Other Fuel System Problems of Hyundai Sonata - part 1

Subject: non-collision engine compartment fire - 2010 Hyundai Sonata (VIN: 5npeu4af3ah630796) ?"on Dec 19 2025, my 2010 Hyundai Sonata suffered a sudden, non-collision fire that originated in the engine compartment. While there are currently no 'open' recalls on this VIN, I am formally reporting this incident as it matches the failure patterns documented in NHTSA defect petition dp18-003 regarding non-crash fires in Hyundai/kia vehicles. ?preliminary inspection of the damage shows characteristic signs of a manufacturer defect, specifically potentially related to a connecting rod bearing failure leading to an engine block puncture and oil ignition, or an electrical short in the abs module—both of which have been subjects of major Hyundai fire investigations and class-action settlements (e. G. , engine ii settlement).

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My 2022 Sonata has had to have its fuel injectors replaced two times in the 3 years I've had it. On 12/18/2025 my car started to become very slow and could not reach over 20mph, and started to smell like gasoline and shake slightly. I had to get it towed to the Hyundai dealership and there they told me that the fuel injectors need replacing. I had the same exact problem with this car before where I had to get the car towed to Hyundai and then they had to replace the fuel injector.

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My vehicle had Hyundai safety recall 227 (fuel tube replacement) completed on December 7, 2022. After the recall repair, the same fuel-system symptoms returned. A Hyundai dealership diagnosed failure of the high-pressure fuel pump and high-pressure fuel pipe and stated the condition was critical and a safety risk due to fuel system involvement and potential fire hazard. Hyundai motor America declined assistance, citing vehicle age and mileage, despite this being a recurring fuel-system safety issue following a recall repair. The vehicle continues to present fuel-related safety concerns, and operating the vehicle poses a potential fire risk. In addition, the estimated repair cost exceeds $2,000, which represents a significant financial hardship for a safety-related defect that occurred after a recall repair. I am submitting this complaint due to concern for vehicle safety and the recurrence of a fuel-system defect after a manufacturer safety recall.

See all problems of the 2013 Hyundai Sonata 🔎.

Unknown- while driving on highway, from 70 mph speed the car suddenly lost acceleration and speed dropped. No response to accelerator. Even with pushing the accelerator high, car will go in high rpm and speed will barely reach 40 mph. I was lucky that there was no other vehicle behind me, especially heavy automobile like semi truck as it would have crashed in me from behind due to sudden propulsion loss. The car started working fine next day. I took it to dealer and they couldn't find any error code but said it could be 12v battery bms software update and they updated it. They mentioned that this is not a safety issue which is mind-blowing and concerning as this is a major safety hazard. I would request you to investigate this further and if this is a software issue then please direct Hyundai to update this with all vehicles and cover the cost for those who have had to pay for it.

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On 11/28/25 at approximately 6:30 pm, I was driving on a highway 17 going about 60 mph when my car's engine completely shut down. A "hybrid system failure" warning flashed and my car was no longer drivable. The car was towed to the dealership. In mid October 2025, my car stopped running with the same "hybrid system failure" warning, but it happened in my driveway. The car was towed to the dealership and supposedly repaired.

While driving on the highway, my 2018 Hyundai Sonata experienced sudden loss of engine power and became undrivable. The failure occurred without warning at approximately 86,500 miles. At the time of the incident, there were two children in the vehicle, and the breakdown occurred at night in cold temperatures (approximately 20°f). An authorized Hyundai dealership later diagnosed zero compression in cylinder 3 and confirmed a cracked piston, recommending full engine replacement. The sudden loss of power while driving created a safety risk due to traffic conditions and environmental exposure.

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Upon topping up gas to full or anytime fueling after there is a heavy scent of gas inside the cabin lingering.

My 202 Hyundai Sonata is involved in the current Hyundai fuel system recall. On 10/26/25 the fuel tank expanded and caused three explosive "boom" sounds inside the vehicle while I was driving with passengers. The backseat began heating and rising upward due to fuel tank swelling. The tank became pressurized, hissing, bubbling, and would not accept fuel. The vehicle became inoperable. The car has now been at Hyundai of camelback since 10/27/25 (30 days). Hyndai corporate has repeatedly delayed providing a remedy and keeps telling me they "need another week". I have received no repair plan, and no decision. This violates the requirement for a timely recall remedy. The defect caused structural damage and created a serious safety hazard. ".

