Hi Folks,within the next week or so I'm going to be replacing my fuel pump on an 02 Jeep GC, 4.0L with 140K. It's been whining and getting louder and louder, especially at tank levels under 1/2 tank and every now and again I get a rough morning start up. With that said and while I have the tank down I was wondering if anyone else had experience with the fuel spillage during refueling? I know Chrysler had issues with this on other models and I have not been able to find out any solid information on how to fix this issue. If I let the vehicle run during refuel, it does not spill out. If I turn it off during refuel, I need to pump the fuel at a very slow rate and even then it still spills out. I did a quick inspection around the fuel tank and if I had to guess, I would say that someone replaced the fuel neck during a previous life. The fuel cap was definitely replaced with an aftermarket brand as I changed it back to a Mopar cap in an effort to resolve code P0440. That did not fix the code. I also have P0455 code as well. I already began replacing dry rotted and cracked rubber lines at the engine compartment around the evap test port and I assume I will find more cracked and dry rotted lines around the tank.

Any info on this issue would be greatly appreciated.

 

Check the tank vent line. It's supposed to vent air from the top of the tank into the upper part of the fill pipe. If the fill pipe has been replaced, it might not have this vent line so air is trying to escape up the fill pipe and blowing gas out.

 

I will check that Dave. Thank you.