Troubleshoot gas pump shutting off during tank fill up on Chevy truck

Here is how to troubleshoot the problem of the gas tank shutting off every gallon or so during fill ups on a full size Chevy Truck. Mine is an 04 with 5.3L engine.

[@arfarms5711]

Did I’ve been fighting putting gas in my truck for 4 years. It’s my service truck. 2500 w tool box body. I honestly figured someone that installed the body on truck screwed something up. Thank you so much. Now I can get fuel like a normal person! Without having to take 30 mins 🥵

[@treyspetch]

Awesome. I’m glad it helped!

[@chrisricks9583]

I have the same truck and same issue

[@arfarms5711]

@@chrisricks9583 I’m still dealing w it. Thankfully I only hand yo put gas in ab once a month

[@Louisianawhips]

@@arfarms5711 did you find the issues for yours? I changed both parts and I’m still dealing it.

[@davidinchcliff4560]

I changed my charcoal canister. It worked. Don't over fill you gas tank

[@Trippleroc]

Fantastic video. I went ahead and replaced the vent valve. So bummed out today when I went to the pump and my avalanche was still doing it. So glad your sharing your diagnostic approach. Thank you so much

[@emeraldwordcool1023]

Did you ever figure it out because I replaced both the vent valve and the charcoal canister and it’s still having fill problems

[@Trippleroc]

@@emeraldwordcool1023 Yea I was able to fix it. Ended up being the media from the old charcoal canister backing up and getting into the lines and tubes that vent the fumes from the gas tank to the canister and vent tubes. I Found out this was pretty common in these GM’s. We had to drop the tank set it on a bench and blow out all of the lines from all different sides and ports. A lot of the charcoal beads were flying out everywhere. It took about a good 20-30 minutes of blowing air through all the the hoses and lines that were attached to the gas tank. Went ahead and reinstalled everything and put in a new charcoal canister, and finally I was able to pump gas without any problems. Did it just about 1 year ago and still haven’t had any problems. I hope this helps. 👍🏽😎

[@jasonsprouse2803]

Good explanation on how to narrow down the issue. One other thing that would need to be checked, the tube between the charcoal canister and vent valve could be plugged. I would suggest checking all of this by getting a piece of hose that fits over the charcoal canister inlet, then blowing through, and removing different parts, rather than driving up to put gas in.

[@IamBigYon]

I changed all of that on my 07 avalanche and still having the same problem

[@EricMalek]

Thank you! We have a Chevy Tahoe that has done this since we got it. I’m hoping this will keep me from taking 3 hours to fill up with all the shut offs! Must be a Chevy thing…

[@davidx8576]

I fixed my same issue (another make and model vehicle) by shaking and squeezing out loose charcoal from the vent line that goes to the charcoal cannister. Hope all went well with your fix and thanks for sharing.

[@paulgray6856]

You sir are a genius! This really helped me identify where my problem is. Also got to get a full tank of gas

[@FunkyMonk93]

Best video on the topic. Great explanation on how to debug what is actually wrong. Thank you!

[@trey5630]

Glad you found it helpful!

[@CHIBA280CRV]

Informative video 👍👍👍, also I have flushed out the canister and then blew air with compressor thru it , and it worked again with no problem..

[@ptm1837]

⁰

[@jamesguralski5156]

I get like ¾ of a full tank! Thanks for sharing! If a person doesn't fix this.. It will start pushing the charcoal materials into fuel lines..

[@williamc2930]

I have a 2011 Suburban that you can hear the air girgling up the filler neck every few second and then pump nozzle shut off. I can go slow, same thing! Now, I know where to look and what to do. Thanks.

[@georgiaboi22]

Very helpful for my 2005 Chevy Suburban! I’m definitely doing this when I go back to the pump!

[@saltlifefishingchannellets2437]

Just did this to my chevy avalanche then went got gas worked perfect thanks

[@jayeff4457]

Thanks for the trouble shooting technique, I'll try this out. Im having a hard time pumping gas in to my 2008 Silverado.