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I was driving the car home from massachusetts when, after 6 hours of driving, the car started to shake and would not accelerate. It was also emitting a burning smell. I exited the highway and called for a tow truck. I was told by the Hyundai dealership that, at 4,100 miles, a fuel injector and high pressure rail had failed.

While driving at highway speed, my vehicle suddenly lost power due to fuel injector failure and could not be restarted, creating a serious safety risk for myself and others in high-speed traffic. This is the second vehicle of the same year and model that I’ve owned to experience the exact same injector failure. In the first case, one injector was replaced under a Hyundai service bulletin before I sold the vehicle. This second occurrence confirms that the issue is not isolated and should be escalated to a formal safety recall. The most recent failure was diagnosed and repaired by Hyundai, confirming the problem (this time replacing all injectors). The vehicle has not been inspected by police, insurance, or other outside representatives. There were no warning lamps, messages, or symptoms prior to the failure—it occurred without any warning, significantly increasing the risk of a crash.

The problem with my vehicle is a failure of internal engine components, specifically a known defect in the piston rings of the Hyundai theta ii engine. This failure causes excessive oil consumption, which is burned internally. The internal engine components have failed, leading to a widely documented defect in the Hyundai theta ii engine. The primary symptom, which began to get serious around 80,000 miles, is the constant need to add oil to the engine every two weeks. If I do not do this, the low oil warning light illuminates on the dashboard, serving as a continuous alert of the problem. This failure was officially confirmed by an authorized Hyundai dealership. About two weeks ago, they first documented that there were no external leaks on the vehicle. When I returned because the oil had been consumed again, they performed a new diagnostic, for which I paid over $300, that confirmed the engine is burning oil internally. The dealership, acting as the manufacturer's representative, is the only entity that has formally inspected the vehicle. The situation places my safety and the safety of others at serious risk. First, the oil consumption can lead to a sudden and catastrophic engine failure, resulting in a loss of power and control of the vehicle while in transit. More alarmingly, the guidance I received from Hyundai staff was to simply "wait for the engine to stop working or start making a lot of noise. " as someone who depends on the car for a daily commute, following this dangerous recommendation is an unacceptable risk.

See all problems of the 2016 Hyundai Sonata 🔎.

Car keep cutting off and fuel injection is not right.

Unknown. 2018 Hyundai Sonata engine has failed. Only purchased the vehicle in December 2024, and the engine is defective. There is much information, via research, indicating that Hyundai is aware of the engine issues with this year vehicle, but are unwilling to make amends. Vehicle has 100,189 miles.

Filled gas tank up on Friday [xxx] about 10am as leaving boca raton, FL to head north to new port richey, FL. About 30 minutes later the gas mileage said there was only 90 miles left in the tank. Stopped at the next gas station to make sure nothing was leaking, added a little more until it clicked, basically full again. Got to approximately [xxx] near morris bridge in tampa area, the car started to decelerate and then all the engine lights came on and car was shutting off, was able to pull to the left side of the road and looked into the back seat noticed the back seat was rising. Looked under the back of the car and the frame looked like it was pushing up into the backend of the car. Dot was called out to the scene as it appeared the car could have exploded. This could have killed my [xxx] daughter (which was who was driving the car) or other people on the road. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

To whom it may concern, I have own my vehicle since Jan 2018, which was purchased from the dealership's owner w/less than 10k miles. Maintenance has been performed iaw Hyundai's recommended schedule. However, yesterday, I was informed that my vehicle needed a new engine and other replacements totaling $13,934. 89. This is outrageous. How can a well kept vehicle w/106445 miles, need such replacements? thus your assistance will be greatly appreciated.

