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.