Hard Start after refuel - No CEL

Hey Guys,

Hoping to get some advice. For the past year my 02 2.7 DC Pre-Runner has been hard to start only after refueling. There are no codes or CEL. I'm not mechanically inclined so I've had the following done over the past year:
Replace purge valve solenoid
Replace fuel filter
Clean MAF sensor
Clean Throttle body

The charcoal canister was replaced in late 2018 (non-OEM). Any suggestions on what can be done? The mechanic I use is out of ideas and I'm running out of money. Thanks.

 

Does the truck start normally when the engine is hot and/or cold?

 

Yes. The truck starts completely normally every time except for when I put gas in it.

 

Interesting. Does this difficult-to-start situation happen if you refill to half tank as opposed to a full tank?

 

My experience with most all makes and model cars and trucks is when that happens its most likely the purge valve. Quick test is to unplug the valve electrically, remove the vacuum line from it to the tank,(not the intake side) start the engine and see if there is vacuum present. Should be no vacuum. Have had bad new ones right out of the box. Or try unplugging the vacuum side before refueling and see if it starts normally.

 

Do you have access to a scan tool? Based on your description, really sounds like evap system to me. Were the parts that you put on OEM, or parts-store knock-offs?

 

Yes I’ll put 20 dollars worth of gas and it still does it.

 

No I don’t have access to a scan tool.

 

I’ll have the mechanic try it when I take it back in. Trying before Thanksgiving. The first place I took the truck to refused to take it to the gas station so I didn’t take it back when I picked it up because it’s a little far from where I live.

 

So, it hard starts when hot?

 

Purge valve is likely leaking.

If you want to experiment, pull this hose off, a listen/feel it while re-fueling.

 

Only when I put gas in it.

 

You aren’t over filling it either right? Not topping off, stopping at the first click of the pump?

 

I don’t overfill when I gas up. I stop on the first click. Half of my fill ups are just putting in 20-30 worth of gas.

 

Any resolution to this? I'm experiencing the same issue. Hot or cold doesn't matter full or partial refill doesn't matter. My mechanic says the purge valve is working when tested. I have an '03 with a 2.7 and 312,000 miles. No fuel economy issues. Runs strong otherwise.
Could it be leaky injectors? What symptoms are common with leaky injectors?

 

Ever try to hold gas pedal down for that restart,,,,
,,,,,that should cut pump....allow wet cylinders to dry out...

If you have a leaky injector......crank few times to determine no start....
....then start pulling plugs....looking for gas soaked ones....

Dry em out and should start right up....

Same procedure to find out which cylinders are leaking/ affected by a head gasket failure in progress....
same hot no restart for those too....

 

I’m taking the truck back in to the mechanic next week. She’s not running right after the maf and throttle body cleaning as well. Beyond frustrated at this point.

 

Shit

 

I had the exact same problem with my ‘02 DC . Would not start after refilling no matter what the amount. I check all the purge valves and everything was working correctly. I even replaced nearly all the fuel components including the tank with oem parts…check the new aftermarket Charcoal canister and found that it wasn’t allow enough Vapor to escape… replaced it under wanted and voila! It pumped gas at full speed and started right up.

 

On a side note I used to overfill the tank all the time and this prob caused gas to enter the canister and when I pulled the hoses off and blew on the ports a bunch of white material fell out… Presumably filter material.

Do NOT over fill the tank!!!