NHTSA Complaint #11439600 — 2002 LEXUS RX

The system component that malfunctioned was the Fuel Tank Overfill Check Valve, also referred to the Rollover Valve located in the top of the gas tank. The valve is suppose to prevent any fuel purging or fuel leaking during a rollover accident. Unfortunately, the valve can malfunction during normal refueling without the owner being aware. For a few years, I have been smelling fuel fumes during and after refueling. I would sometimes discover a pool of raw fuel under the gas tank and charcoal canister during/after refueling and up to 12 miles later. The vehicle started hesitating, missing and actually stalling after refueling. Three professional mechanics couldn't solve the problem. In an attempt to eliminate this safety issue, I replaced the gas tank, gas filler tube, fuel vapor purge valve and charcoal canister. I finally discovered a tube from the malfunctioning Overfill Valve was sending raw fuel directly to the charcoal canister, filling the charcoal canister and ultimately overflowing onto the ground outside of the vehicle. I decided to cut a hole in the vehicle floor under the rear seat and replace the Fuel Tank Overfill Check Valve. The design of the replacement valve was different from the original and incorporated a float type check valve rather than just the simple diaphragm in the original. Maybe Toyota/Lexus quietly redesigned the valve, but all owners should be aware of the redesign and the vehicles should be recalled. Thousands of these vehicles are still on the road because people love them. These vehicles and the valves are aging and failing. Dangerous fire potential certainly exist. One previous owner did have this problem, I believe, and his vehicle burned to the ground. It's an extreme safety issue not just because of the hesitating/stalling in traffic after refueling, but mostly because of the raw fuel leaking from the charcoal canister under the vehicle right in the immediate vicinity of the hot exhaust and the gas tank.