P0451 (Fuel Tank Pressure Sensor Performance). These vehicles have a capless refueling system and do not have a fuel cap.
If these conditions are found, inspect the vent lines at the fuel tank for damage and drain any fuel or remove any contamination from the evap vent lines. There are three vapor lines near the fuel tank. (Fig. 15)
Fig. 15
The vapor lines (shown with green quick connectors) (Fig. 16) also should be disconnected from the evap canister to clear the lines of any liquid fuel. (Fig. 17) To access the evap canister, remove the right-hand rear wheel and wheel liner. Lightly blow shop air into each line to clear any fuel.
Fig. 16
Fig. 17
TIP: Be sure to remind customers about overfilling the fuel tank. The tank should not be topped off after the fuel station fill nozzle handle automatically shuts off when the tank is full. Do not exceed the three-click recommendation when refueling the vehicle to help prevent overfilling issues in the future. Refer to the Owner’s Manual for additional information about fueling the vehicle.
For more details, refer to Bulletin #22-NA-203.
– Thanks to Matt Gager
Why is a customer induced concern, covered under warranty at all?