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2006 Kia Rio stalls after fill up

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11K views 10 replies 6 participants last post by  Habanero64  
#1 ·
Hello all.

I put $20 in my tank and the car stalled when i tried to turn it on. I had to keep my foot on the gas pedal until i pulled away and got code P0496. I cleaned the Purge Solenoid Valve under the hood and put it back together. Random misfire and misfires in 1, 2, and 4 cylinders showed up (as pending) afterwards when i tried starting the car so i cleared the codes.

It was fine for a couple days and i seem to still get a misfire in cylinder 1 when idling (only when i park) and the rpms jump up. I figured i would try to put more gas in it to see if i fixed the valve but it stalled again. I only put $10 in it. Code P0171 showed up.

My obd reader website tells me it could be air leaks in intake manifold, one or more injectors restricted or pressure regulator has failed, air is being drawn in from leaks in gaskets or other seals, O2S element is deteriorated or has failed, and a "fuel control" sensor is out of calibration (ECT, IAT or MAP).

When i took the purge valve off, i had to take the hose off that was connected to the intake manifold and it seemed slightly dry right around the top of it. Would this cause the code?

Better yet.. would that even make the car stall after putting gas in it? I'm not sure where to go from here. Thanks for any suggestions
 
#2 ·
Number ONE suggestion...DO NOT "top up" the filler neck, It will send raw gas into the EVAP system which it is NOT what it is designed to handle. Check and make sure ALL rubber hoes to the intake manifold are in good condition, no splits/cracks or "soft feel" on the ends. MY supposition is also that you have more than 100k on the "clock" and could probably use a set of spark plugs.
 
#3 ·
It has 166,000 km. I just bought 4 new spark plugs but reframed from putting them on yet because of these other issues. I never put enough gas in it to top up.

Would bad hoses cause the car to stall after getting gas? I was going to replace the hoses that are connected to the purge valve anyway. Just remembered that i also disconnected the rubber boot from the throttle body, but it doesn't seem there's anything wrong with it.
 
#4 ·
The "boot" between the intake manifold and air cleaner assy. must also be sealed(clamped) securely and not have any holes or cracks in it either or it will cause idle/stalling troubles. seems there are a few threads with your similar concerns for your model, try reading up on them.
 
#5 ·
I've been reading up about it quite a bit. Thing is, this only happens immediately after filling up. Once i get it started, it doesn't happen again until i put more gas in. I noticed my gas cap is loose so i'll buy a new one tomorrow. When i filled up today, i didn't get the code for the purge solenoid again (since i cleaned it) just the P0171. Seems the purge solenoid is the most common issue with stalling after refueling..
 
#8 ·
#11 · (Edited)
Thanks for following up with the solution. Glad it worked for you. I've been having the same problem myself, but with no OBDII codes (except a general P0650 MIL malfunction that may or may not mask more serious codes). I.e. only after a fill-up. How much did the purge valve cost and was it hard to DIY? Does this model have only one purge valve or are there several, and if so which one do I need to replace?

Also, out of curiosity, does anyone have any idea why a bad purge valve would cause the engine to stall after and only after a fill-up? Could it be because the new fuel is colder (I assume) than the existing fuel, and that somehow confuses the valve, or causes the ECU to confuse the valve? Or, perhaps, the resulting change in the fuel tank vapor pressure is throwing things off that a new valve would compensate for? Is there a sensor in the valve that's malfunctioning, or perhaps the valve solenoid, and in either case how and why would this happen only after a fill-up?

Btw, unrelated except that it has to do with replacing an often overlooked but important "minor" part, but while checking for loose wires to fix an electrical issue, I pulled out the cabin air filter and man was it disgustingly filthy. It might never have been replaced (on an over 150k miles car) and why the air blower had to be replaced a while back (when my dad owned it). I'm going to order and put in a new one this week. Amazon sells an aftermarket one for around $11 that has a carbon element, which apparently the OEM one does not. My lungs will be happy.