Has anyone successfully fixed the fuel overflowing problem? - Hyundai Forums : Hyundai Forum
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#1 Old 02-17-2012, 12:10 AM
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Has anyone successfully fixed the fuel overflowing problem?

My Sonata has the fuel overflowing problem that seems somewhat common on these cars.

I've searched the forum and found several threads on the topic, but no one seems to follow up and write how they fixed it.

When I fill it I always use the auto fill setting on the pump handle. The pump will click off when it's full and then it will puke out gasoline down the side of the car and onto the ground. I always set the pump on the lowest setting, which sometimes helps prevent the problem. I bought my Hyundai used and it's always had this problem. I never top off the tank. It doesn't do it every time, but it happens frequently and it's really annoying.

I know people recommend replacing the fuel tank air filter, but I haven't seen anyone post and say this fixed the problem. This link shows how to replace it. It's part number 314533K500 and the MSRP is just under $50.

http://www.amdmaddness.com/sonata/ts...kairfilter.pdf

I'm hoping it's not the charcoal canister, as they appear to be about $200 from Hyundai parts websites.

I'm a DIY'er, so I'll be doing all the work myself.

Last edited by stephen9666; 02-17-2012 at 12:26 AM. Reason: fix title
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#2 Old 02-17-2012, 12:16 AM
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Im currently at 94K and have luckily never had this issue not even once (knock on wood) and i always use the auto pump at the gas station.

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#3 Old 02-17-2012, 06:58 AM
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Just to let you know I experience the same problem. If I don't pay attention with the auto pump will overfill my sonata about 50% of the time. As of now my solution is listen to the pump and stop filling right when the frequency changes.

I would also be interested in a solution if anyone has one though.
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#4 Old 02-17-2012, 09:19 AM
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I have a solution.....kinda
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#5 Old 02-17-2012, 09:19 AM
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I have a coworker that had a similar problem on a different model.
He described the problem as more of a 'burping' of the fuel, so it may be a significantly different problem.

He would fill up the car, and at the last moment, just before the pump would 'click' off, the car would 'burp' or gently splash fuel back out of the fuel door and down the side of his car.
His mechanic finally found that a vent that allows the pressure to release, was stopped up. The pressure would build from filling the tank, and then fuel would be released back out around the nozzle.

/good luck
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#6 Old 02-17-2012, 09:30 AM
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That vent is the fuel air filter, a.k.a. charcoal canister. Sometimes the check valve within the canister stops working properly. Typically the fix involves replacing that canister at a not insignificant price. What was the exact repair made to your coworker's vehicle? Was it a repair or replace? If it was a repair, what exactly was performed during the repair? That's what has never been answered before on any prior post regarding this topic. Inquiring minds want to know!


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#7 Old 02-17-2012, 09:33 AM
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my solution involves a shopvac

I simply switched it to exhaust and blew some air into the tank.
I guess that it cleaned all the passages and stuff but since than everything was ok.
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#8 Old 02-17-2012, 09:47 AM
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Quote:
Originally Posted by ActionMan View Post
That vent is the fuel air filter, a.k.a. charcoal canister. Sometimes the check valve within the canister stops working properly. Typically the fix involves replacing that canister at a not insignificant price. What was the exact repair made to your coworker's vehicle? Was it a repair or replace? If it was a repair, what exactly was performed during the repair? That's what has never been answered before on any prior post regarding this topic. Inquiring minds want to know!
I'll confirm when I next see him (next week-ish). I think his approximate comment was, "they replaced a part and I didn't see the issue again." He did indicate everything was covered under warranty, so it might be a dead end lead. He was only 3 tanks into owning it at the time, so the dealer's option was fix it or own it.
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#9 Old 02-17-2012, 10:50 AM
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Quote:
Originally Posted by ActionMan View Post
That vent is the fuel air filter, a.k.a. charcoal canister. Sometimes the check valve within the canister stops working properly. Typically the fix involves replacing that canister at a not insignificant price. What was the exact repair made to your coworker's vehicle? Was it a repair or replace? If it was a repair, what exactly was performed during the repair? That's what has never been answered before on any prior post regarding this topic. Inquiring minds want to know!

Here's the charcoal canister. $188 plus shipping from an online parts dealer.


I can't find any additional vent valves other than the fuel tank air filter (which is actually a valve assembly) that I listed above.

CANISTER ASSEMBLY for 2007 Hyundai Sonata (314203K600)

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#10 Old 02-17-2012, 11:13 AM
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yjbeach
I thought it was my car, but I think it's more about the gas nozzle. Rented a Kia Soul (horrible car) and this happend traded it in for a convertible mustang and it did the same thing when filling up.

as a response in another thread, when i realize it's getting full, you can hear it, I pull out the gas nozzle put it back in and fill up slowly. Has not happend to my car since.
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