All cars » Hyundai » Sonata » Gasoline Fuel System » Tank Assembly

Tank Assembly Problems of Hyundai Sonata - part 1



Hyundai Sonata owners have reported 53 problems related to tank assembly (under the gasoline fuel system category).

car image   Tank Assembly problem of the 2000 Hyundai Sonata 1
Failure Date: 10/07/2013

When I try to fill the vehicle with gas it stops every few cents, simular to when the gas tank is full, even when it is on empty. It takes upwards of 30-45 minutes to fill the gas tank. Sometimes the gas gauge is on low when I try to fill it up but it stops filling so often that I have to change pumps to be able to fill my tank to full. I have also had the gas spill out the top of the tank just by trying to put enough gas in my vehicle to make it home. I have done quite a bit of research on the issue and have found it to be a common problem among Hyundai vehicle. We bought this car to have a good, reliable vehicle for our daughter to drive. I do not feel safe allowing her to go on a long road trip when she has to spend so long filling the car with gas.

See all problems of the 2000 Hyundai Sonata.

car image   Tank Assembly problem of the 2009 Hyundai Sonata 2
Failure Date: 11/16/2011

The contact owns a 2009 Hyundai Sonata. The contact was refueling the vehicle when fuel started to escape the filler tank and splash on the contact. The contact did not take the vehicle to the dealer for diagnostics or repairs. The manufacturer was not made aware of the failure. The failure mileage was 92,000.

See all problems of the 2009 Hyundai Sonata.

car image   Tank Assembly problem of the 2005 Hyundai Sonata 3
Failure Date: 11/13/2011

The contact owns a 2005 Hyundai Sonata. The contact stated that the rubber seal around the fuel tank failed, causing fuel to leak. The vehicle was taken to the dealer who replaced the fuel tank. The manufacturer was contacted who stated that they would take the liability for the cost of the replacement parts but the contact would be responsible for the labor costs. The VIN was unavailable. The failure mileage was 78,000.

See all problems of the 2005 Hyundai Sonata.

car image   Tank Assembly problem of the 2005 Hyundai Sonata 4
Failure Date: 03/19/2011

Check engine light goes on (and produces code of p0441) . From that point forward, whenever you add gas to the tank, the car hard starts and continually stalls. Purge control valve replacement becomes necessary to eliminate the problem. Online research revealed that this is a common problem with many Hyundai (perhaps all) models, and thuerefore a recall is in order.

car image   Tank Assembly problem of the 2002 Hyundai Sonata 5
Failure Date: 03/13/2011

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.

See all problems of the 2002 Hyundai Sonata.

car image   Tank Assembly problem of the 2011 Hyundai Sonata 6
Failure Date: 02/01/2011

There has been an odor of gasoline entering the passenger cabin of the vehicle. I noticed it started at my last gas fill up. I did not top off the tank. The pump shut off when full, and I stopped pumping. This odor starts when sitting at a stoplight and stays in the cabin until I'm moving again. I thought it only started when I came to a stop at a light and sat for a couple of minutes, however when I was driving home in a blizzard yesterday at slow speeds (15-25 mph) continous, the smell was constant. Lately it is so bad I have to roll down the window. One time, I almost pulled over at the roadside, and was going to get out of my car to get fresh air, but there was too much traffic. There are no fuel leaks that I can find. No standing fuel under the car after I park. It has done this most times I've driven the car to more or less degrees, but not everytime - most times. I have not been to a dealer yet, but I will be taking it in to have it checked. Apparently there are quite a few other owners of this car who have noticed this same thing based on a Hyundai internet forum. I read it previously in this forum, but I did not have this problem until lately. I can't imagine that this is not a safety issue with the gas odor. Not only are passengers having to inhale these fumes, but I'm wondering if it could be a potential source of fire/explosion. Here is a link to the forum where people are claiming to have the same problem. I'm not so sure these are just very few, isolated incidents. I see a problem starting to emerge. Certainly, I will not drive a car that I have to smell gas fumes nearly everytime I drive it, not even to mention the profound safety problem this may cause. . Read more...

