The fuel filler kicks off when i try to put gas in my 06 ion. Is this a common problem with these cars??

can i re-post the symtom for you.
at the gas stations the filler nozzle cuts off way too soon.
RIGHT?
if this happens at all gas pumps/islands and gas stations.
the car has EVAP system failure.
and the valve that opens key off, allowing the vent at cap to work
is failing

P1457 90 EVAP Emission Control System Leak Detected (Control Canister System) Possible causes
- Missing Fuel cap
- Incorrect fuel filler cap used
- Fuel filler cap remains open or fails to close
- Foreign matter caught in fuel filler cap
It means that your fuel tank isn't airtight. It could be a crack in the filler pipe, a loose hose or even a blown gasket at the fuel gauge sender.
Your car does a vacuum check on the fuel system now and then. If it detects it's not air tight, it throws a code. Now, the gas capis the most common thing. But from the fuel filter to the filler neck something is not right. Look for a small gas leak, stick your head under the car and give it a whiff. see if you smell it, if you have a garage put sheets of news paper under your car over night and see if any leeks drip on it. There's other things but try those first.

If the pump kicks on, then it should be getting to the rail.
Sounds like an immobilizer issue (Not powering the injectors).
Disconnect a hose from the fuel rail inlet point (put it into a bottle or tub) and check if fuel is pumping during cranking.
If you get fuel at the rail, check immobilizer or ECU.

well first have you tried using another pump,and if so are you sure the tank is not full i know these sound simple but fuel gauge cold be faulty ext...but if so the fuel tank pressure could be to high do you or have you had the fuel come back up the filler neck something like a fuel tank overfill valve could be faulty in this case would need to see a prof. mechanic to diagnose ,and last pour gas in with a gas can see what happens you may get some type of answer fegas coming up filler or gauge inop ect...hope this helps

The most common reason is a restriction or blockage in the filler pipe, or something wrong with the vent for the tank.
I would start with inspecting the filler pipe.

Your car has a EPA mandated fuel vapor recovery system as part of the fuel tank filler device, this is malfunctioning and is blocking air from being vented while filling which causes the fuel to kick off. You must see the dealer to have this diagnosed. This may be covered under an extended warranty for emission system components.

HI Bridgette,

Due to the different shapes of fuel tank filler necks in cars & trucks, it may be necessary to vary one or more things to allow fuel to flow uninterrupted until the tank is really full.

The main problem can come from the new "vapor recovery" gasoline pumps. These pumps and hoses actually recover gasoline fumes from your tank as the liquid gasoline displaces the air / fumes in the tank is it is being filled. If gasoline flow is started at full blast, it can splash back slightly, causing liquid to be pulled back by the pump - so it shuts off. So, start with a slow rate of filling and gradually increase flow rate to maximum over 5 to 10 seconds. If it still shuts off, try some of the suggestions below.

First, don't fill at maximum flow rate from the pump - that is, don't set the nozzle for wide open. Select one of the other "latches" on the handle instead of the fastest flow and let the tank fill entirely at this rate.

Second, you should experiment a bit with the length of nozzle that you push into the tank's filler neck. If you push it in too far or too little, the pump nozzle can do what you're describing.

Third, try twisting the nozzle slightly so that it doesn't hang straight downward - a little to the left or right may provide a solution.

Lastly, try a different gas station. Their pumps may not be so picky with your tank's filler neck.

Good luck!

Sounds like you have something stuck in your gas tank maybe someone put something in your gas tank perhaps you might consider a good flash light and a pen open the cap insert the pen hold tight and put flash light in filler neck flap hole to see what kind of obstacle you have stuck in your filler nozzle neck if your unable to see anything you might consider taking the car to certified technician for service to you clogged gas filler neck.

There is a fault with the fuel tanks in the 06 cars (and some 05). It is a well known problem and Ford has issued a service bulletin on the issue.

It also seems to be a problem with the fuel pumps at certain gas stations but not others. Try a couple of different service stations (not the same fuel brand) and see if you have the same shut off problem because some people have found that the pumps at some gas stations do not cause premature shut off when re-fueling their 06 Stangs.

I would contact the nearest Ford dealer service people and see if they will rectify the problem for you FOC even though the vehicle is now out of warranty. In some vehicles the fuel tanks were replaced to fix the problem but not in all apparently.

In the meantime you can try 2 means to resolve the problem that has worked for some (not at the same time).

1. Turn the fuel pump nozzle 45 - 90 degrees when re-fueling and do not run the pump full bore. Slow the fuel flow a little.

2. I would avoid this one and I do not recommend it but it has worked well for some people with your problem. Turn on the car's ignition (not the engine)before you fill the tank . Switch it off immediately you have completed re-fueling.

you have a vapor vent issue. The fuel filler pipe has a vent inside of it to let out air as you pump gas in. If no air comes out, it will kick of the nozzle
The other possbility is that it is a poor design and others are having issues too. Cal your dealer service manager, not a service writer and ask him if there is an issue. Write or email Chrysler and ask them too. If the fuel filler pipe has a sharp bend and goes up hill at all, that will back up the fuel fill. Try putting the nozzle in upside down & see what happens. Also, try inserting the nozzle just a couple of inches. Report back please.