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I am reporting a serious coolant system defect on my 2023 Hyundai Sonata hybrid with about 13,500 miles. The vehicle develops an internal coolant leak while driving. Coolant burns off and white steam/smoke comes out of the exhaust, especially during acceleration. When this happens, the coolant level drops quickly, the interior heater stops working, and the car soon displays an engine overheating warning, forcing me to stop driving. This has happened multiple times and makes the vehicle unsafe. When I checked under the hood, coolant was at a low/empty level after overheating events. The car becomes undriveable once the alarm appears. I took the vehicle to a Hyundai dealer, and even though the vehicle is only 2 years old, they told me it was “out of warranty. ” I had to pay about $1,500 for repairs, and since the dealer refused a loaner, I paid $250 for a rental car. I called Hyundai USA on 9/13/2025 and opened case number xxx. Hyundai acknowledged they are aware of coolant issues on the Sonata hybrid but said no recall exists. This issue appears widespread. Many other owners report the same symptoms: white exhaust steam, coolant smell, coolant loss, no interior heat, and engine overheating. Hyundai released TSB 23-em-009h, describing a failure where coolant leaks internally in the exhaust heat recovery system (ehrs), causing white smoke and overheating—matching my symptoms exactly. This defect is a safety hazard because overheating can occur suddenly while driving, risking engine damage or breakdown in traffic. I request NHTSA investigate this issue as a potential recall-level defect on the 2023 Sonata hybrid. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

While driving car stuttered check engine light and check hybrid system flashed. Check engine lights stayed on until getting home. Next day. I scanned and code p0b68 was set.

The fuel injectors failed on my Hyundai Sonata in two instances. Once on 5/23/24 and once on 9/7/25. During the first instance, I was driving on a local road when the accelerator stopped working and the engine started sputtering. We were fortunately able to stop at a nearby parking lot before the engine completely stopped working. During the second instance, I was also driving through a local road when the accelerator stopped and the engine started sputtering again. This time, we weren't able to reach a safe stopping point and the engine died on the road. My family was with me at the time, so we had to push the car in neutral to the closest safe space. In both cases, our safety and the safety was others was put at risk as the car become unable to accelerate, and the car stops moving. We had to get out on the road and push the car with oncoming traffic. The problem was confirmed by the dealer in both cases, and they replaced the fuel injectors in both cases. So far, they've replaced 3 out of the 4 fuel injectors so I still drive in fear of another fuel injector causing a breakdown while I'm driving. There were no warnings or symptoms prior to the failure so there was no way to know to stop driving and to stop in a safe spot. We were fortunate to be able to move the car to a safe place for both instances, but if this had happened on the highway or secluded location, our lives could've been at risk. I've requested Hyundai to replace the last fuel injector but they're refusing to do so. I only feel safe driving in local roads or short highway trips as I fear for the reliability of my car, my safety, and the safety of others.

In November of 2024, I had a check engine light for a cylinder 2 misfire and a fuel to air mixture ratio. Had it towed to a Hyundai dealership. Got a call the next day saying it was fixed. Picked the car up and 50 miles later it popped back up. Had it towed back again. They said my fuel injector was cracked. They had to order the fuel injector directly from korea. Took 5 days to get the part and it installed. Fast forward to September 2025, cylinder 2 misfire showed up again(same cylinder the fuel injector was replaced) and now the car shakes violently when accelerating and stalled at a stop light. Massive safety concern due to risk of an accident. Car to be towed to another dealership for the same issue less than a year apart.

Theres a know recall for this issue. Recall 189 and 227 for Hyundai. Fuel leak right by the regulator on the hose. Mine is doing the exact thing. My motor isnt covered for some reason. Same make and model. So id like to make a complaint and make it know the exact same issue is happening still, 2013 Hyundai Sonata and they wont cover it. So if another recall could be opened to help others. I mean its the exact same issue.

Fuel injector failed. The vehicle stall and accelerate poorly due to misfires. It is leaching gasoline into the oil which can result in total engine failure. Dealership verified the injector was bad. There was a warning light at one time after refueling, presumed it was my fuel cap, tightened it, and the light went away.

Car has been running great. We Ave had the car almost 3 months. My wife drove the car to church. On the way home the car engine started acting up. She pulled over and called me. I went to where she was about 1 mile from home . My son and I got the car started it would not hardly run we got it home. It was running roughly and smelled like gas making white smoke. A rollback truck picked it up the next day. Took it to the closest dealer in cape girardeau mo. It has been in the shop3 weeks found out today it will be over another week before Hyundai gets in touch with the dealer about the problem. (injectors).

Fuel injectors cause car to lose power while driving in traffic, on the highway which can cause accidents. This event happened twice one while entering the highway and one while going past a light. Neither caused an accident at the time. The car both times were taken to the dealership and the fuel injectors had to be replaced both times. The first time was in December 2024 at 12k miles.