[@smitty522]

This is the best video I found. Thanks for all the info

[@wandameadows5736]

You don't always need to replace the canister. If its clogged you can unclog it pretty easy & put it back on. I've seen some canisters with a vale in them & people would spray wd40 in the hole where the valve was to lube it if it was getting stuck closed. Anyway the canisters are nothing fancy, just plastic with charcoal pellet's but the cost $200 plus. You can buy a delete kit that removes the canister all together.

[@trey5630]

Thanks for the comment, Wanda. My canister had a foam barrier inside that keeps the charcoal from backwashing, and the foam had deteriorated, so I needed a new one. The charcoal was floating back up the vent lines toward the tank.

[@juanespinoza7668]

Dude where???

[@adamvalenzuela6626]

Seems like some one knew I needed help with 02 Hyundai. Having the same problem with gas fill up. This video helped thanks.

[@frankmorgan5234]

Just the info I needed even though I'm working on a 2010 DTS, mucho gracias Amigo.

[@valkyrierescues7861]

thank you for the video iv been having major issues with this on my 2005 sierra hd ... il give it a try.

[@wacoldestv1704]

Thank God almighty for your video sir! This is a true blessing to my dilemma! Thanks X's million. Yes it helped!XXX Char oal canister XXX

[@sinegra30]

Best Issue approach ever!

[@johnthompson7420]

blow canned air in thru the filler neck vents. fixed mine without rolling around on the ground.

[@shoutdowncreative2705]

can you explain how to do this? thanks

[@dilippatel3268]

excellent video

[@snakejr.9196]

Thanks for the video. I am having the same problem. I replaced the vent solenoid and the fuel kept clicking off. I will try the line to the charcoal canister next.

[@treyspetch]

Good luck. Try just disconnecting the line to the canister and let it vent freely to the air first and try gassing up. That way you’ll know without throwing parts at it.

[@pedrovaldez9559]

Arthur, did it work after all. Fixed it. I have same problem. I already did the first test. This weekend or once I can, I'll be trying the second test with rhe charcoal canister. And then the lines. This way I'll know my lines are not clogged up.

[@kevinspahr6632]

@@treyspetch Hypothetically if one was to leave that connection disconnected, would there be a code thrown or any problems other than the obvious one?

[@trey5630]

@@kevinspahr6632 Yes, the vehicle periodically goes through a diagnostic test where it closes the valves and tests that the system is sealed. With a vent tube is left open to the air, you will fail that test, and it will throw a code. But this has absolutely no impact on the health or performance of the truck. It only means that your vehicle is venting some gas fumes to theair without running them through a charcoal filter dictated by emissions standards. HOW DARE YOU!!! kzbin.info/www/bejne/rofPg6Kjpchkr6c

[@kevinspahr6632]

@@trey5630 Yeah that's what I figured. Mine is actually doing it on an 04 Chevy Venture. I'm hoping I have the same set-up as your truck. I'll wait till the weather gets warmer before I take a look.

[@josecardenas1467]

Nice and easy explanation. Well done. ! 👍

[@lukepodolski8818]

Excellent video-thank you

[@owenordonez9315]

Thanks 🙏 for the info I will fix mi Avalanche 2005 5.3L

[@ksmith3116]

Excellent video and advice in the comments. Thanks man. Helps alot.

[@antoniosingletary4473]

Best video yet thanks

[@user-pw6sh1wu2j]

Very well done. Thank you 👍

[@clintstein8743]

Good video. I’m having the same issue with the pump turning off just after adding about a gallon of fuel. I disconnected the vent line running form the fuel tank to the charcoal canister and tried to get gas. This time, gas is pouring out of the vent line. What’s that about? I’ve changed out some many parts and haven’t fix a damn thing.

[@johnpavon799]

Easy fix thanks for sharing!

[@chasenoorda9931]

Excellent video, Thank you sir!!!

