If your tank isn't filling, it isn't the tank. It is the venting system.

So fuel goes in, air needs to go out. If air cannot get out, you fill the neck.

So what there is, the vent goes into a charcoal canister. From the charcoal canister, it runs to a check valve of sort. The thing is, if you continually overfill the tank, IE, topping up to the nearest dollar, or adding a couple bucks more to "fill" it, then you start putting gas into this canister which can then put charcoal into the vent line, blocking it.

Here is a good video explaining that issue. Another video being from a youtube car show of sorts where the same issue was occuring on a lambo.

The odds of it being the whole tank is effectively impossible. It would only be a component that is part of it. Is like saying you have to replace a bucket because water isn't coming out of the hose.

 

The next time it stops, press the gas cap release button again. See if that helps

 

If you don't top it off for a while the problem might just clear itself.

 

Maybe, but if charcoal got into the evap, then it might need replacing.

For OP, demand a diagnostic before discussing solution. The tank is an "Open" system so is fully verifiable. Demand then they scope the tank to show how the tank is blocking the fuel flow. The whole system is easily testable, plus you said it has happened since bought it which then if is reported to dealer, you have a paper trail for warranty perhaps too.

 

Vaporisor, if he had a blockage would he be smelling gas like they say in the video?

 

Smelling gas can vary. So overfilling, you might smell as it leaks out, but often gas smell is caused by vapor pressure in the tank venting out cap for example vs the evap system.

A sure sign of a blocked evap is if you get a bit of a pfffff when you crack the cap. Sorta like opening a bottle of soda. Then would probably get a wiff of gas smell. This is built up pressure in the tank since it cannot exit via the venting. Especially if you fill and drive when cool, and then open tank after sitting in warmth.

 

Hey everybody has anybody had this same problem.
No matter what gas station i go to, when I go to pump gas the pump repeatedly stops over and over, sometimes even flowing out towards me if i keep pushing the handle. I have to pump severely slow, i’ve tried pumping it at different angles, nothing worked.
When the dealership did an inspection they didn’t see a issue until they took my car to the gas station to see the problem for themselves. Then they told me it’s the gas tank is the problem and i have to get a whole new one which they told me will be $3,000.
I’ve been reading it could be the filler neck, or the evaporation system, or the charcoal canister, but those posts have all been for older models.
So can somebody please help point me in the right direction on how to solve this ?
I’ve been dealing with this problem ever since I got the car and i’m tired of it.

Good evening fellow community members,

Does anyone have any experience or insight into troubleshooting a Highlander where the gas pump keeps shutting off as you try to refuel? I have taken a look under the car and have identified the the fuel tank and filler tube but not sure really where to go from here. I have watched tons of youtube videos but found nothing particularly for the Highlander. It seems to have become an issue all of a sudden. I need to begin by inspecting evaporation canister/tubing if anyone has any experience with this it would be greatly appreciated or can point me to any existing resources. It appears the fuel flow into the tank is exceeding the air flow out of the tank as the air is displaced. Even at a reduced flow I can hear the fuel back-filling up the fill-tube. Thanks in advance!

Recently had this fueling shutoff happen with a 2017 camry (after I started using high pressure car wash)
.Try this as it is filling rapidly click the fuel lever over and over as it starts to fill. I did it 30 times. It filled better. Next time I did it 20 times. My idea is that the rapid pressure changes may dislodge an obstruction in the tank vent or evap tube. Next fill up there was no pump shutoff at all even at full speed flow.
Also I read somewhere that high pressure undercarriage car washes could affect a relay.
Try the rapid clicking pumping method and I hope it works for you. RJ