Question about Hyundai Motor 2002 Sonata

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Problems fillng the gas tank 2002 Sonata

I recently purchased a 2002 Sonata with 99,000 miles on it. The car is in great shape, except that I'm having problems filling the gas tank. I can't pump gas for more than one or two seconds before the automatic shut off valve at the pump shuts it off. It takes me 20 minutes to fill the tank. I have yet to fill the tank more than 2/3 full because of this problem.

Anyone have a similar situation? What was the problem and the fix? I'm not looking to dump a lot of money into this car as I didn't pay much for it.

Thank you in advance for your advice!

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  • 3 more comments 
  • maryfoxua Feb 23, 2009

    Yes, the check engine light has come on, but no noticible gas fumes.

  • Anonymous Mar 07, 2009

    po455

  • Jake1964 Mar 23, 2009

    I just purchased a 2002 Sonata and also cannot get gas to enter the gas tank. The automatic shutoff also keeps me from filling up. I have a check engine light on with the code being read as P0446. I called the Hyundai local dealer and of course they wanted $120.00 to diagnose 1 of 6 problems that emit this code. I have found a Hyundai Service Bulletin for this problem , 06-30-005. There are some intermittent problems that send this code but if "check engine" light is on all the time and gas wont go in car at all, I think someone could narrow it down to 1 or 2 parts. Please help if you've repaired this problem!

  • Anonymous May 20, 2009

    I have the exact same car when I bought it at 96000 miles.
    1) Same gas problem. Had to manually fill the tank at low pressure and it takes lot of time to fill it. The Gas meter does not work. It shows full when the tank is full and after a while it goes down.

    2) The check engine light is due to oxygen sensor either left or right. Replace that and it will go away until you get your car washed under the hood. When it is dry it will go away.

    3) Having one by one problems and it is very expensive to get these repaired. Had to replace the alternator. Cruise control does not work in cold weather. Even expensive Michelin tires are getting worn out pretty quickly despite getting the wheel balancing etc done. Door auto lock does not work where as unlock works. Child side does not unlock automatically with remote with or without child lock. read passenger side auto window does not go down from driver control, goes up, and works from passenger control after getting the car unlocked when my wife forgot the keys inside.

    Don't buy Hyundai !!


  • Frank Magliocca May 11, 2010

    Do you get any check engine lights or any gas fumes while your driving?

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I just went through that problem

Evap canister / close solenoid and air filter $211- 230.00 in parts

$675- $71.00 at dealships for this small 30 minute task

If no check engine light Evap canister and air filter - fixxes problem 100 %
note:you may be able to get by just replacing air filter- works
rarely

if have check engine- close solenoid and purge solenoid may need replace- you local autozone- like autozone will pull check codes for free

the how to:

Jack car up in rear - behind right rear tire - canister -canister close solenoid & air filter are located in a plastic box with metal strap and one bolt.

Unscrew bolt everything drops down the EVAP CANISTER is held to plastic box by wirer tie . Remove wire tie and solenoid connection.
There is a small metal wire clip the holds the solenoid electrical connection together with a flat screw driver pry up the wire clip , off is okay too , ....it will go back on.

Once you have done all that you have full access there are i believe from memory 3 rubber hoses with clips ......Mark hose connects very important mark the hoses way the going on evap canister with color tape .

Next, remove whole assembly- the solenoid and air filter will come with the evap canister.

Now that have the whole assembly move to your work bench
look to see how the soleniod hook up to the canister and the air filter - now, disconnect the hose to black solenoid and remove the air filter which hook to solenoid and solenoid at same to ......

Next seperate the the solenoid and air filter- you should be air to put your mouth on solenoid and blew air in one hole and out the other- this solenoid is noramlly open- if air dosen't go threw is stuck closed and must be replaced.

same with air filter- this air filter are know for get plugged and should be replaced every 30,000 miles.

Also note: over fill you gas tank , at fill up - can cause the Evap to get liquid gas inside which cause the chorcoal in the filter to swell up and plyug the system up.------ you should when fill up stop pump gas after the auto pump click off on normal work tank and not try to top off you tank.

note: check with your deal for exact wieghts
weigh the evap canister - six pound - replace it- new one is about 4-4.5 pounds - it is just best to replace .The evap holds gas fumes then send to engine so that dosn't vent to

All parts are dealships only -

This is easy fix and normal, for gas fill problems

canister Evap 161.00
canister close solenoid 43.00 may or may not be used
air filter 7.00

not used in this fix- check engine fix use these parts
sensor price ?
purge valve 39.00
canister close solenoid 43.00

Posted on Mar 02, 2009

  • gregswabs Mar 02, 2009

    I HAVE SPENT A MONTH RESEARCHING THE PROBLEM OF CLICK OFF ARE 2-3 SECONDS AND TAKING 20 MINUTES TO FILL MY TANK ON 2002 HYUNDAI SONATA GLS

    I TOOK TO THE DEALERSHIPS THEY CONFIRMED THAT PROBLEM AND MY RESEARCH CONFIRMED THAT
    FILL PROBLEMS ARE DUE TO THE EVAP CANISTER AND AIR FILTER BE PLUGGED UP.

    GET A KNEW GAS TANK YOU WILL GAS TANK YOU WILL STILL HAVE THE SAME AND ANOTHER 350.00 FOR TANK
    PLUS IF NEED HAVE INSTALLED WOW 550.00 AND NOT FIX THE PROBLEM.

    WOW... BUT YOU WOULD BE FIRST PERSON THAT HAS DONE IT>



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My 2002 does the same thing, but if I put the nozzle in and then lift the rubber seal a 1/4", it works good, and fills the tank.
Cost $0.00
Not so good for the environment I would guess...

Posted on Sep 09, 2011

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  • Master
  • 424 Answers

The gas tank may have been replaced & the vent hose is not on properly.

Posted on Feb 23, 2009

  • Frank Magliocca Feb 23, 2009

    try to see if the neck of the gas tank has any kinked or disconnected hoses . look under the hood also.I am referring to the emissions system which has vacuum lines from the tank.The tank needs a vent while your pumping gas in (which Im sure someone messed up) You can get your computer read at a shop to see what codes that the check engine light are leaving.

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I have the same problems. No Solutions can't get gas in the fuel-line/ tank and check engine light still one after Western Auto ran computer and replaced engine air filter..

Posted on Mar 20, 2013

  • ben_reese
    ben_reese Mar 20, 2013

    I have the same problems. No Solutions can't get gas in the fuel-line/ tank and check engine light still one after Western Auto ran computer and replaced engine air filter..

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