how to fix a Ford Explorer Sixth Generation (2020-present) that won’t start after filling gas

Ford Explorer Sixth Generation (2020-present)

Error Codes

2-4 hours

Time

medium

Difficulty

high

Severity

4 min read

648 words

⚠️ Safety Warning

This issue requires immediate attention. If you are not experienced with automotive repairs, consult a professional mechanic. Working on critical systems can be dangerous.

Problem Statement

Learn how to diagnose and fix a no-start issue after refueling in a Ford Explorer (2020-present). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Fuel System

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery before working on the fuel system.
•Allow the vehicle to cool before working on any components related to the fuel system.

Symptoms

•Engine cranks but does not start
•Fuel gauge indicates fuel level is full
•Check engine light may be illuminated
•Strong smell of gasoline around the vehicle
•Possible fuel vapor or evap system codes present in the diagnostic scan

Diagnostic Steps

1
Scan for error codes using an OBD-II scanner to check for any related trouble codes.
2
Inspect the fuel cap to ensure it is properly sealed and functioning.
3
Check the fuel pump operation by listening for the pump activation sound when turning the ignition to the ON position.
4
Verify fuel pressure at the fuel rail using a fuel pressure gauge to ensure proper pressure is being delivered.
5
Inspect the EVAP system for any leaks or blockages, focusing on the purge valve and vent valve.
6
Check for any signs of fuel leaks around the fuel lines and connections.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•OBD-II scanner
•Fuel pressure gauge
•Socket set
•Screwdrivers
•Multimeter

Parts Required

•Fuel pump (if necessary)
•EVAP purge valve (if necessary)
•EVAP vent valve (if necessary)
•Fuel cap (if damaged)

Related Faults

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Diagnostic Steps

1
Scan for error codes using an OBD-II scanner to check for any related trouble codes.
2
Inspect the fuel cap to ensure it is properly sealed and functioning.
3
Check the fuel pump operation by listening for the pump activation sound when turning the ignition to the ON position.
4
Verify fuel pressure at the fuel rail using a fuel pressure gauge to ensure proper pressure is being delivered.
5
Inspect the EVAP system for any leaks or blockages, focusing on the purge valve and vent valve.
6
Check for any signs of fuel leaks around the fuel lines and connections.

Solution

1. Preparation

Ensure the vehicle is on a flat surface and the parking brake is engaged.
Disconnect the negative battery terminal to prevent any electrical issues during repair.

Tools Required:

OBD-II scanner
Fuel pressure gauge
Socket set
Screwdrivers
Multimeter

2. Inspect and Replace Fuel Cap

Check the fuel cap for any cracks or damage. If damaged, replace with a new fuel cap.
Ensure the cap is tightened properly to create a proper seal.

3. Test and Replace Fuel Pump

Fuel Pressure Check:
1. Connect the fuel pressure gauge to the fuel rail service port.
2. Turn the ignition to the ON position without starting the engine and check the pressure reading.
3. If the pressure is below the manufacturer's specifications, proceed to replace the fuel pump.
Fuel Pump Replacement:
1. Relieve the fuel system pressure by removing the fuel pump fuse and starting the engine until it stalls.
2. Disconnect the battery negative terminal.
3. Access the fuel pump assembly (may require removing the rear seat or access panel).
4. Disconnect the electrical connector and fuel lines from the pump.
5. Remove the pump assembly and install the new pump, ensuring all seals are replaced.
6. Reconnect fuel lines and electrical connections, and reinstall access panel or seat.

4. Inspect and Replace EVAP Components

EVAP System Check:
1. Inspect the EVAP purge and vent valves for functionality.
2. Test the purge valve by applying voltage and checking for operation (it should open).
3. If faulty, replace the purge valve.
Vent Valve Replacement:
1. Access the vent valve, typically located near the fuel tank.
2. Disconnect the electrical connector and remove the valve.
3. Install the new vent valve and reconnect.