Sonata NF (2006-10) :: 2008 Won't Start After Refilling Tank


Sep 14, 2011

My 2008 Hyundai Sonata wouldn't start on two separate occasions after I had refilled my tank. The first incident happened a little over a month ago (early August 2011), the starter would crank, and crank, but no signs of life in the engine. Tested the spark plugs, I was getting spark, but the sucker wouldn't start. The car was only at about 55k miles when this problem began.

I had the car towed to the dealership, and they said after 4 long attempts, they got it to start. I took it home, and the next morning I couldn't start it again. Towed it back a second time, and it started right up for them. Drove it back home again, and for a little more than a month, the car ran fine, but things started acting up again.

A few days ago the wife pulled the car out of the garage (fyi: my garage is level) stopped the car on our slanted driveway and when she came back to start it just minutes later, it hesitated, but did turn over. I filled up the tank, parked it in my garage and the very next morning, I could not start my car again.

Called for a tow from AAA, and the driver said "let me try something". Pulled out a hammer, and wacked the bottom of my gas tank 4 or 5 times. The tow guy gets in, tuns the ignition to engage the fuel pump (didn't turn the key all the way), he does this about 4 times, then the very next turn of the key it starts right up. The driver said it sounded like a bad fuel pump.

I drive the car back to the dealership (this is the third time) and talk to the same guy I had dealt with all along. He calls me later in the day to tell me they finally got it to not start and were able to isolate the problem to the fuel pump sensor. They replaced the fuel pump assembly and I was off and running.

To summarize:
*Refilling the tank on two separate occasions seemed to be related to the car not starting the following day.
*Towing the car allowed the car to jostle back & forth, which for some reason would allow the dealer to start it when it arrived.
*Was able to start the car by hitting the fuel tank (just underneath it) with a hammer, turning the key 3/4 of the way on a few times, then turning the key all the way.
*Dealer diagnosed bad fuel pump sensor, and replaced fuel pump assembly.

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