Fuel System - Refueling Concerns

SOURCE: Kia Technician Times

TITLE: Refueling Concerns

APPLIES TO: Sephia

SERVICE TIP:

CONDITION

Vehicle will not accept fuel to the tanks capacity, fuel gauge does not read full, and/or fuel filler nozzle shuts off repeatedly during refueling.

CAUSE

ORVR valve prematurely closes vent line, causing fuel filler nozzle to shut off.

CORRECTIVE ACTION






Replace ORVR valve. The ORVR valve has been redesigned to improve flow characteristics from 2000 MY production (P/N has not been changed). All ORVR valves in KMA parts stock are the improved parts.






Replace valve only after verifying that the fuel gauge is working properly; indicator should follow float movement from lowest to highest point, and the float should be free to travel over entire arc inside the tank. Rollover valve, hoses, and CCV should be unobstructed for free airflow/venting.
Note: If fuel spits back from the filler neck after refueling, it may be that the one way flapper valve inside the fuel tank is not closing properly.

Test the valve as follows: Make sure fuel level is at 1/4 tank or less. Remove the fuel filler cap. Test per instructions in step 7 of P0440 checklist. If the valve works, you should be able to pressurize the EVAP system and monitor the voltage from the fuel tank pressure sensor. If you can't pressurize the system or the pressure won't hold, listen at the filler neck. When the valve leaks, you will be able to hear it. If so, the tank must be replaced (the flapper valve is not replaceable). If not, a leak is present elsewhere and will have to be located and fixed first. In that case, pressurize with the fuel filler cap on, until the leak is found, then test again without the fuel filler cap for correct flapper valve operation.