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Old 03-01-2013, 04:55 PM   #1
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2004 Dodge Ram Hemi 1500 - Vapor canister/fuel issues

Hello everyone,

I have an odd one for you:

When I fill up my truck completely with fuel I get fuel leaking down the driver's side of the tank at the rear strap where it straps to the truck. If I don't fill it plumb full, leave like a gallon out, I don't have the issue.

Also, when I pull away from the gas station after fulling plumb full within a mile or two the truck will die a couple times.

I took it to a mechanic who indicated that he thought my vapor canister had gone bad allowing fuel to get in there and then be sent to the motor, flooding it out. When the truck dies it's hard to restart.

The truck NEVER has an issue unless we fill it up to full.

A couple questions:
1) Does this seem right?
2) Where is this vapor canister located on the 2004 dodge rams?

Thanks very much for the help!
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Old 03-01-2013, 05:27 PM   #2
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More info...

When I fill it full with gas I removed the large hose on the drivers side of the lower canister that's under the rear of the driver's side cab (in front of the fuel tank). Gas poured out of the large hose coming from the gas tank to the lower canister. (maybe an 1/8th of a cup of liquid gas).

I started the truck up and it ran for about 3 to 4 minutes then died. I checked that large hose again and more gas came out of it after the truck died.
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Old 03-01-2013, 06:06 PM   #3
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Are there any diagnostic trouble codes set? That would point to something. There is a natural vacuum leak detection pump (NVLD), a filter, and under the hood on the driver side is the EVAP system purge solenoid. I'd check to see if raw gasoline is getting to the EVAP purge solenoid. Obviously you are going to need new charcoal canisters.





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Old 03-01-2013, 06:58 PM   #4
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They replaced the soleniod per a code but didn't have the part for the evap canister. I'm a little torqued they didn't hold off and replaced the solenoid if it can be damaged by raw fuel.
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Old 03-01-2013, 07:10 PM   #5
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My evap canister doesn't look like the diagram above... I attached a picture of mine.

The hose I disconnected that had liquid fluid come out of it was the large one on the left (driver's side) of the picture. I took the picture from the rear of the truck facing the front.

Thanks so much for all of the suggestions!

I can understand why the canister needs replacing, but I don't know why liquid fuel is getting to it.

Also, why when I top off the tank, fuel leaks down the rear drivers side of the tank at the rear bracket. I checked the fuel filler as far as I could feel and there was no fuel on it or the connections it made.
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Old 03-01-2013, 07:38 PM   #6
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Good questions and good answers, makes me realize how little I know about the system. Time to do some research. Hope you keep updating your post about this. A flooded condition can be cleared by holding the throttle to the floor while cranking. Good luck..
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Old 03-01-2013, 09:05 PM   #7
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Your issue is in the rollover valve the piece in this picture with three nipples on it they rarely go bad but when they do its bad the entire tank has to be changed out the valve is part of the tank non serviceable

As for the leak when completely filled the seal around the fuel hat is likely leaking or the plastic weld where the filler neck attaches cracked

Another rare occurrence I have seen if you had an exhaust leak the heat can go above the heat shield on tank and melt the top of the tank or the lines
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Old 03-02-2013, 08:37 AM   #8
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Just as a habit I stop pumping fuel the first time the pump shuts off. I've heard topping it all the way up may cause problems eventually.

I just wonder how much fuel is still in the EVAC system?
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Old 03-06-2013, 12:35 PM   #9
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Quote:
Originally Posted by HemiByrd View Post
I've heard topping it all the way up may cause problems eventually.

I just wonder how much fuel is still in the EVAC system?
There may be some stock in that. I had a habit of filling my '03 all the way to the top. I had the EVAP canister go bad at 55K miles, and I started throwing a code for bad EVAP canister again at 120K miles. I never replaced it the second time. I traded it in.
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