Hard starting after fueling up.

[Mjoe7]

Hey guys. My 2010 2.5L Fusion runs great, but it has a engine light on and after filling up the car with fuel it doesn't start well. It spits and sputters and dies, then after the 2nd or 3rd try it's fine. It only does it after a fill up. All other times it starts perfectly.

I used to top off the fuel but I read someplace not to do that.

What is causing this?

Thanks for any help.

[FusionDiffusion]

Correct, you should not top of the fuel tank when fueling because it can damage parts of the EVAP system. Stop after the first click to prevent overfilling.

 

If you have an engine light on, you should get the codes read and report back.

Edited April 14, 2013 by FusionDiffusion

[Mjoe7]

Correct, you should not top of the fuel tank when fueling because it can damage parts of the EVAP system. Stop after the first click to prevent overfilling.

 

If you have an engine light on, you should get the codes read and report back.

 

There is a TSB for this issue that involves replacement of the canister purge valve (hybrid only): http://www.revbase.com/BBBMotor/TSb/DownloadPdf?id=169354

Thank you. I'll get the code and get back to you.

I don't have the hybrid or doesn't that matter?

...and I think that is a design flaw that should be fixed by a recall of sorts. It's ridiculous. I bet they sell a lot of these parts! I also prefer to have a gas cap.

[Mjoe7]

Correct, you should not top of the fuel tank when fueling because it can damage parts of the EVAP system. Stop after the first click to prevent overfilling.

 

If you have an engine light on, you should get the codes read and report back.

 

There is a TSB for this issue that involves replacement of the canister purge valve (hybrid only): http://www.revbase.com/BBBMotor/TSb/DownloadPdf?id=169354

 

The code is P144A. Where is this located on the car so I can fix it and how much is the part usually?

Thank you so much for your help!

[FusionDiffusion]

Okay, here is the correct TSB: http://www.revbase.com/BBBMotor/TSb/DownloadPdf?id=176566

 

You need to check the canister like it says to make sure it's not full of gas. Since you overfill, there's a decent chance that's the issue rather than the purge valve. EVAP canister is under the car directly below the spare tire well.

 

Purge valve location: http://www.fordfusionforum.com/topic/8733-evaporative-purge-valve-and-canister/?p=66780

[Mjoe7]

Thank you for the help. Problem fixed.

[FusionDiffusion]

Thank you for the help. Problem fixed.

 

So was the fix just the purge valve? Was the EVAP canister dry?

[Mjoe7]

 

So was the fix just the purge valve? Was the EVAP canister dry?

 

Evap canister was wet. Got one at a junk yard. So far so good. Time will tell.

[FusionDiffusion]

Great, thanks for the update.

[DocMN]

Figured I'd reply to this as well. Engine light was on, p144a code among a few others(p1450 and p2196). Everything was pointing to the purge valve, so before I go any further with anything else, I replaced that valve. To test the old one, I just blew in it and sure enough, air was going right through.

 

Got the code cleared just now, and so far so good. Haven't filled up yet again, but I suspect that will be resolved as well with this new valve.

 

$50 for the new valve from AutoZone and 10 minutes to replace. Easy.