Question about 2001 Hyundai XG300

1 Answer

Problem trying to fill the gas tank. The pump shuts off continually even though the tank is no where full.

Posted by on

  • FRUSTRATED ATPUMP Mar 15, 2012

    From Hyundai Service Website (which is awesome)
    All 1999 and later Hyundai vehicles incorporate a new emission control system known as On-Board Refueling Vapor Recovery (ORVR). A general schematic of the system is provided below.
    Some owners may experience difficulty filling their vehicle with gasoline and a premature shut off condition as a result of the gas pump nozzles installed at their gas stations.
    If the refueling difficulty continues, verify that the 1/2" vapor path from the fill vent valve on the gas tank to the air filter on the charcoal canister (see schematic below) is completely
    free and clear. To perform the procedure below, make sure the fuel tank is below 1/4 tank full.
    To quickly determine the general location of a possible vapor path restriction:
    Disconnect the hose connected to the canister side of the liquid-vapor separator (see schematic below).
    Take the vehicle to a known "good" or major brand gas station.
    If the vehicle readily accepts fuel, the restriction is located between the liquid vapor separator and the air filter.
    If the vehicle does not easily accept fuel, the restriction is located between the liquid vapor separator and the fuel tank.
    On-Board Refueling Vapor Recovery (ORVR) Schematic
    The following components are contained in the ORVR system:
    Vapor hoses
    Liquid-Vapor Separator(s)
    Fuel Fill Vent Valve
    Fuel Cut Valve (anti-spitback)
    Canister Close Valve
    Air Filter
    Charcoal Canister
    After the restriction has been isolated to either half of the system, inspect each component to make sure it is free and clear of any restrictions. Verify that no
    back pressure can be felt anywhere between the fill vent valve and the air filter at the canister.
    1999 Accents have two (2) liquid vapor separators: one located on top of the fuel tank, the other located alongside the filler neck.
    When checking the liquid vapor separator, blow through one end of the pipe using lung power. NO
    back pressure should be felt.
    Verify that the Fill Vent Valve is open by carefully removing the valve and confirming that the white plastic shut-off plunger moves freely inside its cage.
    If the fuel cut valve plunger is stuck closed, a hard-to-fill condition may result. Verify that the plunger moves up and down freely allowing fuel to enter the tank, but does not allow fuel to travel up the neck (under pressure). The plunger should be "up" (closed) in its free state.
    When working with the Fill Vent Valve and associated plumbing, be sure to replace the hoses into the proper hose clips to prevent fuel from getting trapped / puddled in the vapor hose. Return fuel from the liquid-vapor separator must have a clear path to drain back to the tank.
    Four Way Valve
    The Four Way Valve provides an additional vapor path to the canister during refueling.
    NOTE 1999 Sonatas have a Four Way Valve located between the liquid vapor separator and fuel tank.
    Proper operation of the valve is as follows:
    Air flows freely in either direction through the 1/2" ports.
    Air flows freely in either direction through the 1/4" ports.
    Air flows from 1/2" port to the 1/4" port when blowing into one of the 1/2" ports while plugging the other 1/2" port.
    Air does not flow from 1/4" port to the 1/2" port when blowing into one of the 1/4" ports while plugging the other 1/4" port.



1 Answer

  • Level 3:

    An expert who has achieved level 3 by getting 1000 points


    An expert that got 10 achievements.


    An expert that got 5 achievements.


    An expert whose answer got voted for 500 times.

  • Hyundai Master
  • 3,433 Answers

It's not the car, it's the vapor recovery system on the pump nozzle. Report it.

Posted on Nov 19, 2009


2 Suggested Answers

  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

Hi there,
Save hours of searching online or wasting money on unnecessary repairs by talking to a 6YA Expert who can help you resolve this issue over the phone in a minute or two.

Best thing about this new service is that you are never placed on hold and get to talk to real repairmen in the US.

Here's a link to this great service

Good luck!

