Evap Refueling Vent Valve Failing

[Kevsong]

I have a 2022 Maverick XLT Hybrid with 42k miles, and I went to fill up the other day and was unable to get the fuel door to open. After some searching, I used the release cable in the wheel well and started to fill my tank. I noticed that I was unable to fill the tank at a normal rate because it seemed to be filling up the fuel port immediately. In order to refuel, I spent more than a few minutes trickling fuel in at a reduced rate.

I returned to the cab and started the truck, and to my surprise, the check engine light came on and stayed on. I thought this was an anomoloy and continued driving. I made a service appointment; however, before the appointment I drove enough to refuel again. Same thing happened again. Unable to open the fueling door without using the manual release cable.

I searched the forums to see if this is something that was common, but I was unable to find anything that matched my issues.

When I went to my dealer, I explained the issue and was told because I didn't have the extended warranty they wouldn't diagnose it without charging me a diagnostic fee. Fee paid, what else was I to do? At that point they told me that the truck's "evap refueling vent valve was failing"; however, for them to fix it, it would cost me $704.75 and of course the labor would need to be added, so I'm looking at $1000.00. While they were at it, they also told me that I needed a "Fuel injection & Air Induction Service". Hey, that's only $199.00...

Needless to say, I'm pissed and perhaps clueless about how service works.

My assumption is if something is failing on the truck, by no fault of my own, Ford would be happy to replace that part. That said, the story I get from the dealer is if I had only paid for the extended warranty, I wouldn't have had to pay for the diagnosis or the replacement of their faulty part.


If I'm being naive or just plain dumb here, that's fine, but this whole experience on top of the numerous recalls and time spent dealing with service have me rethinking what brand I purchase from in the future. Or maybe I just should have purchased that extended warranty?

Thoughts?

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[L30n1d45]

Kinda surprised that doesn't fall under the powertrain warranty.

 

[Glen Baker LLC]

Someone else reported the same problem.
https://www.mavericktruckclub.com/forum/threads/changing-out-the-purge-valve.50219/

https://www.mavericktruckclub.com/forum/threads/p04f0-evap-high-purge-flow.38440/

If it were the evaporation canister itself, that would be covered under the 8/80 emissions but the purge valve is not.

 

[Darnon]

Kinda surprised that doesn't fall under the powertrain warranty.

Nope.

Engine: all internal lubricated parts, cylinder block, cylinder heads, electrical fuel pump, powertrain control module, engine mounts, flywheel, injection pump, manifold (exhaust and intake), manifold bolts, oil pan, oil pump, seals and gaskets, engine thermostat, engine thermostat housing, timing chain cover, timing chain (gears or belt), turbocharger/supercharger unit, valve covers, water pump;
Transmission: all internal parts, clutch cover, seals and gaskets, torque converter, transfer case (including all internal parts), transmission case, transmission mounts (front and rear);
Front-Wheel Drive: axle shafts, support bracket, front bearings, seals and gaskets, universal and constant velocity joints;
Rear-Wheel Drive: axle shafts, rear bearings, center support bearing, drive axle housing (including all internal parts), drive shaft, retainers, supports, seals and gaskets, universal and constant velocity joints.
Four-Wheel/All-Wheel Drive: axle shafts, support bracket, bearings (front and rear), center support bearing, drive shafts, final drive housing (including all internal parts), hubs-automatic front locking (four-wheel drive), locking rings (four-wheel drive), seals and gaskets, universal and constant velocity joints.

It'd be the Emissions Defects Warranty as one of the non-major components so Federal statute is only 2yr/24k miles which is surpassed by the 3yr/36k bumper-to-bumper.

 

[Meeka]

Someone else reported the same problem.
https://www.mavericktruckclub.com/forum/threads/changing-out-the-purge-valve.50219/
If it were the evaporation canister itself, that would be covered under the 8/80 emissions but the purge valve is not.

Of course not! Ford planned that well.

 

[Sticks]

"Fuel injection & Air Induction Service". Hey, that's only $199.00...

This part is a scam. It's not required and it costs about $5 for a bottle of fuel injector cleaner if you really insist on it.

I'd take their diagnosis to an independent shop and get it done cheaper.

 

[matmondro]

This part is a scam. It's not required and it costs about $5 for a bottle of fuel injector cleaner if you really insist on it.

I second this. All they'll do is run some STP cleaner through and replace the engine air filter (about $15 to $25, depending on where it's purchased). Between those two, that's like 20 minutes of labor max.

