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2001 BMW 5-Series 525i 4dr Sedan 5-Spd Manual

2001 BMW 5-Series
Trim Info:
Rear Wheel Drive, 4 Door Sedan, Compact
20 mpg city / 29 mpg hwy
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December 27, 2012, 1:47 pm

James S
 

Question: engine stalls after filling gas tank.

2008 BMW 528i, 57K miles

Car runs great, except for when we get gas. When we fill it completly (not top off) after the nozzle shuts off automaticaly, the vehicel stalls and sputters after initial start-up. It takes 30-45 seconds of gingerly caressing the gas pedal to find the right combo to get the car running again. After that, no problems starting the vehicle, until its time for another fill-up. The fuel filter and fuel pump has been replaced, problem exists before and after replacement. I have some knowledge about the EVAP system, could fuel be getting past the valves and into the charcoal canister, thus creating too rich of a formula after re-start.


December 31, 2012, 5:08 pm

Elizabeth K
Expert Mechanic

There aren't any valves between the fuel tank and the charcoal canister, the charcoal canister is there to absorb fuel vapors from the tank. So yes, if the tank gets overfilled the liquid fuel, it can run into the canister, and then will get sucked into the engine when you first start it, causing a rich condition.

Some fuel tanks were of a poor design and known for that problem, but it's not a common problem with the 528i (that I'm aware of). Besides poor design, there could be another problem in the evap system causing it--though that should set a code (assuming you've scanned for those already, if you haven't, then you should).

Also, check the entire evap system for vacuum leaks, and check the purge valve for proper operation--it should not be open when the engine is first started.



In the meanwhile, you can fill the tank until only 90%.


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