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Discussion Starter #1 (Edited)
This FAQ covers issues, questions or concerns encountered with the process of filling up the car with gasoline

  1. The fuel gauge says “Low”, how much is left?
  2. I can only pump 7-8 gallons of gasoline?
    Problem with filling the gasoline tank.
    My Volt fuel gauge is not showing as full.
  3. DTC P043E error code?
    Slight smell of gasoline in the back seat or cargo area.
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  1. The fuel gauge says “Low”, how much is left?
    It means you have roughly 1.5 - 2 gallons left in the tank and you should fill up soon.
  2. Problem with filling the gasoline tank? I can only pump 7-8 gallons of gasoline. Volt fuel gauge not showing as full.
    Due to the reserve left in the tank, the filler nozzles vapor shut off setting, and the design of the gas pump it may be difficult to fill the tank completely. You might find this situation better (or worse) when you fill at another station.

    Also, the amount of fuel that can be pumped can depend on fuel station pump design, model, and adjustment. Pump design can be adjusted to prevent potential spillage by clicking off early or by slowing to a crawl. The premature shut-off problem is most likely experienced in states that use a fuel vapor recovery system as part of the fuel nozzle (identified by a collapsible rubber boot/bellows on the nozzle that seals against the fill cap housing.)

    It is very important that you insert this type of nozzle completely into the filler neck in order to "jump over" a small detent feature built into the neck. The detent is designed to help maintain the nozzle into the neck with less effort, (see A in diagram below) necessary because the "spring-loaded" behavior of the sealing boot tends to push the nozzle OUT of the filler neck. If the nozzle is not fully engaged (as in B in the diagram below) the fuel delivery pipe shoots fuel up against the neck which builds up back-pressure and triggers the pump to shut off.

    By raising UP on the nozzle slightly during insertion before fully engaging the nozzle into the filler neck this scenario will be rectified.
    Volt_Fuel_Neck.jpg
  3. DTC P043E error code. Slight smell of gasoline in the back seat or cargo area.
    NEVER ATTEMPT TO FULLY FILL THE VOLT TO THE POINT THE FILLER NECK FLOODS WITH FUEL OR DAMAGE TO THE FUEL TANK PRESSURIZATION SYSTEM COULD OCCUR. Make sure to not attempt to force any more than 1 or 2 clicks past original nozzle shut off.

    Over-filling can flood the Volt's vapor recovery system causing a DTC P043E (Evaporative Emission (EVAP) System Reference Orifice Flow Insufficient) error and a dealer visit for repair. With a P043E error, the charcoal canister that traps gasoline tank fumes is typically flooded with gasoline. This can happen when someone accidentally or intentionally overfills the gasoline tank beyond the auto-shutoff. You may also notice a slight smell of gasoline in the back seat or cargo area wafting in from outside the car.

    The error code could also be caused by a shorted/faulty pump or a a cracked hose in the EVAP system.

Reference Posts
http://gm-volt.com/forum/showthread.php?6732-Problem-with-filing-gas-tank&p=75171#post75171
http://gm-volt.com/forum/showthread.php?5940-My-Volt-Fuel-Gage-only-goes-up-91-8-Gal&p=75453
http://gm-volt.com/forum/showthread.php?12702-Problem-filling-up-with-gas
http://gm-volt.com/forum/showthread...almost-had-to-use-an-eye-dropper-to-get-it-in.
http://gm-volt.com/forum/showthread.php?48322-DTC-P043E-Has-anyone-else-seen-this
http://gm-volt.com/forum/showthread.php?5940-My-Volt-Fuel-Gage-only-goes-up-91-8-Gal
http://gm-volt.com/forum/showthread.php?42393-Why-can-t-I-fill-my-gas-tank-90-as-much-as-I-get.
bout 1.5-2 gallons. Seehttp://gm-volt.com/forum/showthread.php?18761-Gasoline-range-following-quot-Low-Fuel-quot-indicator-and-running-out-of-gas&p=214161#post214161
 

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I don't know how many times I see people topping of their tanks when Tom and Ray on Car Talk always tell people that doing so risks ruining the evaporative canister. That extra half gallon of range isn't that important in the grand scheme of things.

If I ever get around to plastidipping my car, I will do one further. Since plastidip disintegrates when gas touches it, I will probably only put 5 gallons or so in at a time as I recently ran into a pump that didn't stop automatically thus spilling gasoline everywhere.
 

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If I ever get around to plastidipping my car, I will do one further. Since plastidip disintegrates when gas touches it, I will probably only put 5 gallons or so in at a time as I recently ran into a pump that didn't stop automatically thus spilling gasoline everywhere.
My 1995 Buick Regal has a small 1/4" hole below the filler port, so if it overflows the gas will spill inside the fender and not over the paint. I wonder why GM didn't follow this on the Volt, but I believe that a small hole drilled under the port will do the same feature.
 
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