I was driving my 2023 Hyundai Sonata with 22,000 miles on I-96 near grand rapids michigan at or slightly below the speed limit of 70 mph. Suddenly, with no advance warning of any kind, the engine shut down. I was able to coast and maneuver to the right shoulder of the road while avoiding traffic, including a large tractor trailer that almost hit us. The vehicle than had just enough power to get off the next exit and on a local side street. At that point the vehicle would not restart and you could smell a strong odor of fuel. I called Hyundai and they sent a tow truck to take it to the nearest dealer. (I am 700 miles from home). The dealer's service department diagnosed the problem then replaced the fuel injectors still under warranty.

The vehicle went in for repair at the dealership early July for a check engine light and dtc error code. It was revving high after being driven for more than 20 min or so and wouldn’t get to above 60 mph. Jerky, dangerous acceleration and deceleration seemingly out of nowhere. The dealership replaced the fuel pump which is what they said was causing the error. Today on August 10th, check engine light popped up again with a dtc error code. Weird acceleration and deceleration and general jerkiness when driving. Scheduled service appointment for next week.

My 2017 Hyundai Sonata limited check engine light came on at approximately 103,000 miles of use. This happened last week. The code it was pointing to was a faulty fuel pressure sensor. Could also be combined with faulty fuel pump, but the primary code indicates the sensor. I will be taking it in to the Hyundai dealership shortly. The main reason I’m reporting this is because of my previous experience owning a 2011 Hyundai santa fe that had to have the engine replaced three times all under warranty. There ended up being a class action lawsuit because of several owners experiencing the same proglem. While this may not be the same case, I am leary of engine problems like this. I take very good care of my cars with regular maintenance, so I’m reporting this just in case others are experiencing the same problem.

I had a standard oil change done on my car and it was running fine afterwards. Later that evening, my car started smoking and spontaneously burst into flames from the hood. The fire originated in the hood of the car and melted the entire front of my car as well as the entire inside. It burned a lot of fuel and oil, which leaked onto the ground and continued burning on the ground. My car was overtaken by flames in a matter of a few minutes. It burned so fast that there was nothing I could do to stop it. I was not aware of anything wrong with my engine or fuel lines, or anything like that. However, something was very wrong for the engine area to catch fire like that spontaneously.

See all problems of the 2015 Hyundai Sonata 🔎.

My Hyundai consumes oil and I have to put oil in it every two weeks! also my ignition coils has had to be changed 4 times. Also check engine light just came on code saying catalytic converter or oxygen sensor changed oxygen sensor a couple months ago. I purchased it brand new and as soon as I got over 100,000 miles nothing has been going good since then please help also my paint on the top of the car is starting to peel. Will never buy a Hyundai again.

The plastic fuel pump housing cracked at a spot outside of the fuel tank. When the pump was running, the crack caused the pump to spray fuel outside of the gas tank where the fuel puddled on top of the tank and dripped down over the sides of the tank. During a non-related repair, my mechanic noticed the bottom of the fuel tank was wet with fuel. I'm lucky the plastic fuel pump crack was found before the spilled gas cause my car to catch fire.

The fuel pump filter housing is the cause of the malfunction, it is available for inspection upon request. When I am driving I intermittently lose fuel delivery altogether and my car comes to a halt for a second until I press on the gas pedal to get the car going again, this puts myself and other people in danger if my car randomly stops while I am driving around others and causes crash risk. An independent service center ran a diagnostic and stated it was the fuel pump filter housing. It has not been inspected by the manufacturer, police, or insurance reps. But it has been inspected by the service center near me. An engine code was produced that pointed to the gas cap, but the gas cap was fine, which indicates fuel delivery issues. There was also shaking during acceleration prior to the incident happening. My VIN does not fall under the current extended warranty, but the issues are identical to the issues of the vins that do fall under the extended warranty.

