Question about Hyundai Motor 2002 Sonata

2 Answers

2002 hyundai sonata - when dispensing fuel pump is shut off. Must pump gas very slowly.

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  • lyndonbourgo Aug 05, 2010

    Gas pump at service station shuts offprior to gar tank being filled. Does this many times while trying to fill fuel tank. You must allow the gas to flow only at a trickle. Acts as though the fuel is backing up into the fuel nozzle.

  • 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.



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  • Hyundai Master
  • 17,970 Answers

This is perfectly normal. It happens because as the fuel goes into the tank it splashes and bubbles. As the tank gets closer to being full, the displacement caused by the bubbles forces the gas to go up the pipe that feeds the tank and triggers the "full" switch on the pump nozzle. This is similar to if you are filling up a cup of cola at a restaurant, you have to wait for the fizz to die down before you can put that last 1/4 in.

Other opinions comment most of the time the problem is the charcoal canister. Five things needs to be checked/fixed:
1.- a canister close valve could be clogged with charcoal or not working
2.- a canister filter
3.- electrical connection to the close valve
4.- broken canister
5.- a purge valve which pull fuel vapors from the canister
6.- all the hoses of canister should be open, means not clogged

I can hear about similar problem of pumping gas and have replaced the canister close valve, now they can pump gas without a continuous auto shut off.

Here I find and quote other comments about this "normal" shut off function...

Cecil replies:
Pal, you're going to need a doctorate to understand the following, so cleanse your mind of distracting thoughts. In a gas pump handle you have two valves: the main valve, which is actuated by the oversize trigger you squeeze to make the gas flow, and the check valve, which lets gas flow out but won't let anything back in again, thus reducing fire hazard. In the seat of the check valve you have a little hole. To the backside of this hole is connected a Y-shaped tube. One branch of this tube runs down the nozzle and exits at the tip while the other runs back to a diaphragm connected to a release mechanism on the main valve. When you squeeze the gas pump trigger, gas running past the hole in the check valve sucks air out of the Y-shaped tube. (This is because of the Bernoulli principle: a moving stream of fluid tends to pull things in from the sides. Take my word for it.) As long the end of the Y-shaped tube exiting at the spout is unobstructed, air is simply pulled into the tube and nothing much else happens. However, as soon as the gas in your car's fill-up pipe gets high enough to cover the end of the tube, a partial vacuum is created therein, which yanks on the diaphragm, releases the main valve, and shuts off the gas. If the gas happens to be especially foamy one day, it may actuate the release mechanism prematurely, with the result that you end up with less than a full tank of gas. Simple, huh? Sure, just like nuclear fission. Stick with English lit.

Hope helped.

Posted on Aug 05, 2010

  • lyndonbourgo Aug 05, 2010

    OK, but what do I do to fix the problem. It takes me about 10 minutes to fill the tank. It doesn't matter where I go to fill it.

  • ZJ Limited
    ZJ Limited Aug 05, 2010

    I really dont know if this solve the problem, but for Hyundai owners is the solution...

    This procedure work in 2002 Accent with the same problem.... Here is how I bypass this and get gas with out shut off.First find this hose in the red square(check the pic #1 and #2)
    pic #1 / pic #2

    Next take a look in the under left rear side of the car, you will see some thign like the pic #3.
    pic #3

    The green square is what you call charcoal canister and the red square is the canister close valve.
    get under the car and lock for the hose from the pic #1 that goes to
    the charcoal canister the rubber hose of 1/2 inch check the pic #4 to
    see what I mean. (locked from the front side of the charcoal canister,
    the side where is the left rear tire)
    pic #4

    The green square is the purge line that goes to the motor side and the red is the hose what we want.
    Here another angle of the charcoal canister, locking straight up
    pic #5

    Green - canister.
    Red - 1/2 inch Hose(this one).
    Blue - cober from the filler neck.

    Just disconnect this hose each time you want fill gas, and conect it back after that. If
    this works that means some thing is blocking the pass of the air in the
    canister, close valve and air filter side, problably some of charcoal
    in the close valve. if not the problem is in the fuel tank side.

