Question about 2004 Hyundai Santa Fe

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Car won't start after filling up the gas tank.

Immediately after putting gas into the car, the car won't restart. I've been stuck several times next to the gas pump. After a while, and more cranking, it will finally start and then runs fine until I fill the tank again. Ideas? 2004 Hyundai Santa Fe, 3.0 liter (middle size) engine.

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Just helped a friend fix this exact same issue on his 2004 hyundai santa fe. Replaced the purge control valve - a $39 part, even from the dealer. Had to get our hands dirty, but it took literally one single hour to replace the part. Filled it up immediately afterward and no more starting problems. Part is located directly behind the manifold - top, rear of the engine compartment - just between the engine

Posted on Aug 16, 2010

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  • lkrav3 Aug 16, 2010

    Sorry about the post above... it got cut off for some reason. Here's another try...
    I recently helped a friend fix this on their 2004 Santa Fe with the 2.7L engine.
    We purchased the part at a Hundai dealer, in stock, for the same or less (only $39 + tax) as quoted at O'Reilly's where it would have been a same-day special order. (If, btw, you are asked at a parts store about whether you need the straight one or the one w/ the elbow... the '04 2.7L uses the straight one. In fact the dealership only listed the straight one for all but I think the 3.5L...)
    Here's how the rest of the job progressed:
    Disconnected the battery first thing.
    Removed the big plastic cowling or cover over the main part of the engine. Six small screws on top hold it down - needed an extension on the socket to get to them, but this was very easy.
    The purge control valve on the 2004 2.7Liter Santa Fe was directly behind the manifold?. At the very back of the engine - between it and the firewall, close to the top.
    One hose (roughly 1/2" dia.) attaches to it from the left/drvrs side and one attaches to it going toward the pssgr side. There is also an electronic connection plugged into it.
    We had to remove another small electronic connector plugged into another part to gain better access. Most difficult part of this job is reaching back there and working round a couple of cables that run across the top.
    First disconnected the elec. plug to the valve.
    Then loosened/removed the clamp from the hose on first one end of the valve, then the other.
    The valve itself sits in a sort of rubber sleeve which has a slot underneath that holds the whole thing in place. Work the rubber sleeve toward the drivers slide to get it loose. Remove the valve from the sleeve, and replace it with the new part. Reconnect the hoses, slide the rubber sleeve back onto its "holder". Replace the engine cover. Re-connect the battery.
    Head to a gas station for a fill-up and confirmation that your starting problems are fixed.

  • David Lechner Apr 28, 2011

    just wanted to agree with this solution. However, on my 2004 hyundai santa fe there is a second purge control valve under the car in front of the gas tank. I replaced that one first. Wrong! Don't make the same mistake, just replace the one behind the engine. Thanks

  • terrys394 Sep 03, 2011

    Just had the same problem in my 2003 Hyundai Santa Fe. Thanks for the tip on the repair. I went to Pep Boys and they had the part for $37 but said it would be 5 days shipping. Next day was available for about 12 bucks more. I went to the dealer and got the part, it was in stock, for $41 after tax. Brought the part to the local repair shop and they charged me 1 hour labor, $95 to install it. It was actually repaired in less than 20 minutes.

  • Jrez Apr 30, 2015

    So which part did you buy?
    was it the purge valve solenoid or purge vent/ purge canister? I guess there is 2 different parts - lol purge-solenoid-valve-911-800/10017804-P#
    or canister-purge-valve-cp620/10101059-P?searchTerm=purge+valve+




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It sounds almost like you're getting air or into the fuel lines when you're filling the tank or some kind of temporary blockage. I would suggest to change your fuel filter first and add a fuel system cleaning agent to a full tank of gas. If that doesnt work, get a fuel pressure test done. The results of the test will let you know more. It could be a vacuum leak. Every time you open the fill cap, the pressure is leaving the system and without a good vacuum it will take time for the fuel to move through the rail to the cylinders.

Posted on Jan 07, 2010

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Check the fuel filter, fuel pump and fuel pressure regulator. This could also be clogged injectors. But it sounds like you are not getting enough fuel to your system on a full tank which would be your regulator.

Posted on Jan 07, 2010

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Thanks for this! At least I do not have to spend more money trying to find out what is wrong with my baby!

Posted on Jul 02, 2011

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You are overfilling your car,when you click more than once at a fill up,you are filling the expansion tank,which vapor locks your system,stop over filling,besides it also pumps gas into the vapor recovery system of the station,so you are losing gas too

Posted on Apr 30, 2015

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Posted on Jan 02, 2017

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SOURCE: Change serpentine belt 2004 Hyundai Santa Fe

it uses a spring loaded tensioner.use a breaker bar to rotate the tension and it should just come off.if u need a pic or anything else to do it let me know,

Posted on Oct 05, 2009

  • 1 Answer

SOURCE: 2004 hyundai accent. trouble filling gas tank

I have a 2005 Hyundai Accent, It is not possible to fill the tank if you are letting the petrol pump run at full speed.Trying to fill up quickly it will only build up pressure and cut off. Next time you fill up just pull the petrol pump handle half way, it will take longer to fill but you wont get the blow back. Modern petrol pumps are getting quicker all the time.Hope this helps you.

Posted on Mar 23, 2009

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SOURCE: I have a 2003 Hyundai Santa Fe, lately everytime i

Sounds like the purge control valve on your evaporative system is stuck open. In this case, what happens during fill-up is that fuel vapors are forced from the fuel tank into the intake manifold, effectively flooding the engine.
Todays fuel tanks are vented back into the engine. A "Carbon Canister" is supposed to absorb the vapors and then feed them into the engine in a controlled manner. If your canister is saturated or the purge valve stuck open, the fumes can "flood" the engine while refueling. Try holding the throttle wide open when you start after refueling to clear the vapor quickly.

Also next time you go to fill up, don't fill it all the way, maybe half or so, since the evap lines are at the top of the tank this should solve your problem, and give you at least some good information to take to your mechanic

Posted on Sep 15, 2010

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Your problem may be one of the following:
First check or just replace the fuel filter. Usually located under the car in front of the rear axle, drivers side.
Next, the fuel pump may be worn out. Usually they get loud or stop working (running).
Next, check the fuel pressure regulator. Usually located on the front fuel rail, drivers side.
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