See all problems of the 2011 Hyundai Sonata.


car image   Tank Assembly problem of the 2011 Hyundai Sonata 7
Failure Date: 01/02/2011

Fuel smell 2011 Sonata limited no turbo. Very noticeable fuel smell in the cabin after car is warm and at idle or when moving less than 10 mph. Have heard/read similar complaints related to overfilling gas tank, this tank has never been overfilled. Opened hood after car warm and gas smell is very strong. Opened trunk and there is no smell. Long idle when warm and the car is very uncomfortable to be in especially with young kids. Possible safety issue.

car image   Tank Assembly problem of the 2005 Hyundai Sonata 8
Failure Date: 01/02/2011

My vehicle has been shutting off or stalling after filling it up with gas. It began over a year ago with sporadic incidents and has progressed to occurring every time I put gas in my car. The first happened a few months after I bought my car. I was exiting a gas station after filling up. As I reached the main street and was pulling out onto the road, my car completely shut off and began rolling into the busy road. I turned it off, then on and it began running again. This happened 5 more times over the span of 1yr 4 mos, each time only after I put gas in my car. It has now progressed to not starting at all after I put gas in my car. Recently, I filled up my car and when finished , it would not start. I tried multiple times, giving the car breaks in-between and it either turned on then sputtered and died or didn't turn on at all. It took 30mins for me to start my car but I was eventually able to leave the gas station. I did some research and I discovered that this was a common problem for Hyundai Sonatas of the same year (and even some other models/years). The next time, I didn't fill up all the way but put in 1/4 tank of gas. Once again, my car did not start for around 25 minutes. That day, I paid $65 to have my car looked at by Hyundai and was told that I needed approximately $845 worth of repairs/replacements of my canister, canister valve, purge valve, and my idle control vent valve (not including the $219 labor fee necessary if charcoal bits have gotten into my gas tank). I have ever heard of any of these problems, much less believe that it should be the responsibility of the consumer to repair a commonplace problem with Hyundai cars. This problem is dangerous regarding the car's sporadic shutoffs which have happened to me in multiple compromising situations. This puts the consumer's life in danger rolling into the street and being stranded in my case.

car image   Tank Assembly problem of the 2003 Hyundai Sonata 9
Failure Date: 11/15/2010

One day, while fueling my 2003 Hyundai Sonata, the pump clicked off after 1 gallon. From then on, it wouldn't let me fill more than 1 or 2 gallons without clicking off. Since that day, this problem occurs every time I refill and every time my tank is near empty or half empty, so I know that's not the issue.

See all problems of the 2003 Hyundai Sonata.

car image   Tank Assembly problem of the 2003 Hyundai Sonata 10
Failure Date: 11/05/2010

When trying to fuel vehicle the nozzle will click off at 1 or 2 gallons. I have to repeatedly take the nozzle out and keep trying to refuel. The vehicle was taken to the dealer in which they dropped the gas tank and did something. I picked the vehicle up and went to refuel and the same problem still exist. Just out of money. I see this is an on-going problem with this vehicle. There should be a recall.


 
car image   Tank Assembly problem of the 2002 Hyundai Sonata 11
Failure Date: 11/01/2010

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 updated 02/03/11.

car image   Tank Assembly problem of the 2008 Hyundai Sonata 12
Failure Date: 10/31/2010

There is no shutoff when filling the gas tank. Once the tank is full or approaching full, gasoline forcefully spews out and douses the individual while holding the nozzle.

See all problems of the 2008 Hyundai Sonata.

car image   Tank Assembly problem of the 2002 Hyundai Sonata 13
Failure Date: 09/10/2010

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.

car image   Tank Assembly problem of the 2002 Hyundai Sonata 14
Failure Date: 09/03/2010

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).

car image   Tank Assembly problem of the 2004 Hyundai Sonata 15
Failure Date: 06/23/2010

The contact owns a 2004 Hyundai Sonata. While adding fuel to the vehicle the contact noticed there was a small valve on the outside of the fuel tube that fractured and possibly had fallen into the fuel tank. The contact smelled a strong fuel odor emitting in the interior of the vehicle after it was started. The manufacturer was made aware of the failure and informed the contact that the vehicle was not covered under the warranty; therefore, he would be responsible for the diagnostic cost. The vehicle was not repaired. The approximate failure mileage was 47,000.

