Hyundai Hard To Fill Up Repair Review

In this video I review a repair that I performed on an 05 Hyundai Sonata 2.7L. The repair was the replacement of the evaporative emissions charcoal canister (or vapor canister) and removing charcoal pellets, that came out of the damaged charcoal canister, from the fuel filler neck vent tube. These charcoal pellets that were clogging the vent tube were making is very difficult for the owner of the vehicle to fill his gas tank. He complained that when filling up the fuel nozzle would shut off repeatedly if he pumped the fuel too quickly. The clog was preventing his fuel tank from venting while being filled with fuel. this caused the fuel that was being feed into the filler neck to back up and make contact with the fuel nozzle causing it to shut off.
In this video I also explain why I think the charcoal canister came apart clogging the fuel filler neck vent tube. I believe it was caused by the owner over filling the fuel tank. The vehicle owner explained that he had a habit of over filling his fuel tank. He said that he would continue to add fuel even after the fuel nozzle shut off because his tank was full. This caused liquid fuel to be introduced into the charcoal canister causing the canister to become damaged as the canister is not designed to handle liquid fuel. (moral of the story is if you are overfilling your fuel tank you may want to stop).
Note: If this happens to you it is important that you inspect the other lines of the evap system to insure that none of the charcoal pellets got into them. While I only had pellets in the fuel filler neck vent tube it is possible that they can get into the rest of the system. If this is the case they must be removed.
Note: This video is not a "how to" video. Rather it is intended to bring light to a common issue that certain Hyundai vehicles have with charcoal canister coming apart. As mentioned in the video I am not sure what particular years are affected by this problem. I'm also not sure of all the models that are affected. However, this is easy to check for and it will be pretty obvious that this is your problem if you see loose pellets as shown in the video.
Also, it's fair to mention that the Hyundai mentioned in the video did not have any diagnostic trouble codes. There are other ways, other than overfilling your fuel tank, that liquid fuel can enter into charcoal canister. (A STUCK OPEN EVAP PURGE VALVE IS ANOTHER WAY. STUCK OPEN EVAP PURGE VALVES ARE COMMON TOO.) While I said in the video that I suspected one thing only when the owner of the vehicle told me what was happening I did not mean that this is the only thing that could cause this symptom or the only thing that can cause this problem. A full and proper diagnosis of the evaporative emission system is recommended before performing any repair to the system. THIS VIDEO IS NOT DESIGNED TO EDUCATE THE VIEWER ON HOW TO FULLY DIAGNOSE AN EVAPORATIVE EMISSIONS SYSTEM.
IF THE EVAPORATORATIVE EMISSION SYSTEM IS FOUND TO BE IN GOOD WORKING ORDER AND YOU KNOW YOU OVERFILL YOUR TANK AT THE PUMP THEN THE REPAIR EXPLAINED IN THE VIDEO WOULD PROBABLY WORK OUT FINE FOR YOU.
IT IS POSSIBLE THAT THESE EVAP CANISTERS ARE JUST PRONE TO COME APART LIKE THIS WITHOUT OVER FILLING OR PROBLEMS WITH THE EVAP SYSTEM CAUSING LIQUID FUEL TO ENTER THE CANISTER. THE THEORY EXPRESSED IN THE VIDEO IS JUST THAT.... A THEORY.
DISCLAIMER
Barbour's Auto Help is not responsible for any damage or personal injury incurred in the process of performing any auto repairs done by you the viewer. Automotive repair is extremely dangerous. Repair your vehicle at your own risk. It is the viewers responsibility to verify all information and procedures as outlined in YOUR REPAIR MANUAL AND OWNERS MANUAL FOR YOUR VEHICLE. Owning and using a repair manual suited for your vehicle is essential for correctly and safely performing ANY repair to your vehicle. Always wear safety glasses and heed all instructions for use applicable to any piece of equipment you may use. Due to circumstances out of the control of Barbours Auto Help, Barbours Auto Help makes no guarantee that by the use of the information given in this video a quality repair will be made. Barbour'sAutoHelp makes no guarantee that the information provided is totally complete, syncronized and accurate. Verify everything using an appropriate repair manual.
Repair your vehicle at your own risk! Barbour's auto help does not guarantee a proper repair using these techniques.

[@MrJohnthegreat22]

I had this issue. But instead of paying a bunch of $$ for a new charcoal canister. I put small pipe screens in the tubes on canister.. And used a long wire to clean out the hoses. And that solved issue.

[@ferddoes1498]

I did the same solved my issue

[@billsullivan8812]

Good explanation, Keith. Well done.

[@BarboursAutoHelp]

Thank you Mr. Sullivan! Happy Easter!

[@tugsman5]

I was thinking just vent line clogged with dirt...but now I'll take this apart and try some screens also, 300 bucks is way too much for a new canister! Thanks for the info!