[@BrownTigerTV]

Awesome explanation

[@planktonus]

Thank you

[@maxd9352]

Awesome video thank you so much!

[@kenneththomas8299]

Great video. Thanks!!

[@laviar23]

Thanks brother

[@jw228w]

thanks for video . i have 2011 gmc uno 170000 miles doing the same thing.looked at scotty video also and he says can happen when i over fill tank after it shuts off by itself,then extra gas i put in will flow into vent tube and literally clog up the carbon in canister john

[@trey5630]

Yeah, I believe what happens when you overfill is that gasoline flows out the vent tubing and into the charcoal canister. There is a foam barrier at the canister entrance, but it disintegrates over time. Then the liquid gasoline that flows into the canister washes back into the vent tube, carrying charcoal pellets with it. These pellets clog up the vent tube and have to be blown back out.

[@sirhanreid5896]

great troubleshooting

[@chrisnevarez449]

What if I bought both vent valve and the can and still have same problem?

[@xcesarxramosx]

Thanks for the info

[@eds1512]

I have the same symptoms on my camry. The dilemma I'm facing is that I can't find a mechanic to replace the charcoal canister. Apparently it's too much work. Go figure.

[@kraybecht3579]

Good info...thank you

[@whitemorn]

Great, thanks! Very helpful. I just replaced the vacuum solenoid as you did so off to fill the tank and see if it shuts off still. Just wondering if you noticed using more gas before the repair and or hard starting which some say are symptoms of a bad charcoal filter?

[@SheriffofYouTube]

the gas vented directly to the air via a air line that ran alongside the down spouts.. from 1920-till 2001 , before they mandated EVAP systems post2000. california made that no longer possible..

[@rss8400]

will try this on my 2013 tahoe....its been shutting off too :-(

[@lexbrusb.1821]

nice how GM stuck a few hundred dollars of useless parts and weight on the truck to make some side money along the way. what's the point of having charcoal canister in there and a solenoid if the fumes go to the engine and burn anyways?

[@trey5630]

All of this stuff is required by the federal government for emissions standards. The charcoal canister is required to scrub and capture the gas vapors on every car, where the air in the tank has to vent out when you fill it. The valves are required to then close the system to allow the engine to suck them back out of the canister and to do the emissions test, which the government also mandates.

[@pauldavis4656]

Thank you!

[@TheBenjammin]

The vent valve brings in fresh air, not vents it. The purge valve vents the vapor...into the intake manifold.

[@treyspetch]

During refueling, the vent valve remains in the normally open state to vent the air from the tank. That’s what allows you to add gas. When the valve gets stuck closed or the vent lines become clogged, the gas backs up in the filler tube because there is nowhere for the air in the tank to go. The purge valve is closed when the car is off.

[@benderprofessionalservices9018]

I just replace the canister and solenoid kit any the purge valve. Still cuts off at the pump. What could it be? Maybe I’ll just unplug the damn connection and let it blow fumes into the air.

[@treyspetch]

If you disconnect all that and it still stops, then your vent lines are clogged and you need to blow them out.

[@IamBigYon]

I changed both and still having the same problem

[@ralphstas6816]

I am having the same problem of gas pump shutting off unless I fill on very low fiil on my 2014 VW Tourage Sport V6

[@Mysticlyonenterprise]

Hey,after you replaced the charcoal canister did that fix your issues cause mines didn’t.any other tips outside charcoal canister pure valve n vent solenoid?

[@treyspetch]

Replacing the canister fix it for me. If you are still having problems, then it is probably clogged lines from your tank to the canister.

[@ConTxT]

THANK YOU SENPAI

[@newestappleman]

When you disconnected both of those lines to diagnose the problem would that let gas come out or just vapors??

[@trey5630]

If you pump the tank to full and the gas pump then cuts off, you will get a little bit of gasoline dribbling out onto the ground. It's normal for a little bit of gasoline to go down the lines into the vapor canister when you top off. This is a good way to see that the lines are clear (seeing some gas on the ground after filling up with the lines disconnected).

