Corolla :: 2002 - Pump Kicks Off When Filling Gas At Around 10 Gallons


Mar 22, 2014

I have a 2002 corolla and every time I gas it up it seems to kick the pump off like its full (for instance if the car was on empty I could fill it and it would kick off at around 10 gallons) but If I keep pumping really slow i can fit another 3 gallons in it. Is this normal or not. I drive around 150 miles a day so i fill up quit often. It has done this for the last 80000 miles and I have just accepted it but since its been super cold out this winter I really don't want to stand out side no longer than I have to (it seems to take about 5-7 minutes just to get the extra 3 gallons in).

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I know that manufacturers always leave room for reserve, but I pumped 9.89 gallons to fill up.

According to the specs, the 2011 Prius holds 11.9 gallons.

So where did that other 2 gallons go?

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I don't think anyone was able to put something into my tank to plug it up. There is a little hole directly under where the gas cap screws onto that has a rubber opening, I'm wondering if maybe some dirt got into that and plugged it assuming that hole has something to do with making sure the pressure equalizes, but I don't know.

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As I finish up a trip with it, I know I've "pushed the envelope" as far as fuel range is according to the guage/computer. I get the warning that I need to refuel and that I have 50 miles to empty, but I've driven 40 miles into that last range before refueling, and only been able to put 14 or so gallons into the tank.

My question is: If I were to drive until it literally runs out of gas, then fill it, would the guage/computer recalibrate or do I need to install a new fuel sensor?

I get the warning as the guage indicates just under 1/4 tank remaining, and I have yet to run it until the guage indicates that it's actually on empty (family and dog are with me so risking it is currently out). I'm hoping that the guage itself knows what the real deal is and that the computer is just not with it.... OH, FWIW full is EXACTLY on the "full" line and not over as in my Kia.

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It cranks, but won't turn over.
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They spark, although it looks like it may be weak.
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Checked the connections of the wire harness (all I believe)

Anything specific to this model that would suddenly not run. I drove it 3 times that day, no problems starting, running, driving, anything. So I'm kind of stumped on the sudden development.

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I went to fill up the gas (we were at one bar) and got about $0.30 in before the pump clicked off.

I tried again, and got just about as far.

I tried three different pumps at two stations before deciding the problem was with the car and not the pumps.

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The dealer says it requires a complete replacement of the tank but I'm still not clear on what's causing the problem.

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