Fuel smell

[Admin1]

Is there anyone that is experiencing a fuel smell in the car when the car is running on any 2011 Sonata an Sonata turbo?

[n2carz]

Yes. I bought the car 4 weeks ago, now has 3,200 miles on it, and a few times in the garage on a warm engine restart I have smelled a gasoline smell. Checked the gas cap (tight) looked for leaks under the hood (none). Non turbo Limited.

[SteveL332]

Is there anyone that is experiencing a fuel smell in the car when the car is running on any 2011 Sonata an Sonata turbo?

I have had this odor for the past few hundred miles. I have 4200 miles on the odometer. It is at the dealer now for this. They drove it yesterday and could not duplicate the problem, so they're keeping it a couple more days to check it out further. The odor occurs when I drive at slow speeds, or when I come to a stop. It is stronger at times than others. I have had a couple of times where I had to open the window as the smell was strong. When I park the car in the garage, my whole garage smells like gasoline. I have not seen any leaks on the ground under the car.

In another forum, a poster had the same issue and his Dealer said it was an o-ring in the fuel pump. I told my dealer about this. They said they checked it and it was fine.

[Admin1]

Whats going on is the PCV hose at the intake will collapse. Take a look at this picture an compare it to yours.
http://myhyundaiforums.com/Pictures/securedownload.jpg

[SteveL332]

Where exactly do I find this hose?

[Admin1]

Where exactly do I find this hose?

Here is a better picture. A is the PCV hose.

[SteveL332]

Here is a better picture. A is the PCV hose.

Thank you. I will definately have them check this. I'll let you know what happens.

[SteveL332]

I just picked up my car from the dealer. The Service Tech called me first and reported the PCV hose on my car had collapsed. He said they checked with Hyundai and they are aware of this problem. They determined it is this PCV hose that is causing the fuel odor. Unfortunately the replacement hose is on a nationwide backorder. I asked my Service Rep if they were just ordering a part that has already been determined to be defective, or if there will be a "corrected" hose that was ordered and will be installed. He said Hyundai has determined what type of hose is needed to correct this problem and it is this corrected hose that is on backorder. The Rep said the Dealership will call me when the part comes in and they will install it. in the meantime, he said they cut off the collapsed portion of the hose and "rigged" it to function until the proper hose comes in. He also recommended that I have the oil changed as there was a heavy fuel smell in the oil due to this problem. I had them change the oil. I must say, on my 10 mile drive home from the Dealer I did not have ANY fuel odor at all. We'll see how it goes.

[Admin1]

I think this is going to be a very common issue.

[MisterRoy]

How strong of a fuel smell is it? Every so often I think I get a whiff of gas, but just as quickly it appeared, it's gone.

When I got my oil changed at 1800 miles, I thought my oil smelled a lot like gas, but the dealer changed the oil and didn't say anything. I guess it was me...

[Admin1]

Its hard to tell unless you start the car an look at the hose an see if its collapsed.

[SteveL332]

The fuel odor displayed a range of intensities. Sometimes it was very slight and other times it was very strong. It occurred a few different ways, and it was not constant. It would occur when I would come to a stop at a stoplight, or driving slowly such as in rush hour traffic. When parking the car at a store for example, when I got back in, I would smell it immediately upon driving off. I could also smell the fuel in my garage (very strong) when I parked the car. The Dealer found the collapsed PCV hose. They did a temporary fix until the correct backordered part comes in. I'm on day 3 and no fuel smell. I had the oil changed too. The Dealer said it had a strong odor of gas in it.

[juggss6]

Anyone have the smell at 60mph on the highway?

[n2carz]

My PCV hose does not appear to be collapsed, but I really can not tell under the thick foam surrounding most of it. And now my sense of smell for the gasoline smell is heightened, and have not smelled it until today. Drive 2 hours on the interstate (and no I have not smelled the gasoline fume smell while driving 60 mph, or 80 or 45.) then take our exit and sit at the red light for a few minutes and bam, overwhelming gasoline fume smell in the car. Enough that my friend riding with me said something, even though I did not say anything. And get on the 45mph stop and go traffic on Rt 59 (suburbs of Chicago area), most of the stop lights that you have to sit and wait, you get a good whiff of the raw gasoline fumes, and yes different intensities each time too.
These gasoline fumes are coming from the fuel tank vapor recovery system, not the PCV. PCV would have exhaust blow by which does not smell like raw gasoline. However, when looking at the diagrams for the fuel vapor purge solenoid, when it is activated, the stored up gasoline vapor (fumes) are purged into the intake manifold (somewhere else, not the PCV hose).

