Join Date: May 2010
Location: sunbury, ohio
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I just went through this on my ’06 (non-CA model), exact same situation too (stall at ½ tank gas). Try this (again '06 non-CA model, other models and CA emissions may differ):
Step 1: Clean the gas cap vent tube:
1. Place a piece of paper in front of the REAR tire
2. Open the gas cap
3. Spray carb cleaner into the vent tube located on the tank, near the base of the gas cap hinge. Use the straw attachment for the spray can.
4. Observe the drips onto the piece of paper. Continue spraying until it runs clear.
Step 2: Clean the gas cap vent mechanism
1. Open the gas cap and remove the key.
2. Cover the tank inlet tube with tape or a piece of paper to prevent dropping things in the tank. I used a large PostIt note, which worked well.
3. Remove the two brass screws that hold the latch mechanism on the bottom of the gas cap.
4. Remove the latch mechanism. Note: there is a loose component in the base that covers the latch spring. Be careful not to drop it into the tank during removal. Inspect the latch, clean as necessary (chances are this is NOT where the problem is), then set aside.
5. Careful not to loose the 5 small springs mounted on posts under the latch mechanism. You can leave them where they are or remove them for safe keeping.
6. Before proceeding remove the small collar from the male latch connector (look for the round key cylinder). The collar acts like a bearing when opening and closing the latch using the key. It is loose and easily lost. Slip it off and put it aside for safe keeping.
7. Remove the two short screws at the base of the gas cap vent, but DO NOT yank the vent off yet.
8. The vent gasket is glued to the cap (at least it was on mine) and the vent assembly might be stuck to the gasket. GENTLY, wiggle the vent back and forth to loosen it and prevent damage to the gasket.
9. With the vent assembly removed, inspect the gasket for tears or bulges. Spray with carb cleaner (just a little) and wipe with a clean cloth. Inspect the cloth for signs of debris.
10. Now for the root of the problem; Remove the small round plastic check valve/liquid separator located on the underside of the vent assembly. GENTLY ply it out, careful not to damage the silicone valve covering the base of the check valve. Remove the gasket as well and place it aside. Inspect and clean the check valve, ESPECIALLY the tiny 90 degree elbow which leads to the vent hole. NOTE: there is another silicone valve cover permanently mounted in the gas cap vent itself (part of the pressure release part of the valve). DO NOT attempt to remove it or you will damage it. Just make sure it is clean and functioning.
11. Now check the vent hole. Hold the vent assembly up to the light and look up from where the plastic check valve was mounted. See any light where that tiny 90 degree elbow fits? Follow the vent channels on the opposite side of the vent assembly. Any blockage? Unplug the holes and clean the channels.
Step 3: Repeat Step 1 frequently (at least once a year) to prevent this from happening again.
UPDATE 5/5/2010: My Phantom has been uncloaked! I took a closer look at where/how the rubber vent tube exits in front of the rear tire. I found that the tube had been (and still is) rubbing against the rear tire. The 'black fluffy carbon' blocking my vent was probably rubber shavings caused by the vent tube rubbing against the tire. I've temporarily rerouted the vent tube to exit along side the coolant overflow tube to eliminate the vent tube/tire rubbing. I still plan to flush the vent once a year to reduce the possibility of dirt and dust reaching and blocking the actual gas cap vent.