I purchased my S2000 in June with about 50k miles, and ever since then I’ve been unable to properly fill up the gas tank. It clicks super early and often, even when tank is empty or near empty. I’ve driven it 3k miles since and every fillup has been troublesome.

This has happened at like 10+ different gas stations of different companies, I have to fill INCREDIBLY slow for it to work. I’ve also accidentally overfilled it pretty badly twice due to not know which click means actually full.

I’ve had the charcoal canister swapped to another used one, that didn’t help at all.

Today I dropped it off at a local (generic) shop and they smoke tested most of the EVAP system, and told me they don’t see anything wrong - even the new canister seems to be fine. However, they said there are two things they can’t check yet because they can’t easily get to it:
1. a vent control valve on top of the fuel tank
2. breather lines near the area

They’re wondering if it’s possible to reach them without removing the soft top, or without dropping the rear subframe + diff. So I’m wondering if anyone here knows.

Also - does anyone else have any insight to solving this issue? It’s an incredibly frustrating problem and I’m not sure what else to do. It seems like the labor to get to this valve / lines is also really high

 

Not sure it makes any or much difference but we don't know what car you have. Fuel delivery systems are different in the late DBW cars which have "returnless" fuel systems. There may be differences in the filler necks as well.

https://www.s2ki.com/forums/s2000-un...issue-1032157/

-- Chuck

 

I have a 2004 AP2! US Spec

 

It's certainly possible to reach some of the fuel filler components by removing the lining in the trunk. Download the Service Manual for details.

 

I have seen this before and for me it comes down to how much stress is on the hose, how the metal pipe is situated in the opening, and how fast the gas is coming out. Sometimes I do have to hold it just right and not have it full blast. I do not continue to pump/click it as it just dumps gas to the canister. If I can hear it getting topped off and it clicks off, I leave it there.

I might add I have the same issues with my 2002 Tacoma. I think it has to do with all the crap California requires on the pumps.

 

I only have this problem seldom. But, I do notice/remember it happens more often in winter. So, perhaps the atmosphere and ambient temperature has something to do with it too (the pumps, perhaps the car/fuel-filler/related-components, etc., irdk).

I also remember whenever it happens, it doesn't happen again next time I fill it up. So, I think it's the actual pump too. I've always read/heard that those pump-guns break and need to be serviced/replaced often (they're used thousands of times per day if you think about it).