But, if SteveL332 says the temporary fix of the PCV hose has eliminated the odor, then that must be it. I am surprised why that would solve the problem though.

[Bearcats]

I was confused about this smell. Mine has started to smell like exhaust oil. It smells like an engine head when you pull the valve cover off so I didn't associate it to what people were saying about fuel. Mine DEFINITELY does NOT smell like fuel.

So this morning I inspected the PVC hose. Looked fine. Did my errands with the kiddos and my boy tossed his Diesel the train on the floor and wanted it back. So I pulled into a parking lot and retrieved it for him. I smelled the smell and decided this is a good time to reinspect. I did and the hose is collapsed. So for those that are checking the hose, make sure you drive the car until you smell your smell and THEN inspect the hose.

I drove past Superior Hyundai and explained the issue, which they knew about. Went through a courtesy check of the hose (still collapsed) while in the check in bay, wrote me up and sent me on my way. That's TWO great experiences.

My hose was collapsed on the LOWER part near the block. It was collapsed between the block and the start of the BOTTOM of the foam hose overlay.

I put a temp fix on the car so that Hyundai and I don't have to worry about long term engine damage.

The engine block nipple side is 1.125 long. If you can get a 1/2" OD tube roughly 1.25 inches, you will be great. It will slide inside the PVC tube snugly and that's all you should have to do.

If you splice it, you will need a 5/8" OD tube so that the two cut ends will be a tighter fit and you will need either two clamps or two zip ties to very tightly secure it. I got a copper fitting at Home Depot (Shark Fittings?) It has barbed ends on either side. I measured out 1.125 inches from the engine side of the hose (So that the hose can go back all the way on) and then measured my fitting and gave 1/8" distance between the fitting and the nipple and cut the PVC tube. Inserted my fitting and clamped either end and re-installed.

[SteveL332]

My PCV hose does not appear to be collapsed, but I really can not tell under the thick foam surrounding most of it. And now my sense of smell for the gasoline smell is heightened, and have not smelled it until today. Drive 2 hours on the interstate (and no I have not smelled the gasoline fume smell while driving 60 mph, or 80 or 45.) then take our exit and sit at the red light for a few minutes and bam, overwhelming gasoline fume smell in the car. Enough that my friend riding with me said something, even though I did not say anything. And get on the 45mph stop and go traffic on Rt 59 (suburbs of Chicago area), most of the stop lights that you have to sit and wait, you get a good whiff of the raw gasoline fumes, and yes different intensities each time too.
These gasoline fumes are coming from the fuel tank vapor recovery system, not the PCV. PCV would have exhaust blow by which does not smell like raw gasoline. However, when looking at the diagrams for the fuel vapor purge solenoid, when it is activated, the stored up gasoline vapor (fumes) are purged into the intake manifold (somewhere else, not the PCV hose).

But, if SteveL332 says the temporary fix of the PCV hose has eliminated the odor, then that must be it. I am surprised why that would solve the problem though.

The issue I was having was definately a gasoline odor. The first time I could smell it was right after I filled up with fuel. At first I wrote it off as possibly stepping in some fuel that was on the ground and I tracked it into my car. But then the odor remained to varying intensities. It was definately fuel and not exhaust.

It's been a week since the "temporary" fix and still no fuel odor at all. I was having the fuel odor each time I came to a stop (Route 59 traffic lights too!! :) and while the car was parked in my garage. I heard multiple times from the wife about how the garage stunk like gasoline! So far so good on the temporary fix.

[n2carz]

OK, I checked the PCV hose with the engine at idle after about a 30 minute drive and it was totally collapsed at the end near the intake manifold. So I was going to try a temporary fix with 5/16" ID hose, but no way was it going over the 1/2" OD plastic fitting on the intake manifold side. (Fitting 1/4" OD on the PCV side). Looking at the hose, the end near the intake manifold side is 1/2" ID and 1/4" ID on the PCV valve side. Where the hose necks down from 1/2" to 1/4" it is very soft. Poor material choice.

Do we have a part number for the redesigned hose yet? I just don't have time to get into the shop for another month or two! 4,600 miles, and it is only 5 weeks old.

[Admin1]

Alright. In the last two weeks I've been checking PCV hoses on all 11 YF's while doing services to them. I can say that nearly 80% of them with more than 20k on them has hose issues. In my opinion this is going to be a big deal with Hyundai. Also as of this morning the hose is still not advaliable.

[MisterRoy]

Alright. In the last two weeks I've been checking PCV hoses on all 11 YF's while doing services to them. I can say that nearly 80% of them with more than 20k on them has hose issues. In my opinion this is going to be a big deal with Hyundai. Also as of this morning the hose is still not advaliable.

