2002 Hyundai Sonata Fuel System Problems

Your gas tank won't fill normally — the pump nozzle clicks off every few seconds while you're trying to add fuel. After struggling to pump about 3 gallons over 15 minutes, the tank spits gas back out. This problem appears to affect multiple Hyundai Sonatas of this generation, according to gas station attendants you've spoken with.

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHILE ATTEMPTING TO REFUEL THE VEHICLE, THE FUEL TANK FAILED TO ACCEPT THE FUEL. THE VEHICLE WAS NOT TAKEN TO THE DEALER NOR AN INDEPENDENT MECHANIC. NO REPAIRS WERE MADE TO THE VEHICLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 100,000.

FUEL TANK HAS SPLIT IN HALF DUE TO POOR WELDING. SEEMS TO BE VERY SIMILAR TO THE ISSUE WITH 1998 HYUNDAI SONATA. 3-4 GALLONS OF GAS LEAKED ONTO THE GROUND WITHIN A FEW HOURS. *TR

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE REFUELING, FUEL SPILLED OUT FROM THE FILLER NECK. THE CONTACT ALSO STATED THAT THE VEHICLE WOULD ONLY ACCEPT A SMALL QUANTITY OF FUEL BEFORE THE FUEL SPILLED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THERE WAS A FAILURE WITHIN THE FUEL TANK. THE VEHICLE WAS NOT REPAIRED. THE FAILURE OCCURRED INTERMITTENTLY AND HAD OCCURRED MORE FREQUENTLY IN RECENT MONTHS. THE DEALER INFORMED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 04V178000 (FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY). THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 130,000.

NOT MANY SEEM TO KNOW THE SOLUTION HERE. AFTER MUCH RESEARCH ONLINE AND GOING TO A MECHANIC SITE... I SPENT $250 ON A CANISTER,,, VALVE... AND FILTER... THAT WAS SUPPOSE TO FIX THE PROBLEM. NO GO THERE. SO NOW I MUCH CONTACT HYUNDAI AGAIN.... AFTER THEIR ONLY ADVICE WAS TO BRING IT TO A DEALER. THE DEALER SOLD ME THE PARTS AND SAID THAT THIS WOULD FIX IT. JUST WANT TO POINT OUT THAT THERE ARE MANY CONSUMER'S ONLINE THAT ARE SEARCHING FOR AN ANSWER. IMAGINE ALL OF A SUDDEN.... YOUR CAR THAT YOU HAVE MAINTAINED AND KEPT IN GOOD SHAPE... NO LONGER LETS YOU PUT GAS IN THE TANK. *TR

MY VEHICLE HAD A RECALL ON IT IN 2004 FOR THE FUEL SYSTEM, GASOLINE STORAGE AND FUEL SYSTEM, GASOLINE: STORAGE: TANK ASSEMBLY. ACCORDING TO THE HOME OFFICE THE VALVE FIX WAS INSTALLED ON MY VEHICLE IN 2005, I HAVE NO RECORD OF THE INSTALLATION. IN 2011 MY VEHICLE BROKE DOWN AND I HAD IT TOWED TO A SHOP. IT TURNED OUT TO BE THE FUEL PUMP, SO I HAD IT REPLACED WITH A NEW FUEL PUMP I PURCHASED AT AN AUTO SUPPLY SHOP. AFTER THE INSTALLATION OF THE NEW FUEL PUMP MY VEHICLE WOULD HESITATE TO START, THE GAS WAS TAKING TO LONG TO GET TO THE INJECTORS. AFTER RESEARCHING I FOUND OUT ABOUT THE RECALL NOT REMEMBERING ANYTHING ABOUT IT OR HAVING A VALVE INSTALLED. MY QUESTION IS ON SUCH AN IMPORTANT RECALL WHY ISN'T THERE NOTICE AT THE AUTO SUPPLY STORES ON VEHICLES AND PARTS ON RECALL. A RAISED FLAG IF YOU WILL, SO WHEN I (SOMEONE) GO TO PURCHASE THE NEW FUEL PUMP A NOTICE WOULD HAVE COME UP ABOUT THE RECALL. NOW THE HYUNDAI CORPORATION REFUSE TO FIX THIS VERY SERIOUS PROBLEM WITHOUT COST TO ME. I THINK IT IS HYUNDAI RESPONSIBILITY TO GET THE WORD OUT IN EVERY AVENUE AVAILABLE OUT THERE ABOUT THE RECALL. THEY KNEW THE FUEL PUMP WAS BOUND TO FAIL ONE DAY AND HAD TO BE REPLACED. GOING BACK TO THE DEALER (WHO WAS THE ONLY ONE WHO KNEW ABOUT THE RECALL) IS AN OPTION NOT THE ONLY OPTION. *TR

I RECENTLY TOOK MY 2002 HYUNDAI SONATA TO KROGER GAS STATION TO FILL UP MY TANK THAT WAS ON 1/4 FULL. HOWEVER, WHEN I GOT THERE AND STARTED TO PUMP MY GAS IT STARTED OUT BY ONLY PUMPING OUT $0.05 OF GAS BEFORE THE PUMP CLICKED OFF. THEN IT ONLY WAS PUMPING $0.03 OF GAS BEFORE IT CLICKED OFF. I TRIED TO GINGERLY SQUEEZE THE HANDLE TO MAKE IT PRETTY MUCH DRIP OUT, BUT THAT WAS NOT WORKING EITHER BECAUSE IT KEPT SHUTTING OFF. I ENDED UP GOING TO A BP GAS STATION BC I THOUGHT MAYBE IT COULD HAVE BEEN THE KROGER PUMP, BUT THE SAME THING HAPPENED. I ENDED UP PUMPING $16 OF GAS WHICH TOOK ME ABOUT 10 MINUTES TO DO! I HAVE 71,000 MILES ON MY CAR AND JUST STARTED HAVING THIS PROBLEM 2 DAYS AGO. GAS WILL NOT PUMP MORE THEN A FEW CENTS BEFORE IT SHUTS OFF AND I AM WORRIED THAT I WILL RUN OUT OF GAS AS WELL BECAUSE I DON'T WANT TO FILL IT UP EITHER IF PEOPLE HAVE PROBLEM WITH GAS SPEWING OUT. *TR

PROBLEM FILLING GAS TO THE GAS TANK. IT SHUTS OFF SEVERAL TIMES WHEN I PUT GAS. *TR

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT WAS REFUELING THE VEHICLE AS GASOLINE BEGAN TO SPEW FROM THE FILLER TUBE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS INFORMED THAT SHE WOULD NEED A REPLACEMENT OF THE FUEL TANK VALVE. THE VEHICLE WAS NOT REPAIRED. AN AUTHORIZED DEALER WAS NOTIFIED AND THE CONTACT WAS INFORMED THAT HER VEHICLE WAS NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER: 04V178000 (FUEL SYSTEM, GASOLINE: STORAGE: TANK ASSEMBLY). THE FAILURE AND CURRENT MILEAGE WAS 150,000. UPDATED 01/24/11 *BF UPDATED 02/03/11

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. THE CONTACT STATED THAT THE VEHICLE WAS LEAKING FUEL ONTO THE GROUND FROM A STRESS FRACTURE IN THE FUEL TANK. THE DEALER ADVISED THE CONTACT THAT THE VEHICLE WAS NOT UNDER RECALL AND ANY REPAIRS WOULD BE AT THE CONTACT'S EXPENSE. THE VEHICLE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS APPROXIMATELY 242,000.

WAS DRIVING 2002 SONATA WITH CHILD IN CAR DAUGHTER GOT DIZZY FROM GAS FUMES GAS TANK WAS LEAKING FROM TOP OF TANK,CALLED HYUNDAI MOTOR CORP SAID CAR WASN'T COVERED OUT OF WARRANTY,TOOK IT TO THE DEALER WAS TOLD CAR GAS TANK HAD TO BE DROPPED TO FIND THE PROBLEM,HYUNDAI REFUSED TO PAY FOR TANK TO BE DROPPED, FINALLY TOOK IT TO BE FIXED AT A LOCAL SERVICE PERSON ,FOUND THE GAS TANK WAS LEAKING FROM THE MIDDLE OF THE TANK AT THE HALF WAY MARK,HE FOUND THE TANK WAS LEAKING TO A STRESS CRACK ON THE TANK,I FIND THIS TO BE A SAFETY ISSUE REGARDING THIS MATTER,THERE IS A SAFETY REGARDING STRESS CRACKS ON THE SONATA PLEASE CALL ME AT [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

2002 HYUNDAI SONATA, WHEN FUELING VEC CONSTANTLY CUT OFF THE FUELING TAKES ABOUT 10 - 15 MIN'S TO FUEL WITH A 1/4 TANK OF GAS IN THE VEC BEFORE RE-FUELING. THIS HAPPENS NO MATTER WHAT STATION I'M RE-FUELING. *TR

TL* THE CONTACT OWNS A 2002 HYUNDAI SONATA. WHEN FUELING THE VEHICLE, GASOLINE REGURGITATES FROM THE FUEL TANK. ALSO THE CHECK ENGINE WARNING LIGHT WAS ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. SOMETIMES THE VEHICLE WILL HESITATE WHEN ATTEMPTING TO ACCELERATE, AS IF THERE WAS NO FUEL AVAILABLE. THE DEALER WAS NOTIFIED, AND A TECHNICIAN CONCLUDED THAT SHE WOULD HAVE TO PAY $900.00 TO REPAIR THE VEHICLE. NO REPAIRS WERE MADE.. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 82878.

ENGINE LIGHT KEEPS COMING ON. TOOK FOR REPAIR AND THE CODE STATES THERE IS A PROBLEM WITH THE AIR/FUEL MIXTURE. AUTO REPAIR SHOP ASKED IF WE TURNED THE GAS CAP ATLEAST 3 TURNS AFTER LAST FILL--YES WE DID. WE PREVIOUSLY WERE NOT ABLE TO PUMP GAS THE PUMP WOULD SHUT OFF EVERYTIME WE TRIED TO PUMP. AUTO REPAIR REPLACED CHARCOAL FILTERS IN THE NECK OF THE FUEL TANK HAS RUN FINE SINCE THIS ENGINE LIGHT STARTED. *TR

CAN'T PUT GAS IN MY TANK, I WOULD HAVE TO SLOWLY PUT IT IN AND SOMETIMES I ONLY CAN GET 4-6 DOLLARS ALTHOUGH I HAVE DRIVEN ALL DAY AND MY GAS HAND STATES THAT I AM ON EMPTY. I REALLY FEEL THAT THIS IS A SAFETY HAZARD, I COULD POSSIBLE RUN OUT OF GAS WHILE DRIVING AND CAUSE A COLLISION, OR JUST OVER FLOW MY GAS TANK, THIS I AM VERY, VERY CONCERN ABOUT. PLEASE HELP ME. *TR

NO CONCERN WITH INCIDENT. CONCERN WITH DEFECTS WITH FUEL TANKS AND FUEL TANK FUNCTIONS. *TR

WE HAVE BEEN HAVING THE CAR 4 YEARS WHEN WE FIRST GOT THE CAR THERE WAS A STRONG GAS SMELL AND STILL DOES WHEN WE TOOK IT TO DEALERSHIP. THEY COULDN'T FIND PROBLEM. KNOW I FIND THIS SO NOW I KNOW WHAT THE PROBLEM IS AND I'M TRYING TO TAKE CARE OF IT. *TR

ON 10/10/07 MY WIFE DROVE APPROXIMATELY 8 MILES HOME FROM WORK AND PARKED HER 2002 HYUNDAI SONATA IN THE GARAGE. ABOUT 5 MINUTES LATER SHE NOTICED THE SMELL OF GASOLINE IN THE HOUSE, AND RETURNED TO THE GARAGE TO INVESTIGATE. GAS WAS POURING FROM THE GAS TANK FILL DOOR ON THE CAR. THE GARAGE FLOOR HAD A 6' DIAMETER PUDDLE UNDER THE CAR. SHE OPENED THE GARAGE DOOR AND BACKED THE CAR OUT ONTO THE DRIVEWAY AND POSITIONED A CATCH PAN UNDER THE CAR. APPROXIMATELY 1/2 GALLON OF GAS WAS IN THE PAN AFTER SHE OPENED THE FILLER CAP TO RELIEVE THE PRESSURE. THE CAR HAD LESS THAN 3/4 TANK OF GAS AT THE TIME. WE DELIVERED THE CAR THE DEALER THAT NIGHT FOR REPAIR. THEY RETURNED THE CAR ON 10/12 AFTER REPLACING A CANISTER AND VALVE ASSEMBLY UNDER WARRANTY. THIS IS THE SECOND TIME THIS HAS HAPPENED, WITH THE FIRST TIME BEING APPROXIMATELY 18 MONTHS EARLIER, ALSO COVERED UNDER WARRANTY. WE FEEL VERY LUCKY THAT WE DIDN'T HAVE AN EXPLOSION OR FIRE, WHICH WOULD HAVE BEEN A LIKELY EVENT WITH THE AMOUNT OF RAW GAS AND FUMES IN THE GARAGE HAD WE HAD A GAS WATER HEATER. IT IS NOW FOUR DAYS LATER AND WE STILL HAVE NOT GOTTEN THE SMELL OF GASOLINE OUT OF THE HOUSE AND GARAGE. MY WIFE IS ALSO AFRAID TO PARK THE CAR IN THE GARAGE. JUST TO ADD TO THE WHOLE EXPERIENCE, THE SERVICE WRITER WAS RUDE TO MY WIFE WHEN SHE PICKED UP THE CAR, AND WE NOW HAVE A DENT IN THE LEFT REAR DOOR. *JB

DT*: THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE HESITATED AND WAS HARD TO SHIFT. ALSO, WHEN ATTEMPTING TO FILL THE GAS TANK, THE GAS SPILLED OUT WHILE PUMPING. THE VEHICLE WAS DRIVEN TO THE DEALER WHO COULD NOT DUPLICATE THE PROBLEM.

WHEN ATTEMPTING TO FILL GAS TANK THE PUMP CONTINUES TO SHUT OFF AFTER PUMPING ONLY SMALL AMOUNTS OF GASOLINE. WHICH PREVENTS ME FROM FILLING MY VEHICLE. I HAVE MADE NO ATTEMPTS TO REPAIR ATTEMPTED TO FILL THE VEHICLE AT SEVERAL SERVICE STATIONS WITH THE SAME RESULTS. *NM

VEHICLE WAS TAKEN TO DEALER FOR FUEL CUT VALVE RECALL. SINCE NEW FUEL CUT VALVE WAS INSTALLED VEHICLE WILL NOT START AFTER REFUELING. DEALER REPLACED NEW FUEL CUT VALVE, PROBLEM RECURRED. DEALER CAN NOT DUPLICATE FAILURE. FAILURE HAS OCCURRED WITH THE CONSUMER AFTER EVERY REFUEL WITH NO EXCEPTIONS. *NM