I just bought a 02 Ssei back in April. My check engine light has lit up three times. The first time they replaced an injector. The second time it was the same problem but they informed me they found rust in my fuel filter and I might have rust in my gas tank. They inform me the problem is most likely to continue and recommend changing out the fuel filter in about 10,000 miles. At this point I've got $900 in repairs in two visits. Two weeks later, the check engine light comes on for the third time. Same problem. They dropped the fuel tank and confirm there is a hell of a lot of rust (very very fine particles) in the tank The dealer informes me the tack is plastic and the rust must have been from bad gas. Also, he informs me I am looking at the minimum of a new tank, a sending unit and possibly injector replacments (if they can't be cleaned). A minimum of about $2000, maximum of 3500. I hope all the injectors won't need replaced for I drove the car to the dealer and it drove well.

I have a couple of questions:

What coud have caused this and how did this rust get into the tank. I am thinking flood damage, but carfax does not show this ( the car was a FLA car).

Is there a way to determine it'* rust and not silt ? Will rust stick to a magnet?

What are the tell tale signs that could disclose if a car was in some sort of flood or had water damage (maybe it'* rust in the gas tank!) What parts of the car can the dealer or I look?

Thanks and regards,

Malatu

While reading this I thought "there is nothing to rust in the tank"? The rust must have come from out side sources.
As to a flood having caused this I dont know, is the trunk dirty like it was submerged? Water can enter the trunk through the vent flap on the passenger side if it were deelp enough?

That'* what the dealer told me. It'* plastic. That'* why he thinks its an outside source of contamination. I haven't seen or smelled any signs of flooding. Will rust stick to a magnet? Thanks.

No, I don't think iron oxide is magnetic. When iron ferrite oxidizes it looses it'* magnetism.

Larger pieces of rust, bigger than about .002" will be screened by the fuel pump screen. They should be able to pull the fuel pump and inspect it.
The finer ones will pass harmless thru the pump but may clog your regulator and injectors. Could be ugly.

I would recommend that they try removing the fuel tank and cleaning it and the fuel pump only, as a first attempt.
If that doesn't work, then replace the regulator.
Finally, the injectors may have to be replaced but maybe they can be power flushed first.

Thanks....will post a follow-up

What kind and octane of gas have you been running?

I put in the highest octaine available at the pump. I believe it is 93.

What brand?

I'm not sure. It would vary. Sometimes its at the Wawa. I think it is Shell brand. Other times I think it is Mobile.

Its a good idea to stay away from Shell gasoline, they use too much sulfur for our cars and can damage the injectors. I read somewhere that the fuel is acidic?