[@arymniak1]

Disconnect the tube at the charcoal canister. Done.

[@tonyb7748]

For anyone in the rust belt, the old evap canister vent may not come off the slide tab. Just use (I used stainless steel versions from commercial electric) zip ties to secure the new one to the old one.

[@chevyvet69]

Call thank you for telling us how to bypass the system that's we wanted to see

[@treyspetch]

Glad to help. Later on I had another problem where the bad charcoal canister sort of burst inside and charcoal particles got sucked back into the vent line toward the tank. I was able to blow out the tank with compressed air while the charcoal canister was disconnected. About 1/4 cup of charcoal pieces cane flying out. After that there was no more curling problems.

[@chevyvet69]

That's crazy whoever came up with that system is a real asshole

[@chevyvet69]

I just bypassed the whole entire Box altogether

[@raolito1980]

@@chevyvet69 how?

[@shoutdowncreative2705]

@@chevyvet69 at what point did you disconnect things? and the vapors venting caused no problems with anything?

[@michaelcronin8253]

Having this problem on my 2008 Tahoe. Is the solenoid valve in a different location in the 2008- models? I’m reading all sorts of locations and can’t even start with your first step

[@treyspetch]

I’m not exactly sure on a second generation avalanche. I think if you find the charcoal canister and work your way backwards and forwards from there, that should give you a search strategy

[@brettsanford169]

It’s on top of the motor if it is like our 2007 tahoe.

[@SheriffofYouTube]

carbon filter needs changing the hoses go into EVAP

[@SheriffofYouTube]

its always the charcoal filter. that is why they installed tehm after 2000. its a $300 repair every 38-48 months or no gaz4u

[@seamonjosey8027]

Thanks

[@fredtylertx14]

I changed both and still cnt put fuel in it

[@jonezmusicgroup]

Disconnect the lines from your canister & vent and trace that hose from the canister to your fuel tank and disconnect that line, then just blow compressed air thru the lines. You probably have charcoal clogged somewhere. You may have a clogged vapor canister purge valve too. It’s under the hood so check it to be sure. After that, it should definitely work… That covers all bases to the issue.

[@millibarman]

My 2015 Sierra 1500 has had the ‘gas pump shutting off’ problem since day 1.

[@lucaslittlejohn462]

So I disconnected both the lines and the pump still shut off

[@treyspetch]

You probably have carbon pellets in your lines, and they need to be blown out

[@lauradinkins]

I replaced my vapor canister still have the same problem. Could it be I need to clean the lines?

[@trey5630]

Yeah, my guess would be its the lines that are clogged or the valve will not open.

[@lauradinkins]

@@trey5630 okay, my lines is clogged up my mechanic said

[@lauradinkins]

@@trey5630 he said my value is good

[@treyspetch]

@@lauradinkins On my 2004, there’s a very small line near the very back of the tank there’s a fitting that you can disconnect in the middle of the line, and you can put a compressed air gun against it to blow air into the tank and blow those vent lines out. If you can do that, it saves you from having to drop the tank down to get those lines out

[@lauradinkins]

@@treyspetch I have a Hyundai Elantra 2002

[@jameswashington2506]

What if you change the solenoid valve and the charcoal canister and you're still experiencing the same problem

[@trey5630]

clogged vent lines

[@jameswashington2506]

@@trey5630 do you have a part number for that or just say I need the vent lines between the solenoid and the charcoal canister

[@trey5630]

I don't know the parts numbers. You can get the vent lines between canister and solenoid off yourself pretty easily and blow them out. The lines from the tank to the canister are harder to get to, and most people remove the tank (lots of work, never done it).

[@jameswashington2506]

@@trey5630 thank you your video and advice has been a great help

[@michaelcronin8253]

Ok, so having disconnected the hose from the tank into the charcoal canister, the problem persists. If understand correctly, that could mean that the hose may be clogged, correct? Any other thoughts?