Posted on Jan 02, 2017

  • 67 Answers

SOURCE: Hyundai Accent 2003 - gas pump clicks off when tank isn't full.

possible cause could be evap canister full of gas causing back up

Posted on Feb 09, 2009

Add Your Answer

Uploading: 0%


Complete. Click "Add" to insert your video. Add



Related Questions:

1 Answer

Loosing power when drining

Hi Jennifer-
I believe I may be able to help you with the gas spillage you are having when filling the tank. This happened on my 1998 Toyota Camry.
One day, even though I was low on fuel, the attendant had trouble adding gas to my tank. Gas would spill during filling or the nozzle would click off (as though it was full) even though it was not. I had to stand there myself and slowly add gas until the tank was full.
I learned that my car had a thin vent tube that would run from the gas tank to the gas tank opening. As gas is rushing into the tank during filling, the air that is being displaced from the gas tank escapes through this tube. This tube had rusted closed a bit and was restricting the air flow escaping from the tank during pumping causing the problems I described. Once this tube was replaced, my problem was solved!
Hope this helps!

Apr 01, 2014 | 1998 Pontiac Grand Prix

2 Answers

2001 Durango acts like the gas tank is full during filling cutting off the pump. The only way to fill tank is to pump gas really slow

Chrysler and Dodge have a fuel vapor filter that allows air out of the gas tank but filters the harmful fumes. Usually the problem happens from topping off your gas after the gas pump stops due to the automatic shut off and then putting more gas in the tank (to make the bill an even $50. or to the next $5 increment, or pumping more in just because it fits). Anyway the filter gets saturated with gas, is not able to breath, and causes a vacuum in the tank. Because of this, the anti-siphon ball is not able to float around and sits at the opening of the fuel fill tube and won't allow any more gas to be put in (acts like the car is full). If you pump super duper slow like put a nickel to hold the gas pump handle, it will trickle in without a problem, but it takes forever! Solution, get the filter replaced and don't over fill the tank.

Sep 11, 2010 | 2001 Dodge Durango

1 Answer

Cars gas tank

the breather tube for the tank might be clogged not letting the air out. so when you fill the tank the fill cant get in fast enough b/c the air is not excaping. check the breather tube for kinks or bends. or even blockage of somekind

Sep 27, 2009 | Toyota Solara Cars & Trucks

1 Answer

Fuel tank shuts off long before tank is full

the vent tube that runs beside the filler hose is crimped shut or clogged

Jun 29, 2009 | 1999 Chevrolet Silverado 1500

1 Answer

Problem fueling 1999 Dodge Intrepid

does your car run fine on the 5 gallons you stick in each time? if so I would say that your fuel pump is ok. I would take the tank out and see if there is some obstruction in the fill tube and tank orface, also look inside the tank for any floating debris, check and or replace the tank vent

Apr 07, 2009 | 1999 Dodge Intrepid

1 Answer

Hyundai Accent 2003 - gas pump clicks off when tank isn't full.

possible cause could be evap canister full of gas causing back up

Feb 08, 2009 | 2002 Hyundai Accent

4 Answers

Fuel spills out when I fill up.

It is the filler neck it causes splash back.

Oct 09, 2008 | 2005 Ford Freestar

1 Answer

When i try to pump gas in the tank even though it is not full gas will come back out as if it is to full

Spyder web in vent (that lets air out while u fill)
Try cleaning the lines going to the fill check valve or cleaning the lines going to it. It might be on or near the charcoal canistor or behing or on top the tank.
Or replace valve and lines

Sep 06, 2008 | Chevrolet Malibu Cars & Trucks

1 Answer

Gas tank

theres a bend or restriction in the filler neck most likely. have a look under the car to see if thats the problem

Jun 30, 2017 | 2004 Volvo XC90

Not finding what you are looking for?
2001 Hyundai XG300 Logo

Related Topics:

276 people viewed this question

Ask a Question

Usually answered in minutes!

Top Hyundai Experts


Level 3 Expert

80668 Answers

Colin Stickland
Colin Stickland

Level 3 Expert

22326 Answers

Jeffrey Turcotte
Jeffrey Turcotte

Level 3 Expert

8841 Answers

Are you a Hyundai Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides