Can't Fill Up Gas Tank - Inspected Charcoal Canister, Removed Restrictions In Lines Already - Hyundai Forums : Hyundai Forum

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Old 09-08-2009, 01:35 PM   #1 (permalink)
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My wife has a 2002 Accent with 117K miles on it. Fuel pump has never been replaced, but fuel filter and PCV valve changed about 5K miles ago.

The problem started when I added some BG44K fuel injector cleaner to the gas tank by way of a funnel. There was no discernable change in the car until my wife tried to fill up with gas...it kept clicking off. This has been going on for some time and it's pretty annoying.

So I do some research and learned that there could be charcoal pellets in the venting lines coming from the charcoal canister. I removed the charcoal canister from the car, and sure enough, there were a lot of little pellets in the hoses. I disconnected all the hoses and shook out all the pellets (not from the box, from the hoses) and connected everything back up. I went to the gas station and...nope, still clicking off every 2 seconds.

Then I removed the fuel filler neck from the car and inspected it. There were no restrictions in the main tube and no restrictions in the tube that runs up the main tube and loops back down the other side. [b]The blue/black check valve was a little clogged, so I blew it out with compressed air. I reinstalled it with the arrow pointing towards the charcoal box - meaning air and/or fuel can travel towards the canister only. Should the check valve be facing the other way? I assume it should, so gases can vent from the canister to the atmosphere - I don't want air/fuel going into the box, right?

I did find a restriction in one of the smaller hardlines that is connected to the fuel filler neck - it was more charcoal pellets. It was really clogged and I had a hard time removing them. At this point, there are no clogs, restrictions or charcoal pellets in any of the lines (including the charcoal canister), yet I still cannot properly fill the tank. Is the check valve now my only problem?

My wife told me today that the car "felt funny" and didn't "go when she stepped on the gas". Another symptom of the check valve?

I'm not entirely sure why adding fuel injector cleaner would have caused this problem.

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Old 09-08-2009, 07:37 PM   #2 (permalink)
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Another item you need to look at is the purge valve. Mine is located under the hood next to the brake booster. I have no idea about your Accent. Also the charcoal pellets don't just stop coming when you clean them out. I was dumping a handful of pellets out every week for months. I only got it to stop by sealing up the canister openings with fiberglass mesh screen. Even after all that, I still couldn't fill up too fast. It has gotten better over time, though.
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Old 09-09-2009, 09:21 AM   #3 (permalink)
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I haven't checked the purge valve yet, I might remove it and see if it's clogged.

I think I may have fixed the problem. I reversed the check valve and dumped some more pellets out of the DM-TL device. I left the battery unplugged while I was messing with everything to clear the error codes. After I was done, I plugged the battery back in (no CEL) and drove to the gas station. The tank was pretty full, but I was able to put in a whole gallon without clicking off! Normally, it would click off after the first 1/4 gallon and then every 1/10 gallon after that. I did get a CEL immediately after filling up though - it could be an unrelated problem though, who knows.

I guess I'll periodically check the hoses coming from the canister to see if they feel crunchy from being clogged with pellets.

I don't know what my wife was talking about though, the car feels fine. It's not shaking or making weird noises (other than the hiss coming from the cracked exhaust manifold) and it accelerates normally. I have no idea if the gas mileage has been really bad or not, because it's my wife's car, and she wouldn't know if she was getting 300 mpg or 6 mpg.

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Old 09-18-2009, 09:15 AM   #4 (permalink)
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I checked the purge valve the other day and it was clear. I don't think there are any restrictions in any of the fuel or vapor lines at that point.

I tried to fill up the tank, and while it worked, I was still getting some gurgling and the nozzle clicked off a few times. A lot better than it was, but still not perfect. I'm not really sure what else to do, other than replace the whole charcoal canister thing at this point. The canister can't really be "broken" though, since it's just a box with pellets in it. I'm guessing either the filter in the charcoal box is clogged or the DM-TL device is dead.
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Old 09-18-2009, 09:45 AM   #5 (permalink)
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QUOTE (doinkmobb @ Sep 18 2009, 09:15 AM)
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I checked the purge valve the other day and it was clear. I don't think there are any restrictions in any of the fuel or vapor lines at that point.

I tried to fill up the tank, and while it worked, I was still getting some gurgling and the nozzle clicked off a few times. A lot better than it was, but still not perfect. I'm not really sure what else to do, other than replace the whole charcoal canister thing at this point. The canister can't really be "broken" though, since it's just a box with pellets in it. I'm guessing either the filter in the charcoal box is clogged or the DM-TL device is dead.
If you take the charcoal canister out, you can easily clean the canister filter and the canister valve.

For a time I had a little procedure for fill up.

I would simply pull up to the gas pump, pull off the bigger hose to the charcoal canister, and that would allow me to fill up till the cows come home. Upon finishing the fill, I would put the hose back on.

You can do it as a test, then you'll know the canister is not passing vapors (at least not very well). Just pull off the hose clamp so you can disconnect the hose in a hurry.

Eventually, I was able to get my system to almost work 100% by putting some mesh tape over the openings of the canister, thus charcoal couldn't escape anymore. I don't need to pull off the hose to fill up anymore, but it does take time to put in the last few gallons.
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Old 02-08-2010, 01:25 PM   #6 (permalink)
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Checked codes with a scanner from the auto parts store, getting P1402 and 1403. I guess that means I need to replace DMTL thing and possibly the canister itself.

I can pump 2-3 gallons in at full bast without any hesitation, then I can fill the rest of the tank at 50% nozzle capacity without clicking off. Waaay better then before, and I'm not sure I really feel like spending the money to make the CEL go away. I squeezed the hoses by the canister and they feel clear of charcoal pellets.
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Old 02-08-2010, 02:02 PM   #7 (permalink)
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Yeah, mine is the same way. I covered the openings on the canister with mesh screen to keep the charcoal in the canister. It's been good for a year, but sometimes I get gas at a strange place and it shuts off repeatedly.
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Old 04-28-2010, 12:34 PM   #8 (permalink)
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OK, so filling up the tank is becoming a pain again. I might have to break down and actually fix the problem instead of just making it less bad. Hyundai doesn't list a 'DMTL' part, but I think it may be the 'Diagnostic Unit' under the Fuel Systems Components subsection.

This pic is taken from hyundaipartsonline.com.


I believe what I need is part #25, the Diagnostic Unit, for $140. This info is under 2002 Accent Collision catalog -> fuel system -> fuel system components.
The part # is 3144025510.

Can anybody confirm this?
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Old 10-09-2011, 08:44 PM   #9 (permalink)
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My photo of the Diagnostic Module.
Yes, P/N 3144025510 is correct for 2002.
Retail List is $321. I saw a price of $278 on hyundaipartsonline.com

I would want to know the module was really defective before plunking down the cash.

If you're interested, I worked up a diagram of the internals here:




Jim
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File Type: jpg Module.jpg (45.9 KB, 112 views)
File Type: gif Self_Diagnosis_Module.gif (33.6 KB, 110 views)
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Old 11-14-2011, 12:52 PM   #10 (permalink)
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I had the DMTL code, but replaced the whole canister assembly and purge valve with replacement from the salvage yard. Replaced all the hoses and I have yet to have a problem with it. Don't believe it's the Diagnostic module until all else is ruled out.
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