We were sitting in our car at a hardees drive through when we noticed smoke coming out from under the hood. I pulled forward to a parking space and opened the hood. Flames shot up at least 6 feet. I quickly ran a short distance into the fast food place and right near the door was a fire extinguisher, which I grabbed and put the fire out with. The fire burned for about a total of 2-3 minutes, and did not do excessive damage. Coil packs and wiring harness got most of the damage. With the hood closed, you cannot even tell there was a fire. I had the car towed to grayson Hyundai for the recall part, but then entered a claim to Hyundai. Long story short, they stalled me for over a month and then denied the claim. Citing no damage to the cam. Unlike most of the fires with this carline, my car fire was put out very quickly. The recalled fuel line/tube was not damaged much at all. You could inspect the part and see the wear on it and tell it was the culprit. It didn't take a trained mechanic to see this. After I put the fire out and it cooled, I tried starting it, and there was fuel squirting out from the recalled part. There is absolutely no doubt that the recalled part was the cause of the fire. But Hyundai has given me a denial letter that does not state the reason for denial. The Hyundai rep on the phone told me it had to do with no damage to the cam. I then asked, thats because I got the fire out so fast right? and he said no, didn't have anything to do with it. But he lied. First of all, the cam has nothing to do with the cause of the fire. A damaged cam only happens when the fire was long lasting and severe. They should have inspected the obvious recalled part right in front of them. This denial is completely unprofessional and hints of a concerted effort to categorically deny claims. They don't usually have this much evidence, they did this time and still blew it. Had I let it burn to the ground,=approved.

Purchased 2019 after 44,000 miles engine was replaced metal in engine and inverter coolant issue July 2025 117,000 my inverter coolant light came in and off several times then car through all warning lights hev check engine warning shut it down went into limp mode towed to dealership they checked and cleared codes said it threw 13 codes but after clearing they stated nothing wrong with it as they went to pull car around it happened again this time code was knock sensor which they relaxed at no charge extended warranty they next day after picking up while at idle hev warning went in shut car off and it was gone kept driving nonissues the next day again it happened and this time the engine light stayed on spoke with dealership they said they would charge me diagnosis charge of 208 and if it was related to what they did. It would be covered also stated if the engine light was flashing it would be covered or it isn’t the engine isn’t covered the inverter coolant is not bubbling or moving when car is on it is an inverter coolant issue that was a problem back when my first engine was repaired and should be covered I love my vehicle but I have had so many issues since getting it major things and the lighting system showing a black spot in my view as well that could not be fixed I will attach pictures of earning lights and video of coolant not circulating and the dealership filled the coolant way over the top I have to now take it back again to have it looked at.

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After having work done to repair the head gasket and spark plug. I was on mile ~300 after repairs and was nearing to fill up at a gas station, I started losing power and notice the check engine light was on and gas smell filled the cabin. When I stopped the hood started smoking and there was a fire under the engine cover. My VIN is not listed on the fuel line recalls and I believe this is an oversite as it lists, faulty high pressure hose can rupture and cause engine fires and that is exactly what happen in my case. I believe this VIN was overlooked and I need the repairs complete. I have not completed any repairs because I believe this should have been recalled.

See all problems of the 2014 Hyundai Sonata 🔎.

Failed fuel injector caused 3rd cylinder misfire car only has 30,000 miles I'm the second owner I've only had it 2 weeks and this issue happened.

I am submitting a formal complaint regarding ongoing and severe engine issues with my 2018 Hyundai Sonata se. Despite proper maintenance, the vehicle has developed extreme oil consumption and misfire problems that have made the car unreliable, unsafe, and financially burdensome. Beginning around 118,000 miles, the vehicle started consuming oil so rapidly that I was forced to completely replace the oil every 1–2 weeks because it would run dangerously low or nearly empty. This level of oil loss is not normal, acceptable, or sustainable. I have detailed documentation, receipts, mileage logs, and maintenance history supporting this. In addition to oil consumption, the vehicle has repeatedly misfired, produced diagnostic trouble codes, and fouled spark plugs with oil. I have been forced to replace spark plugs approximately every two weeks, which is clearly abnormal for any modern vehicle. On multiple occasions, the vehicle has experienced violent knocking noises, severe loss of power, hesitation during acceleration, and near-stalling. One incident was so loud and aggressive that it felt like the engine was going to come out of the hood. These symptoms pose a serious safety risk while driving. I brought the car to a Hyundai dealership at approximately 118,000 miles for an oil-consumption test. The vehicle failed that test, clearly confirming excessive oil consumption. Despite this, Hyundai refused to provide repair, internal engine cleaning, or engine replacement, claiming the vehicle was already over 100,000 miles I have maintained this vehicle responsibly and have documentation of regular oil changes, spark-plug replacements, inspections, and diagnostic reports. Despite my efforts, the issue continues to worsen, and the vehicle remains unsafe and unreliable. This ongoing problem has caused significant financial strain, emotional stress, lost time, and fear of engine failure while driving. Based on countless similar complaints from other Hyundai owners, this appear.