Big deal as in "oh crap" or big deal as in "they're gonna be all over fixing this one?"

[Rsquared]

Big deal as in "oh crap" or big deal as in "they're gonna be all over fixing this one?"

BOTH. :thumbsup:

[Bearcats]

OK, I checked the PCV hose with the engine at idle after about a 30 minute drive and it was totally collapsed at the end near the intake manifold. So I was going to try a temporary fix with 5/16" ID hose, but no way was it going over the 1/2" OD plastic fitting on the intake manifold side. (Fitting 1/4" OD on the PCV side). Looking at the hose, the end near the intake manifold side is 1/2" ID and 1/4" ID on the PCV valve side. Where the hose necks down from 1/2" to 1/4" it is very soft. Poor material choice.

Do we have a part number for the redesigned hose yet? I just don't have time to get into the shop for another month or two! 4,600 miles, and it is only 5 weeks old.

My fix was for the block/exhaust manifold side which is where mine collapsed. I only "fixed" about to the 90 bend up to the intake manifold side.

What Hyundai better watch out for on this one is engine cleaning. The smell "stains" the engine area and even though while moving you dont smell it anymore, sitting at certain times if will waft back through the cabin.

Its my main reason for my short term fix. I dont want my brand new car to smell like a 1970's oil burner. So I took a bit of a pro-active approach towards it. Good thing too after reading the comments above about supply for the new line.

[elp_jc]

My fix was for the block/exhaust manifold side which is where mine collapsed.
Hey man, do you happen to have a pic where it's collapsing? Thx.

[Bearcats]

Hey man, do you happen to have a pic where it's collapsing? Thx.

Sorry man, I sure dont. But its easy to see. After your car is wramed up, pop the hood and look at the PVC line on the left side. To see the top of the line you need to remove the engine cover.

Follow the line down, it it will make a 90 turn to head for the manifold/block. The foam outer cover will end in about 1.5-2" and then you will see raw hose again. About 1" after the foam covering ends is where mine collapsed.

When they say collapsed, it no longer holds its shape and becomes pinched. In my case, the back side of the hose was the real problem point.

[n2carz]

I'll try a pic, but the hose is not collapsed in this pic.

293

[Bearcats]

I'll try a pic, but the hose is not collapsed in this pic.

293

Yup, thats exactly where mine collapsed. You have to look around the hose well.

[MisterRoy]

So...yesterday I got a whiff of what I think is a faint gasoline smell, and I parked my car (left it running) and checked the hose. It was fine. The catch - my car was running for about 3 minutes.

Do you find that the odor arises when they car has been on for an extended period of time?

Thanks!

[Bearcats]

So...yesterday I got a whiff of what I think is a faint gasoline smell, and I parked my car (left it running) and checked the hose. It was fine. The catch - my car was running for about 3 minutes.

Do you find that the odor arises when they car has been on for an extended period of time?

Thanks!

I am not an ASE certified mechanic. However, my gut hunch is that short trips you wont notice it much, if at all. If you take extended trips I think it will show up easier.

Go for a longer drive, say 15 minutes and monitor the results. Also you could be on the beginning edge of the PVC tube failure.

[mbm]

Hmmm... I often smell an "exhaust like" smell when sitting at idle, it's been very disconcerting considering exhaust means CO. So... yes, this will, and SHOULD, be a very big deal for Hyundai for two reasons:

1) Safety
2) Emissions item.

Will only take a few people failing emissions to get it "recognized" pretty damn quick I imagine, esp. those of you in California.

I'm sure the dealer will say... "Functions as designed."

[MisterRoy]

My dealership did some custom repair by reinforcing the ends with plastic tubes. I don't get the fuel smell in the car anymore, but I did notice over the weekend when I was stopped on an incline for a few minutes that I got whiff of it through an open window.

Weird...

[cmoki1]

I didn't realize that this was a common issue.

I went to the dealer today to have it checked out and immediately they mentioned the PCV hose and that they would modify it. I also had the oil changed, and when they were finished the service rep said, "Your car is a Turbo, it doesn't have the issue with the PCV hose. The car had 4,500 miles before the oil was changed, you just need to make sure that the oil is changed every 3K miles".

What!!? Sure sounded like a load of bull to me. After reading all of these posts, I am almost sure that the smell will be back tomorrow!

[Admin1]

I didn't realize that this was a common issue.

I went to the dealer today to have it checked out and immediately they mentioned the PCV hose and that they would modify it. I also had the oil changed, and when they were finished the service rep said, "Your car is a Turbo, it doesn't have the issue with the PCV hose. The car had 4,500 miles before the oil was changed, you just need to make sure that the oil is changed every 3K miles".