[@treyspetch]

Yes it’s very possible that charcoal pellets have floated back up into that hose and clogged it. It happened to me once. I found a very small 1/4 inch line coming out of the back of the tank that think led up toward the filler neck. It had a little disconnect in the line. I disconnected it and blew compressed air through it to inflate the tank. About 1/2 cup of charcoal pellets came blowing out of the vent line that goes to the canister. After that, I Hooked the vent line back up to the canister and everything was cool. Some people say that this is a consequence of overfilling your tank by continuing to click after the pump shuts off. I think the idea is that fuel flows into the charcoal canister and then back washes into the line carrying charcoal pellets with it.

[@treyspetch]

And make sure you keep the filler cap closed, so the tank will hold the pressure when you blow air into it.

[@michaelcronin8253]

treyspetch I suctioned lots of carbon debris out. Still not working. I now recall in the past that when this began, at one point when I was trying to “rapid fire” fill my tank that fuel actual spilled out at one point. At the time I figured that the evap system shutting of the filling caused stoppage of fuel intake, but now I wonder if it’s a problem in the first stage of the fuel line, from the top (the neck) down to the tank. How common is that? Might be time for me to give up and take it into the shop? Appreciate your comments and suggestions. Was fun while it lasted

[@treyspetch]

@@michaelcronin8253 I’m not sure if suctioning out really provides enough force to clean the line out. I think I would take compressed air and blow it out from the other side to ensure that there’s nothing still stuck in there. It just requires a compressor.

[@michaelcronin8253]

treyspetch The issue there is that I think I’d need to drop the tank to get to the other end of the line, correct? That’s a bit beyond my capabilities I think

[@michaelcronin8253]

With either one of the vent hoses disconnected during troubleshooting, is there a risk that when filling the tank the gas pump won’t shut off in time and gas overflows when filling tank?

[@treyspetch]

No, I have done this. The worst that will happen if you get a little triple of gas on the ground when the tank is full. That’s the gas that normally with triple into your charcoal container.

[@treyspetch]

The pump will still shut off when the gas work his way back up the filler neck.

[@michaelcronin8253]

treyspetch thanks!

[@jasonsprouse2803]

There is a check ball at the top of the tank. Liquid gas should never go into the evap system. If there is, there is another problem, and the charcoal canister will be bad because of the liquid gas.

[@trey5630]

@@jasonsprouse2803 The check ball is a rollover protection. It only blocks the flow when the gas tank is upside down. If it activated all the time, the rush of air out the vent hose would be blocked, completely invalidating the idea of a vent hose. Liquid gas goes right out the vent and into charcoal canister when you overpump. Give it a try by disconnecting your hose from the charcoal canister and you will get a pool of gas on the ground when you pump the gas beyond full. The charcoal canistetr can take a little bit of liquid gas. This is why they tell you not to pump beyond when the pump shuts off, because it dumps more gas into the canister, where it floods it and it takes longer for it to evaporate.

[@taronhowell2523]

What about a constant clicking sound coming from solenoid

[@treyspetch]

That sounds like your computer is malfunctioning and sensing pulse to your solenoid. Or the solenoid is going bad.

[@robmar1969]

THX alot

[@phillipprater2188]

Have same problem on Chrysler 200 2012

[@aromee7696]

Any one have any idea why my fuel would be coming straight out the filter cup as I pump it

[@joeculpepper2235]

What caused the charcoal canister to fail, moisture or fuel?

[@trey5630]

I'm not sure. The foam insert that keeps the charcoal from going out the inlet nipple was all disintegrated. It was 16 years old. Not sure if it was from overfilling too much.

[@joeculpepper2235]

Trey I’m about to do mine on my 16 yr old Escalade. Same system. Thanks man.

