I have a rather odd problem with my 1996 Excel. The problem has been with it ever since I bought it over a year ago. It will run absolutely fine when the tank is less than half full, but when I fill it, it just wants to die. I can't make it out of the petrol station without it stalling once, and until I use about 1/4 of the tank, it will stall, sputter, knock, ping, and has acceleration flat spots and running issues. The further the tank empties, the better it runs. In fact, when it is running on fumes, it runs the best; not a problem at all. Now, I never put any more than 20 litres in at a time when i refill.

I have had the tappet gasket replaced, the timing belt replaced, the timing checked and realigned, a new fuel filter installed, air filter, oil filter, new fuel pump, and new spark plugs and leads. I've put in additives for the engine and fuel, done an oil change, all fluids are fine and there is no oil leak. I regularly check the spark plugs for oil and they're fine too. The autoelectrician couldn't find any electrical problems. The problem still exists (but less) when I put in higher octane fuel.

What could cause a car to hate having fuel in it?

Hey Mate,

Don't know if you found a cure yet but here goes...

Is it blowing smoke that smells like petrol? If so, I had the same problem and replaced everything you did as well.

I also replaced the o2 sensor (you can DIY this one, just screws into the exhaust), the MAF sensor and the injectors and, when combined with everything you've already mentioned and a good service, they seemed to fix the problem.

I found out at the time that mine had developed a crack in the valve guide seal as well. Don't know if they're related or not but you may want to bear it in mind.

Good luck with it.

This post has been edited by imugli: Sep 12 2008, 10:20 PM

WOW over 250 views!

Thanks for the reply, but unfortunately, I don't have an excel anymore. The gearbox died about a week ago and I had to crawl back home from work in first gear. The car has given me problems since I had it, so I've actually bought a new car. I could only get my hands on a second hand gearbox, but the cost of it and installation would be about twice or three times what the car is worth. I recently bought a 2006 Elantra for just $13990. And by "recent", I mean yesterday lol.

I'm still deciding whether to test my luck at the auction place or just scrap it and get $100 for the metal, return the number plates and kiss the box of hassles goodbye.

Maybe you'll see me in the Elantra forums...