    Hope this helps just google a little and check the Hyundai service web page and lock for canister.


    I had the same problem with my daughter's '01 Accent. Found this in another forum, tried it, and it works:
    Disconnect the vapor line at the charcoal canister that comes from the
    liquid vapor separator and goes to the charcoal canister. (The large
    diameter hose from the fuel tank, loops up to the filler neck, then back
    down to the charcoal canister - held on by a spring type clip.) See if
    the fuel tank can be easily filled then.
    2. If the fuel tank can
    easily be filled with the vapor line removed from the charcoal canister,
    reconnect the vapor line and remove the other lines from the charcoal
    canister and see if the fuel tank can be easily filled.
    3. If the fuel tank is once again difficult to fill, replace the charcoal canister.
    If disconnecting the vapor line at the charcoal canister does NOT make
    the fuel tank easy to fill, then disconnect the vapor line from the
    liquid vapor separator at the fuel tank in case the vapor line is plugged/restricted.
    Potential Causes:
    Charcoal Canister
    Liquid Vapor Separator
    Vapor Line

    Tech Tips: Fuel vapors are directed to the canister from the ORVR fill vent valve in the gas
    tank through the liquid vapor separator and to the canister. The metal tube that
    loops up by the filler neck is part of the vapor line to the canister.

    called the local dealer for the price of a new canister. $150.00. No
    thanks, that seems kind of high for a few cents worth of plastic and
    some charcoal pellets to put into a car with lots of miles. It wasn't
    too hard to slide under the rear end, remove the canister, shake out
    some of the pellets, blow the tubes, and put it back together. It's
    working great now-I fueled it "full blast" this evening with no shut

    Tell us news.


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  • Master
  • 11,896 Answers

Either the fuel pump relay is faulty, or fuel filter may be clogged.
Some of these cars have a fuel pump shut off safety valve that can go faulty. Not sure of the exact location on this car, but has been known to happen.

Posted on Aug 05, 2010

  • lyndonbourgo Aug 05, 2010

    How does filling the fuel tank from a gas pump at a service station have anything to do with a fuel pump???

  • Nate Stansfield
    Nate Stansfield Aug 05, 2010

    Oh sorry, I though you meant the car's fuel pump was shutting off.
    If you are fueling and the gas pump shuts off, either the nozzle is in to far or the gas vent is plugged and not allowing the fumes to release therefore causing pressure which shuts off the gas pump



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SOURCE: where is the fuel pump relay located on a 2001

there is 1 relay that controls the ECM / Fuel pump. its located above the center hump in the dash, right side. Like to the right and below radio area.

Posted on Oct 27, 2009

  • 332 Answers

SOURCE: Can't get gas into my 2002 Hyundai Accent.

The reason the gas station pump shuts off is when the fuel reaches the tip of the gas nozzle, so when you are filling your car and the gas nozzle (gas stations pipe) keeps shutting off it means that the pipe that runs to the gas tank is not open completely, what happens is when you pump the gas in the car the supply pipe from the gas tank opening to the tank fills up quickly and this causes the gas station pipe nozzle to shut off, have some body take down the gas tank and have a look at the gas tank opening and also gas supply pipe that runs from the gas filler opening ( on the car body) to the gas tank. Have a look at it and please don't forget to rate the answer if it was helpful, thanks!

Posted on Mar 25, 2010

  • 1 Answer


Ya, check behind the drivers rear wheel. There is a black box which contains the charcoal canister, filter, solenoid. You'll need to jack up the car, take that wheel off, mud flap and another plastic section inside the wheel well which will expose the hoses that run in and out of that box. . . . take note where all the hoses go. You'll need to remove the whole thing to get at the filter. The electrical lead that attaches to the solenoid has a unique locking clamp so its difficult to unplug, I opened the trunk and cut the wire where is runs into the wiring harness.(careful to leave enough wire to work with to re-connect it). The filter is hopefully the problem, its only around $10.

Posted on Nov 07, 2010

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