[@brucehansen7949]

@@joeculpepper2235 could be driving on gravel roads? It's happened to me on 4 different vehicles now in the last 10 years and I've only had 6 vehicles in that time, I drive a lot of gravel roads, do you often travel on gravel or live in a dusty area? I'm in farm country mn tons of dirt kicked up so I'm assuming that dust is the cause of the problem. If anyone is in a city and never drives gravel and still has this issue, let me know. I'd like to figure it out too

[@cali_misfit1387]

i unplugged the solenoid AND the canister…it still won’t fill. Any ideas?

[@treyspetch]

Then it’s clogged vent lines between your tank and the canister.

[@cali_misfit1387]

@@treyspetch i’m pulling off the filer line right now to check the flapper then i’ll blow out the other lines

[@cali_misfit1387]

@@treyspetch I also took the lines off the canister and the solenoid to try and fill up that way and still same issue. even with the lines detached it won’t fill

[@cali_misfit1387]

@@treyspetch blew out the line from the fuel pump to the canister. Completely filled with charcoal. works fine now

[@trey5630]

@@cali_misfit1387 Ah, I'm glad you found the problem. When my charcoal canister got really old, the foam barrier that keeps the charcoal pellets inside the canister disintegrated. Then when gas flowed into the canister on overflow, the pellets back-washed into teh lines and clogged them. Sounds like same problem with yours. You might want to check your canister inlet to see if the foam is gone, so it won;t happen again.

[@kraybecht3579]

Good

[@tonygg1989]

Ive replaced both still same issue any ideas

[@treyspetch]

If you replaced the solenoid and the charcoal canister, then it is probably a clogged vent line between the tank and the charcoal canister. If your canister went bad, charcoal bits can float back into it and clog it. Disconnect it from the charcoal canister. Keep fuel cap on. Find the little quick disconnect fitting on the little line near the rear of the tank that goes up to the filler tube. Disconnect it and blow compressed air into the tank. In my case, about a quarter cup of charcoal bits came flying out of the line to that goes to the canister. Clog fixed.

[@tonygg1989]

Ive done everything minus replace tank same think sometimes makes worse been to mechanic 4 times Friday reblew lines couldn’t put gas

[@trey5630]

@@tonygg1989 Hmmm. Not sure what else could be causing this. Other components can cause evap system faults, but the vent is pretty much just the tank, vent line, canister and solenoid valve. I would be second guessing the mechanic...What happens if you get under the truck and disconnect the vent line from the charcoal canister? Then drive like that to the gas station and try to fill up. The tank should be freely venting right out that line onto the ground. You'll have a little spill of gas on the ground when the tank gets totally full, but no big deal. If it still won't fill, then I would suspect some sort clog in the vent line or the filler tube.

[@brucehansen7949]

@@tonygg1989 I've heard ya take an air compressor and then open your gas cap, then blow out that gas vent line but make sure your gas cap is off first. Haven't tried it yet but it's the most common problem from what I understand

[@zhangtiger9651]

Any code ? Like p2422 valve stuck close

[@jasoncoleman4011]

What if I did that and it still poured out after putting a little gas in it

[@treyspetch]

That’s normal. When the tank is full, it sometimes overflows our through the vent line into the charcoal canister. If you disconnected it to test, it will spill a little out into the ground.

[@robertsestate6421]

I can’t find that part anywhere

[@treyspetch]

This is for full size Chevy and GMC trucks. Do you have one? It’s right above the differential, ahead of the spare tire.

[@robertsestate6421]

@@treyspetch yeah I can’t find it in the part store they always have a different one

[@treyspetch]

@@robertsestate6421 try Amazon prime

[@robertsestate6421]

@@treyspetch thank you I’ll try

[@crackerplayz302]

Dude do this in the daylight or get a flash lite Don’t be so lazy we can not see most of it

[@treyspetch]

Yeah, ok. I’ll get right on that. You should definitely get your money’s worth on my video.

[@tobydozier9030]

I could see just fine if you have any mechanical inclination you know what your looking at not that you can't see in the video.

[@tobydozier9030]

Always that one asshole lol.

[@maxd9352]

Awesome video thank you so much!