2021 Tacoma Spills Gas When Refueling

Greetings Tacomaworld, I have a 2021 OR Taco I purchased CPO this January that spills gas when refueling. I've searched around on this forum and found that I'm not the only one that has had this issue, and normally it relates to a faulty vapor valve in the gas tank itself. What I haven't seen is any way to actually inspect or test this valve, or pictures of a good vs bad valve.

I'm asking because I've had over a dozen phone calls with Toyota, and brought the truck in to two different dealers a total of 5 times and they have made no real effort to actually diagnose the issue, so at this point it's up to me because Toyota has effectively told me to pound sand. At this point I'm just about out of patience, since otherwise the truck is great and a lot of fun.

Here's a video of the issue. It may occur to greater or lesser severity than pictured.

https://imgur.com/a/IA2nnDW

Thank you.

 

Wow sorry to hear that. You showed the dealer this video and they still won't fix it? Pretty dangerous to have gas flowing out onto the ground like that and seems like it would be a liability if they ignore it.

 

Noticed in the vid you have the pump handle at max / full flow auto. Maybe try it a less than max ?

 

Does it happen at other gas stations too (could be crappy nozzle)? Does it happen while you're holding it and pump auto-shutsoff?

 

Dealer has been shown these videos, as well as my case manager with Toyota. They replaced the charcoal canister then gave up when that didn't work (this was in February).

The first tech I had was kind enough to accompany me during one refueling attempt where he was able to replicate and video document the issue, but again that was in February and since then I haven't been able to get anything out of Toyota.

This happens regardless of nozzle position, although when the pump is flowing less than normal it may happen to a lesser degree. Sometimes it's just a few drops that come out, but honestly it seems mostly random.

This issue only happens at Costco stations, or at least there's where I've been able to reproduce it. This has happened at pumps in 3 different states.

Thank you for all the responses, you guys are much faster than other forums I've been on.

 

Maybe go to your local taco forum and see if anyone else has that issue. Or if you see another taco at the costco station ask them if they experience this.

https://www.tacomaworld.com/forums/regions.36/

 

I've spoken to a couple other Gen 3 taco owners while filling up, and no one has experienced the issue. I also had a loaner gen 3 while the truck was in for service, and it did not have this issue. I mentioned this to the dealer.

I'm in MN and there are a lot of tacos around, my office has a couple people with them, and no one has ever experienced this same issue, even going to the same stations. I'm friendly with a Toyota service manager in another state and he has never heard of the issue either, so unfortunately it's a pretty rare issue that's easily written off as someone not knowing how to pump their own gas.

 

That’s BS they won’t fix this, when documented. Not only a safety concern, but you’d think the enviros would have a fit too.
I feel for ya, way back when, I had a hoopty that did this, but didn’t want to sink money in to it, just dealt with it. I also had a GMC Yukon that shut nearly every pump off, every 1-3 gallons.

 

It's leaking at the filler neck. Crack in the neck to the cap?

 

It's total BS considering I bought it CPO and this happened from minute one since the dealer played their game and handed me the keys with 0.1 miles left in the tank. Filled it up on my way home and noticed it dripping but didn't think much of it at the time. Anyway, moving past that I'm at the point where considering Toyota won't fix it I'll just do it myself. Much less headache and stress even if it means replacing the gas tank.

I have not inspected the filler neck, which would be an easy first place to start. The good tech I had at the beginning told my he inspected everything up until the tank when he replaced the charcoal canister, but I might run a borescope down there to check things out myself. The problem is I don't know what I'm looking at.

 

get a lawyer. Lemon law.

 

Fortunately I have a lawyer in my family that I have spoken with, and although I likely do have a case, it's really difficult with the issue only occurring at Costco stations they can feasibly pin the blame on the brand of station. That's of course absurd, but it results in the he-said-she-said situation that I've been going through for the past 8 months. Clearly what is happening is that whatever system that communicates to the filler hose that the tank is full is defective, so the tank overfills and burps back up a portion of the gasoline. The costco handle happens to have a shorter nozzle, so it ends up being particularly easy to spot there.

Replacing the truck would also likely be more expensive than just buying a new gas tank for $800 and doing the job myself. I just want to do my due diligence before I go shotgunning $800 parts on my own dime.

I should note I've been careful to not mention any "L" words while in the presence of Toyota.

 

I guess I missed the whole Costco thing.

One thing that happens with these trucks is the vent system can have issues. If one keeps trying to round up to the next dollar, after this clicked off the first time, the tank can get over full and push fuel into the evap canister.

I would think that is where your problem lies. But seriously if it’s only happens at Costco going to Costco.

 

NTSA and EPA (and state equilvlant of EPA) would love the a copy of letter from Toyota and the video

 

Costco gas nozzles have to be snug against the rim and create a vacuum seal in order to work. I wonder if your issue has something to do with that. Maybe there is a crack in the fuel neck and the pressure created by the vacuum is what causes the leak when using a Costco nozzle. Whereas, with other pumps there is no vacuum and the fuel level is able to rise enough to trigger the automatic cutoff.

 

Unfortunately I'm not willing to sacrifice 20% increased operating costs of the vehicle because Toyota refuses to fix the problem. They have actually acknowledged the problem, but do not acknowledge it is due to the vehicle (I really don't understand how this logic works). Also unfortunately, I haven't been able to get them to give me any of this in writing, even though I have requested it. All conversations have been either in person or over the phone, and I only have my own records to go by.

I usually would hold the nozzle against the vehicle during fueling, but it doesn't have any noticeable effect. In fact if there isn't a good seal the pump won't run at all. I have tested with a seal that is just barely good enough for the pump to run, and that did not result in a noticeable difference. The quantity of spillage seems to be random, or at least I have not identified any controlling factors. I know for sure it is not fuel flow rate or nozzle fit, since those have been easy to test.

Anyway, the point of this post was to try to get a bit of information to help my own diagnosis of the problem. Thank you for the suggestions to check for cracks in the filler neck. Does anyone have any information on how the ventilation system works? I found this image from a previous TW forum post, but I'm not 100% sure what I'm looking at. What does the refueling valve here do, and would that normally be replaced with the charcoal canister?

 

@Bishop84

 

If you are experiencing this at all gas stations and the issue can be easily replicated you are getting the run around.

IMO call corporate and let them know it’s fine your dealer can’t help but you need the info of a dealer who can. Emphasize you are concerned about the health and well being of yourself and your family due to this hazardous situation. 20 bucks the service manager at your dealership calls you to get the truck in for service.

I’ve had to call corporate to have the dealership do things that are in the owner manual. Sucks but gets the job done

 

Ive seen this caused by a damaged flapper from a siphon attempt.

Borescope down the fill neck is the only way to determine this.

A vent valve sticking shut would trigger a code all day.

 

I was curious so I counted. I have had 14 phone calls with Toyota corporate regarding this issue.

The rub is that it only obviously presents itself at Costco stations. Regardless of the station or the state the station is in. I have refueled in MN, SD, and WI and everywhere is the same. So it turns into a finger pointing contest.

And my phone calls with Toyota corporate have been entirely unhelpful. Every conversation from them begins and ends with "the dealer says." They are not on our side.