That is unfortunate though that this is happening to you, with a relatively normal mileage vehicle. I wonder if it's something just as simple as the vent tube being clogged. It's a tiny tube that runs the length of the filler neck. Sometimes, if enough crud builds up and clogs it (generally at the top), then the air in the tank has nowhere to go when refueling. This is why the pump would keep clicking off, causing you to have to slowly trickle the gas in.

 

[Carlitos_92]

I doubt that is a very expensive part, but it might be a pain to get to. This thread is about fueling in general, but the first post has some info. I assume part #7 in the diagram is what you are looking for:

https://www.mavericktruckclub.com/forum/threads/why-topping-off-wont-kill-your-truck.54186/

 

[JDMaverick]

Most auto parts stores will read your “check engine” code for free, before paying the dealer. They hope to sell you parts to fix yourself.

Once you know what the code is you can go to YouTube and find a video showing what it takes to do the repair. Then you can decide if you want to buy the part and do it yourself (or get a friend to help you out) or pay the dealer to do it.

sometimes random things fail and aren’t a big deal to fix yourself.

 

[CaReviews]

EVAP Purge Valves fail due to people "topping off" their fuel tank when filling up. One could argue that there should be an extended warranty on something like that however, they could very easily point the finger at the owner and say "did they fill the vehicle properly?" which was one of the things on the last generation Ford Focus that happened. They did finally issue a recall/warranty extension on that though. Finding an independent shop though to work on a vehicle this new is always dicey, speaking from experience.

 

[Glen Baker LLC]

EVAP Purge Valves fail due to people "topping off" their fuel tank when filling up. One could argue that there should be an extended warranty on something like that however, they could very easily point the finger at the owner and say "did they fill the vehicle properly?" which was one of the things on the last generation Ford Focus that happened. They did finally issue a recall/warranty extension on that though. Finding an independent shop though to work on a vehicle this new is always dicey, speaking from experience.

But I can get 600-800 miles per tank, if I do this.

Sarcasm.
I don't really do this or endorse it.

 

[Kevsong]

I have a 2022 Maverick XLT Hybrid with 42k miles, and I went to fill up the other day and was unable to get the fuel door to open. After some searching, I used the release cable in the wheel well and started to fill my tank. I noticed that I was unable to fill the tank at a normal rate because it seemed to be filling up the fuel port immediately. In order to refuel, I spent more than a few minutes trickling fuel in at a reduced rate.

I returned to the cab and started the truck, and to my surprise, the check engine light came on and stayed on. I thought this was an anomoloy and continued driving. I made a service appointment; however, before the appointment I drove enough to refuel again. Same thing happened again. Unable to open the fueling door without using the manual release cable.

I searched the forums to see if this is something that was common, but I was unable to find anything that matched my issues.

When I went to my dealer, I explained the issue and was told because I didn't have the extended warranty they wouldn't diagnose it without charging me a diagnostic fee. Fee paid, what else was I to do? At that point they told me that the truck's "evap refueling vent valve was failing"; however, for them to fix it, it would cost me $704.75 and of course the labor would need to be added, so I'm looking at $1000.00. While they were at it, they also told me that I needed a "Fuel injection & Air Induction Service". Hey, that's only $199.00...

Needless to say, I'm pissed and perhaps clueless about how service works.

My assumption is if something is failing on the truck, by no fault of my own, Ford would be happy to replace that part. That said, the story I get from the dealer is if I had only paid for the extended warranty, I wouldn't have had to pay for the diagnosis or the replacement of their faulty part.


If I'm being naive or just plain dumb here, that's fine, but this whole experience on top of the numerous recalls and time spent dealing with service have me rethinking what brand I purchase from in the future. Or maybe I just should have purchased that extended warranty?

Thoughts?

An update after picking up my Maverick from the dealer.

I did not pay for the "evap refueling vent valve" repair, and to my surprise, when I picked up the truck, the check engine light was off. I stopped to get gas, and my fuel door opened, and I was able to fill up without issue.

Perhaps the diagnostic fee fixed it?...

 

[Darryl]

Of course not! Ford planned that well.

The purge Valve is a part that commonly fails on many vehicles. Since it's impossible for the emissions canister to work properly with a defective purge or vent valve, the government should make them cover it under 8/80 in my opinion. But evidently the manufacturers (all of them) convinced them otherwise. So they're only covered under bumper to bumper.

 

[Boonie Stomper]

I just had the same issue come up on mine. $262 for the part and $475 for labor.

 

[Master Blaster]

Its a common problem on multiple vehicle types, caused by topping up the fuel instead of pulling out at the first shutoff, filling the evap lines with fuel, ruining that valve, ruining your charcoal canister and degrading the tank-to-filler next seal. Stop topping up to get an extra gallon!

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