Quote:
Originally Posted by MikkiJayne
Its certainly concievable it could be that. What I think is happening is that one or more of the tank vent lines (6-9 in that pic) are unable to vent and so the tank fills to the level of the filler neck leaving a large air pocket in the top of it. Its not clear from the diagrams where those lines go, but I think they go in to the large assembly behind the filler neck first, which then has a single line (4) over to the charcoal container. In theory the only open point is 5 which is right on top of the tank.
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How accessible is the charcoal container? Is it possible to disconnect its combined input from the tank vents (4 in the diagram) and see if it then fills normally (just the last 2 gallons from a can)?
That would narrow it down to the charcoal canister or plumbing.
By the way what is line 3? Is that a vent from somewhere else in the fuel system?
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions and extended leather. Ski hatch retrofit. Aftermarket reversing camera. DVB-T and XCarlink now removed as redundant.
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation".  (Even rarer than a D2 S8!) Oh, and a brand new engine at just under 30,000 miles on the factory one! 
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1998 D2 PF S8. Agate Grey/Platinum. Every option (I think) except electric rear seats, Tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
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