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.