2002 Elantra ongoing gas fill-up issue
 

I have posted this before but have since had some more information so i'm
hoping that this may help.

I've had a long on-going problem when filling up the gas tank the pump
clicks off repeatedly. This has nothing to do with the pump and everything
to do with the car.. That's been figured out a LONG time ago.

I had a code P0441 which related to the purge valve which was replaced
yesterday. From my understanding this is more emmissions realted and
although part of the same system has little to do with my problem.

On fixing the P0441 code i now get P0445. The dealer performed a smoke
test which proved fruitless. The gas cap is also a non-issue. They also
checked another valve near the charcoal canister which was also fine.

However, talking to another senior tech he did say it could be the
charcoal canister that's cloged with gas due to a prior overfilling.

It has been overfilled in the past before i knew this wasn't something
that should be done. He thinks that because the canister is full of gas
(he said it did smell like it was) that this could be a possible cause?

The canister itself is about $250cdn plus time to install.. I'll give the
dealer credit as the tech said they could get one in and try it first to
see if it an issue as he said he wouldn't want to charge me for a part i
don't need. Thumbs up to them for that.

After forking out close to $700 yesterday for other work.. i'll have to
wait to follow this up but any comments on this especially from
hyundaitech would be very much appreciated. ;)

Thanks.

Re: 2002 Elantra ongoing gas fill-up issue
 

P0445 indicates an electrical problem (short) in the purge valve circuit.
Perhaps there's a problem with the one that was installed. Regardless,
the purge valve cannot cause your tank to be hard to fill. Similarly, a
smoke test won't show any problems since you don't have a leak, but rather
lack the ability to vent.

The charcoal canister is a plausible cause, as is the canister filter. In
fact, they're the two most frequent causes of your problem. If either is
blocked, it'll cause the vapor to be unable to vent out through the
canister as designed. There are many other potential causes, however.
There could be a sticking valve in the fuel tank. The metal lines could
be crimped. The rubber hoses could be twisted shut. There could even be
a problem with the filler neck or filler hose, or with the tank itself.

If you do replace the canister, I'd recommend replacing the canister
filter at the same time, since you're already in that area.

Re: 2002 Elantra ongoing gas fill-up issue
 

I took a look on the schismatics on hmaservice and i see the vapour
canister but don't see the filter you're referring to. Does the filter go
in the canister.

It looks very easy to change a few bolts and 4 hose connections. If i
change it myself is there anything i should watch out for? (Apart from the
obvious - connecting the hoses in the right order)

Re: 2002 Elantra ongoing gas fill-up issue
 

It's pretty simple. The canister filter is located inside the same plastic
protector that houses the canister and close valve. If you have a new
filter in your possession when you change the canister, there won't be any
mistaking the filter. In fact, if you replace the canister only, you'll
need to transfer the filter from the old canister to the new one.

Re: 2002 Elantra ongoing gas fill-up issue
 

Fixed hopefully !

Switched out the vapour canister tonight went to fill up and it worked
normally with no problems. I reset the code so we'll see if any lights
appear over the next few days or so.

Thanks for the input as always it was of help. Hopefully this long running
saga is over.

A note to everyone out there.. Don't top up your tank once it clicks..
trust me it's not worth it !!!

Re: 2002 Elantra ongoing gas fill-up issue
 

jmh_ottawa wrote:

Fixed hopefully ! Switched out the vapour canister tonight went to fill up and it worked normally with no problems. I reset the code so we'll see if any lights appear over the next few days or so. Thanks for the input as always it was of help. Hopefully this long running saga is over. A note to everyone out there.. Don't top up your tank once it clicks.. trust me it's not worth it !!!

Not sure about that, always top to the next dollar in both my cars, 02 Elantra, 03 Santy, never had a problem ....
Only problem in the Elantra was running with low gas in tank, was down to 1/2 a gallon, add 1 gallon to hold until get to cheap gas station (about 10 days in between, the Elantra is the city car, short drives) went down to 3/4 a gallon before fill up, Check Engine came on before fill,
 P0456 (slow leak) ... reset it after fill, now OK.
Way too sensitive stupid computer, Yup, do not trust it too much at all.

Re: 2002 Elantra ongoing gas fill-up issue
 

You'd likely only create a problem if topping up more than that. Up to the
next dollar isn't too much... trying to squeeze in 3-4 more is.

From what i gather if you considerably overfill the gas will leak into the
vapour canister and if enough gets in over several fill ups the vapours
from the tank won't have anywhere to go.

Re: 2002 Elantra ongoing gas fill-up issue
 

That's exactly correct, jmh.

Re: 2002 Elantra ongoing gas fill-up issue
 

jmh_ottawa wrote:
> You'd likely only create a problem if topping up more than that. Up to the
> next dollar isn't too much... trying to squeeze in 3-4 more is.
>
> From what i gather if you considerably overfill the gas will leak into the
> vapour canister and if enough gets in over several fill ups the vapours
> from the tank won't have anywhere to go
Well, that will be more than 1 gallon extra ...... yup, probably a messy
problem, gas will have to go some place, canister, side of your car,
floor, etc.
In those conditions, you are right: " NOT recommended "