See all problems of the 2004 Hyundai Sonata.

car image   Tank Assembly problem of the 2009 Hyundai Sonata 16
Failure Date: 02/18/2010

1) was making a right turn into a parking lot. There was a slight incline. There was a quarter of a tank of gas in the car. 2) the engine appeared to turn off, however the electronics never turned off. Power steering was no longer available once the engine stopped running. 3) I attempted to restart the car, but it wouldn't start. You could hear the engine trying to start. I placed the car in neutral and pushed it into a parking space. About 5 minutes later I successfully restarted the car. I had the car towed to the dealership and they could not diagnose the problem or detect that anything had occurred.

car image   Tank Assembly problem of the 2009 Hyundai Sonata 17
Failure Date: 11/12/2009

There has been an odor of gasoline entering the passenger cabin of the vehicle. I noticed it is "worse" when I fill the vehicle with gas but the problem occurs more frequently than that. I do not top off the tank. The pump shuts off when full, and I stop pumping. This odor starts when sitting at a stoplight and stays in the cabin until I'm moving again. I thought it only started when I came to a stop at a light and sat for a couple of minutes, however when I was driving home at slow speeds (15-25 mph) continuous, the smell was constant. Lately it is so bad I have to roll down the window. One time, I almost pulled over at the roadside, and was going to get out of my car to get fresh air, but there was too much traffic. There are no fuel leaks that I can find. No standing fuel under the car after I park. It has done this most times I've driven the car to more or less degrees, but not everytime - most times. I have not been to a dealer yet, but I will be taking it in to have it checked. Apparently there are quite a few other owners of this car who have noticed this same thing based on a Hyundai internet forums. But I did not have this problem until 2010. I can't imagine that this is not a safety issue with the gas odor. Not only are passengers having to inhale these fumes, but I'm wondering if it could be a potential source of fire/explosion. I'm not so sure these are just very few, isolated incidents. I see a problem starting to emerge. Certainly, I will not drive a car that I have to smell gas fumes nearly every time I drive it, not even to mention the profound safety problem this may cause.

car image   Tank Assembly problem of the 2002 Hyundai Sonata 18
Failure Date: 08/19/2009

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.

car image   Tank Assembly problem of the 2004 Hyundai Sonata 19
Failure Date: 06/23/2009

I have a 2004 Hyundai Sonata v6 that gives me problems when I fill the gas tank up. I know that this might sound crazy but, when I go to start the car, it will not turn over. I recently had a major tune-up done on the vehicle along with changing the timing belt. When I fill up my car, I have to include an additive such as gas treatment, lucas gas treatment, fuel cleaner, etc. I had my mechanic look at the vehicle four times and he has found nothing wrong with the vehicle. I ask for assistance to diagnose the problem and would you recommend bringing the car to a dealer. Please help! thank you. The system would not allow me to enter my VIN number.

car image   Tank Assembly problem of the 2002 Hyundai Sonata 20
Failure Date: 04/19/2009

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.

car image   Tank Assembly problem of the 2002 Hyundai Sonata 21
Failure Date: 01/01/2009

Problem filling gas to the gas tank. It shuts off several times when I put gas.

car image   Tank Assembly problem of the 2002 Hyundai Sonata 22
Failure Date: 07/01/2008

No concern with incident. Concern with defects with fuel tanks and fuel tank functions.

car image   Tank Assembly problem of the 1998 Hyundai Sonata 23
Failure Date: 11/28/2007

Crack in gas tank discovered after several removals of tank to replace hoses, then clamps. Replaced 1998 tank with used tank from 1996 model. Within 3 month replacement tank was leaking from crack in same area as before. Discovered recall on this model and took vehicle to local dealer. Dealer refused to honor recall due to service performed in 2006 where they (supposedly) added check valve to prevent gas tank cracks from developing. Appeals to regional and national Hyundai offices were also rejected. Dealer sent me away with seriously leaking / dangerous tank.

See all problems of the 1998 Hyundai Sonata.

car image   Tank Assembly problem of the 1998 Hyundai Sonata 24
Failure Date: 06/07/2007

The contact owns a 1998 Hyundai Sonata. The contact smelled gas and noticed a gas leak coming from the fuel tank. Recall # 00v314001 (fuel system, gasoline:storage:tank assembly) was found. The dealer stated that there was a hole in the gas tank, but refused to repair it because the vehicle was not included in the recall. The contact felt they should replace the gas tank as stated in the recall. The current and failure mileages were 117,000.

car image   Tank Assembly problem of the 2002 Hyundai Sonata 25
Failure Date: 12/04/2006

: 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.

Other Common Gasoline Fuel System related problems of Hyundai Sonata