[@TwitchRadio]

Do you happen to know where the fuel filter is on a 2003 Hyundai xg350L.... I have three different sources two saying it's around the gas tank which I have not seen or found and one saying kind of where your feet goes when you're driving down over in that area but not seeing it.. unless there's a access door somewhere hidden I don't know about.... already replaced the fuel pump, camshaft position sensor... Having stalling issues while at idel and in motion under power... Just dies at random times... started the replace the more common things that it could be, Thanks for your time and the video

[@artbuck1368]

Yes sir I appreciate you and your knowledge. I have a 2003 sonata 2.4. I am having that problem so I took the canister off and ended replacing the filler neck assembly as it was rusted bad and also blew out the lines to the tank. Even when into to tank to replace the flue filter and felt the check valve and it does move up or down. So I wonder that possibly I didn’t confirm that the vent line is clear.

[@BarboursAutoHelp]

So, you still have the same issue? Fuel pump shutting off several times while pumping gas?

[@rda9441]

I am having this issue with 2009 3.3 l sante fe. It also causes the car to struggle to start at times. The new charcoal cannister is like $600 to $800 and $400 for labor I was told which is pretty pricey.

[@robertmontefusco8302]

I have a 2008 sonata with the 2.4 engine. If I fill the tank then the engine will hiccup, stall, surge etc. for a while then will run better. If I fill it up from 3/4 full then I don't have this issue. If I let it go to 1/2 full or lower and then fill it the problem occurs again. I checked the fuel pump and the tank is clean. MAF has been changed. Vehicle has 204,000 miles on it. Any idea how to fix this? Purge valve? Charcoal canister? Both? What does this canister look like? Exactly where is it located? (Actual Pic?) I've seen a couple of different shapes. How would I remove it without a lift? I'm doing this in my driveway and I can't locate the canister. Any help will be much appreciated.

[@eddysmith6476]

I have an 07 sonata limited 3.3L. The problem I have is that I believe that the pellets went into the fuel pump area all the way to the purge valve on the top of the engine what would you recommend.

[@BarboursAutoHelp]

You gotta get the pellets out. Either blow the lines out or remove the lines and the blow them out. The one on top of the fuel tank may require tank removal.

[@ioustininicolaou7618]

thank you it give me a starting point

[@BarboursAutoHelp]

No problem.

[@kurtedmonds3864]

This was the exact same issue I have i already replaced the charcoal canister but I wasn't aware I needed to also do that one hose I'll do that now

[@donaldlehew1931]

Yes helped

[@BFArch0n]

Would this cause the interior to smell like gas when you fill it? Mine fills fine, but smells like gas inside since filling it. (since drove 75 miles over 2 days and smell is gone, smell wasn't there on empty tank either)

[@BarboursAutoHelp]

Possibly

[@kellyngrey4950]

Great information, thank you!

[@BarboursAutoHelp]

No problem. Thank you!

[@user-si6xg8yj3s]

We have an 09 doing it!

[@ceeg149]

i have a 2011 hyundai sonata with the exact problems you described. I took it into the hyundai dealership today and they told me i was missing the filler neck piece? He said hes suprised my check engine light isnt even on lol

[@BarboursAutoHelp]

Glad you have it figured out

[@user-oc9bt1wr1o]

2006 Sonata gls 3.3 V6 can't figure out p2422 changed gas cap, solenoid , canister behind rear driver's side, fuel pump pressure sensor.still no luck.

[@BarboursAutoHelp]

This may require the evap system to be smoke tested. You may have a leak in the system that does not concern the parts replaced already. May be time to take it in to the shop.

[@jeniferparker7220]

Having same problem with my Hyundai Santa Fe Plug In Hybrid

[@mwolf9623]

Would this at some point cause stall and no restart?

[@BarboursAutoHelp]

It could

[@mrsamsung8184]

NO way..

[@nickaccardo9494]

I'm sure my veloster's previous owner kept overfilling, it's a 2012 and I'm getting worse than a Chevy v8 milage

[@thurmanpugh7823]

Hello, I have a 2007 Chevrolet Tahoe. I try to put fuel in and the pump keep clicking . It takes me about 30 minutes to get 25 dollars of gas .

[@thurmanpugh7823]

I was told it's the purge Value and canister.

[@oliverriggs4535]

What is the cost of that charcoal canister and how much should I pay for this type of job

[@BarboursAutoHelp]

You'll have to call around. Prices and cost of labor varies.

[@jenniferlambert3886]

It’s 2024 and a local mechanic is quoting $120/hr to clean out system and install vapor canister. Back in 2021, I was paying only $75/hr.

[@BarboursAutoHelp]

Yea prices are going up. $200/ hr some shops.

[@BarboursAutoHelp]

When I first started working on cars our labor rate was $75/hr. Those where the days

[@jeremyfrederick2931]

i got 2004 elentra and i can’t put gas in it

[@BarboursAutoHelp]

Ok

[@sandraperkins3320]

Can you fix my

[@BarboursAutoHelp]

No, can't fix that....

[@embededfabrication4482]

I have this problem and I never overfill my tank

[@HeydaCarreras]

I have 2008 Elantra with176K miles and never have any problem at all. Never overfill the tank either. I put gas when tank is half.

[@thurmanpugh7823]

I wa told it's the purge Value and canister.

[@tricia8656]

Need a how to to fix it.