What!!? Sure sounded like a load of bull to me. After reading all of these posts, I am almost sure that the smell will be back tomorrow!

I haven't personally seen a issue with the turbo PCV hose(Not saying there isn't an issue with them). They are right though it is a little different hose but to me after looking at it, sure does seem to be the same material that the none turbo hose it made of.

[cmoki1]

Thanks for the reply, Admin1.

The dealer's implied comment about waiting "too long" to change the oil was the clincher. How could these 2 things possibly be related? I've never heard of problems related to not changing the oil at the "recommended" interval!

Could the ECM firmware update they also did on the car computer be an attempt to fix this problem?

[Bhova]

I was having the same fuel/exhaust smell, I tried checking the PVC hose but couldn't tell if it was collapsed due to the insulation so I took it to my dealer to have them check it out. They didn't find any issue with the hose but found an O Ring was leaking a small amount of oil onto the exhaust causing the smell. I will say it def. did not smell like burning oil but ever since they fixed I have not had the smell. My experience was similiar to most, I never had the smell while moving but if I stopped for any extended period of time while calling for outside air it was terrible, my garage also smelled terrible in the mornings. My car has been fixed for about a month now and I haven't had the smell since.

[CraigS26]

I was having the same fuel/exhaust smell, I tried checking the PVC hose but couldn't tell if it was collapsed due to the insulation so I took it to my dealer to have them check it out. They didn't find any issue with the hose but found an O Ring was leaking a small amount of oil onto the exhaust causing the smell. I will say it def. did not smell like burning oil but ever since they fixed I have not had the smell. My experience was similiar to most, I never had the smell while moving but if I stopped for any extended period of time while calling for outside air it was terrible, my garage also smelled terrible in the mornings. My car has been fixed for about a month now and I haven't had the smell since.

I found a Feb '11 (another Forum) Thread where the same Gas Smell complaint involved Checking the PCV Hose to see if it is soft.

Important: Some guys would check the hose and find it OK. Drive awhile and smell gas. Check hose again - Collapsed. So, check PCV when gas smell is noticed.

Hyundai waffled back & forth on hose re-design, back-orders, then believing the design was OK but just a bad batch of hoses - but into June '11 the Collapsed PCV was being noticed. A Temp Fix was Inserting a Hard Tube into the hose til replaced.

[VegasGolfer]

Hi All,

Is the answer to the gas smell on the 2011 Hyundai Sonata a collapse PVC intake hose?

I have the same problem with the gas smell and I'm scheduled to take my car in next week for routine service.

Thank You

[CraigS26]

Hi All,

Is the answer to the gas smell on the 2011 Hyundai Sonata a collapse PVC intake hose?

I have the same problem with the gas smell and I'm scheduled to take my car in next week for routine service.

Thank You

Re-visiting this to Find Out What Happened with your Gas Smell appointment and hopeful FIX?

[VegasGolfer]

After taking my Sonata in for service and for them to check out the gas smell, they indicated that they could find the problem. They indicated to me that it could be that it was the gas being purged out in hot weather. I will surely keep my eyes on this problem...

Thank You...

[Tiny1]

I have had this odor for the past few hundred miles. I have 4200 miles on the odometer. It is at the dealer now for this. They drove it yesterday and could not duplicate the problem, so they're keeping it a couple more days to check it out further. The odor occurs when I drive at slow speeds, or when I come to a stop. It is stronger at times than others. I have had a couple of times where I had to open the window as the smell was strong. When I park the car in the garage, my whole garage smells like gasoline. I have not seen any leaks on the ground under the car.

In another forum, a poster had the same issue and his Dealer said it was an o-ring in the fuel pump. I told my dealer about this. They said they checked it and it was fine.
Yes, I have been experiencing a very strong fuel smell in my 2011 Sonata 2.0T, often when starting the vehicle. When I start driving the smell disapates. I have had it into the dealer several times in the past 7 months. they have changed a collapsed hose, changed the O2 sensors and also changed the cabin filter. The smell was still there. I took it back again this week to get my winter tires removed, a new tech looked at it and was able to resolve the problem in minutes.
Shortly after I purchsed the vehicle I had the under-coatings applied. When this new tech looked at the car on the hoist he discovered the problem. When the coatings were applied the exhaust sheild must not have been protected and the undercoating solution was sprayed on to the exhaust sheild. When this solution is heated it creates an aweful fuel smell. After 17,500KM I am finally getting rid of that awful smell!!
If you have had under-coatings applied to your vehicle this could possibly be the issue.