2002 Hyundai Elantra Fuel System Problems

Which parts fail

• Storage › Tank assembly
  3
• Fuel injection system
  1
• Storage › Tank assembly › Filler pipe and cap
  1

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  14%
• 25k–50k
  626%
• 50k–75k
  522%
• 75k–100k
  417%
• 100k–150k
  626%
• 150k+
  14%

Owner reports

Selected complaints filed with NHTSA by 2002 Hyundai Elantra owners, lightly cleaned up (personal details are redacted by NHTSA).

When pumping gas I can only pump about $1.50 worth of gas at a time before it starts coming back out and spilling everywhere. I have tried pumping gas with the car on, not safe I know, and it still only takes about $1.50 before it comes back out. I have spoken to multiple Elantra owners and they all have the same issue. It takes about 20 minutes to fill up. The more gas you get in your tank, the less you can pump. From the research I have done online it's that the EVAP canistor has failed and it's pushing charcoal thru the fuel lines. What if that gets into the fuel tank and the pump sucks it up? Don't think that would be a good thing. But the gas that comes out is starting to eat away the paint because it does it multiple times each time I'm refueling. My vehicle has high miles but alot of people that have this issue say they have below 100K miles.

On the evening of 6/27, my son was driving our 2002 Hyundai Elantra. There were three other passengers in the vehicle. A deer ran in front of the vehicle, and my son veered off to the right (in an attempt to avoid hitting the deer), ran off the shoulder of the road, and into a ditch. The vehicle did not roll over, but it came to rest on it's right side. The two front and two side airbags did not deploy. A fire ignited (almost immediately) in the engine compartment area of the vehicle. All passengers were wearing seat belts, and through the grace of god, all were able to escape the vehicle before it became thoroughly engulfed in flames.this is related to the fuel tank assembly recall 04V178000

I believe my vehicle should be eligible for a campaign acknowledged by Hyundai to correct a defective fuel valve assembly. NHTSA campaign number: 04V178000 www.NHTSA.dot.gov manufacturer Hyundai motor company recall date: apr 06, 2004 potential number of units affected: 263968 description fuel system, gasoline:storage:tank assembly summary some passenger vehicles contain a fuel tank assembly valve that May not close properly. If a vehicle with a fuel tank assembly valve that is not properly closed were to roll over, fuel spillage May occur. Consequence fuel spillage in the presence of an ignition source May result in a fire. Remedy dealers will install an additional fuel tank assembly valve. Owner notification began on June 30, 2004. …

My Elantra's issue is with the gas tank getting over-filled at the gas pump due to a system failure that allows the pump to fill the car until the gas reaches the fuel spigot and then shutting off. Not only does this result in gasoline pouring out of the filler cap, but it also floods the entire gas tank evaporation system. As a result of this, after the car has sat for several hours gas starts draining from the emission canister, leaving a 1 to 2 gallon fuel spill and causing the car to stall or run rough. The entire system ,including the canister, sensor, and solenoid was replaced in August 2008. On September 3 2008 I filled the car up with fuel and the car repeated the same symptoms. The dealership is replacing the parts but insist that the problem is filling the car with fuel too quickly. …

Tl contact owns a 2002 Hyundai Elantra. The fuel rail is leaking gas onto the engine and the check engine light remains illuminated. The dealer stated that this was a common failure and was caused by a manufacturer defect. The dealer performed a diagnostic, which showed that two sensors failed. The dealer stated that this was a very serious issue that could result in a fire. The contact was not allowed to take her vehicle home due to the risk of fire and the severity of the gas leak. Hyundai stated that nothing more could be done because the part was out of warranty. The contact stated that they were not even interested in looking at the part. The vehicle has a 100,000 mile powertrain warranty; however, the manufacturer stated that this particular incident was not covered for that warranty. As a result, other components, such as the gasket, have blown. …

My 2002 Hyundai Elantra gt developed a fuel leak which dripped just behind the left rear wheel. Associsted with this problem the engine began to stall and die. I took the car to my local dealer to have the problem investigated. The service department said that the leak could have been a result of my overfilling the fuel tank. I had just refuled the car but did not "top-off" the tank during the process. Since I am the original owner and the car has over 100,000 miles, I feel that I know how to put gas in it by now. The following Hyundai part#s were replaced: 31420, 31430, 31453, 31135, 31155, 31190 (basically all of the fuel valves/canisters in the system). When I spoke to the service manager, after calling Hyundai customer affairs, he informed me that the valves were replaced due to fuel saturation and as a prevenative measure. …

(1) events leading up to the failure fuel tank was filled at local station the afternoon of 7/18/05. Temperature was 102 f. (2) failure and its consequences, and car was at work between 7 am and 3 pm on 7/19/05 where it sat all day in the parking lot of my work location. Temperature was 107 f. I noticed the back left rear corner leaking fuel at a fast drip rate. It appeared the fuel had been dripping for some time since the spill was around 1 foot in diameter. Car was taken to local dealership after leak noticed. (3) what was done to correct the failure; I.e, parts repaired or replaced (and if old part is available) dealership told me the tank was overfilled and fuel had flooded a chorcoal canister that filters emissions from the gasoline. The canister required replacement. …

Tl contact owns a 2002 Hyundai Elantra. The contact was putting gas into the vehicle when the fuel shut off as if the vehicle was full with fuel, although the tank was not full. In addition, the gasoline would intermittently spill back out from the filler tube. The contact was informed by three different dealers, without performing a diagnostic, that the vehicle would need a closed valve and charcoal canister at her expense. The manufacturer would not provide any assistance. The vehicle was not repaired. The VIN was not accepted. The failure mileage was 58,000 and current mileage was 60,000. Updated 08/13/10. The consumer was unable to put gas in the vehicle unless it was at a very slow rate and gas would shoot out of the vehicle. Updated 08/23/10

After refueling, the car has difficulty starting. The car stall like it has flooded. After numerous attempts trying to start the car (the car sputters), it finally starts. There are several other Hyundai Elantra owners in this area have the same problem. The car initial started with difficulty refueling. After putting in 0.25 - $1.00 worth of gasoline, the pump would click off. Refueling could take up to 5-10 minutes to fill the tank. I have spent over $500.00 dollars trying to fix the problem. I have called Hyundai of America and received little to no assistance.

After refueling, the car has difficulty starting. The car stall like it has flooded. After numerous attempts trying to start the car (the car sputters), it finally starts. There are several other Hyundai Elantra owners in this area have the same problem. The car initial started with difficulty refueling. After putting in 0.25 - $1.00 worth of gasoline, the pump would click off. Refueling could take up to 5-10 minutes to fill the tank. I have spent over $500.00 dollars trying to fix the problem. I have called Hyundai of America and received little to no assistance.

Related recalls

Fuel System complaints in other Elantra years