Other Fuel System Problems of Hyundai Sonata - part 2

Whille driving back to washington state my car check engine light came on and the car shut off while I was driving. I had to have it towed to the nearest city whi ch was laramie wyoming. There is no Hyundai dealer had to drive the car once it started back up to cheyenne wyoming it was checked. My on star told me there was a problem dtc p0145100 the status had red triangle the dtc power system powertrain and the dtc sub system ems. I was told and given paperwork by the dealer and was told the car would need major repairs and could take up to 21 days once the work started it would have to he completed there because Hyundai had campaign dealing with my cars problem. I was told I could drive the car home but if the check engine light is flashing pull over immediately. My car is now at the 3rd dealer when I took it to korum in puyallup they did not have anyone to diagnose the vehicle only update onboard computer. They said and documented nothing was wrong with the vehicle which is inaccurate. I told korum about the paperwork from the dealer in cheyenne they did not so much as look at it. I took the car to the dealership in auburn washington they to had the same findings as wyoming also there was additional findings which corresponded with the smell of gas and my tank going empty after filling and trying to fill tank because was showing low fuel warning. Pictures were taken of the gas tank which had expanded as well as other pictures of the findings. I was told in wyoming and auburn that the code and findings are consistent with the Hyundai campaign.

See all problems of the 2020 Hyundai Sonata 🔎.

Is anything being done about the known oil consumption issues with the 2019 Sonatas? my daughter bought the car used -- it currently has 70,000 -- but Hyundai won't do anything because she is the second owner and those cars don't get 100,000 protection, they only get 60,000. It just doesn't seem right.

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The fuel tank expanded/swelled up causing frame damage to the vehicle.

See all problems of the 2022 Hyundai Sonata 🔎.

It was about 100 degrees outside yesterday, and while trying to pass a car, I look in my rearview mirror and notice there is fuel shooting out from my fill hose under my gas flap. I lost over 3 gallons of fuel on the road. This happened my whole 60 mile trip. This has happened to me before, but the temperature was around 76 degrees and it does not happen in cold weather. I have a feeling my fuel tank is expanding because when I took out my back seat where my fuel tank is located, the body of the car is all buckled up to the point where I can't get my backseat to latch down anymore. My car is available anytime for inspection upon request. I have not taken it to a dealer to get it looked at, there has not been a police report filed. And there were no warning lights or indicators other than a popping sound coming from my backseat area before the problem occurred. There are no warning lights or indicators after the problem either. I feel like I'm driving a bomb because my fuel tank could blow up at any time. This problem can be reproduced anytime by filling the tank and driving it in 90 degree weather.

Car has 39,495 miles. First owner of vehicle. Have advised dealership since 2024 that there was a oil issue as I have only went to them for oil changes. I advised that as they can see the car is barely driven and the oil is disappearing. They claimed nothing was wrong and made me pay for a oil change again. Come this year, I advise again there is a issue, they tried to have me pay for a oil change again and I advised something else needs done. They argued I was not the first owner and the car was not in warranty however I bought the car from their lot and I am the original owner. Then they stated I had to pay for another oil change for the oil consumption. Then they claimed they would just do the oil consumption and then to drive 1,000 miles and bring it back. After the oil consumption engine light is on. I drove 1,000 miles, brought it back and the engine failed the test. The dealership changed the engine. 5 days later engine light is on, car is stalling and brake locked up, then car would not start and was smoking under the hood. Car was then towed to the dealership. They claimed nothing is wrong and they reset the code for the engine light to go away. They stated evap code was on but was not persistent so it's fine. Few days later engine light comes on again and once the car has been running, you shut it off go to start it again it won't start unless you have it sit for a while. I take it back to the dealership they point next to the engine saying a purge valve, but the wants money for a diagnostic. They do the diagnostic and still provide maybes, as they claim the filler neck is rusted and corrosion. I take the car to another place who states the filler neck is fine.

The fuel injectors failed again, leaving me stranded on a busy road. The first time this happened, I had a little over 8,000 miles on my vehicle - 5 months after purchase. That was two years ago. Now, the injectors have failed for the second time and I am having to pay just north of $1,000 to get them replaced at my Hyundai dealership. It was a terrifying thing to experience and my safety was at risk due to my vehicle decelerating on a busy street. I had to call the police to help shield my vehicle from other drivers. The problem has been confirmed by a dealer upon inspection and diagnosis, and the police officer that was at the scene also could see that my vehicle would not start. This dealer works at the company that manufactures Hyundais. Prior to the fuel injection failure, there were brief moments where the 'check engine' light would illuminate but it would never stay on long. Directly before my vehicle shut off on the road due to the failure, there were no light/lamps/or other symptoms noticeable.

See all problems of the 2023 Hyundai Sonata 🔎.

First owner, sporadic acceleration problems reported from approx 6k miles. Documented with dealership. . “couldn’t reproduce” issue every time I brought it in after an occurrence. Dangerous when entering highway, as I never knew when it would fail/stall. Eventually broke down on busy interstate highway, replaced 1 fuel injector, and guilt tripped me into “needing” to have fuel injector cleaning because the others might fail as well. 27k miles was the first breakdown. 38k was the second breakdown and almost caused a serious accident when I was unable to accelerate. Replacing all 4 fuel injectors but not covering the oil change due to their faulty fuel injectors.

I bought this car in June 2013 for its safety and its amazing warranty and all the features that it has Hyundai manufacture had an obligation as a consumer service and failed to send notification of any recalled to us in regards to a recall high pressure, fuel pump, and fuel rail fuel system engine, gas tank this is a product of liability and negligence on time but they failed to take responsibility and comply with federal laws. I was driving with my family in the car when this car was a ticking time bomb not even being aware of the death trap on wheels. We ended having towed our home and then to then had to make a call next day and have it towed to Hyundai service center while we were driving this happen, where we heard two loud pops the gas gauge went down from 200 something to 80 engine lights came right up the backseats were heating up under my son seat in the back stated he felt waves as the backseat was getting hotter, we pulled over to a gas station and that’s when we had to call called o’reillys and then we called a mechanic friend which stated that he ended up looking up the car and stated please pull over and get out car and called the Hyundai manufacture that there was a recall that’s the only way we found out other than that no prior incidents, then called the service technician of Hyundai I called amd complaint with the Honda manufacture corporate. They have failed to take the responsibility for this and they should be ashamed and take their accountability for this we could’ve died and anyone else around us on road as we drive this car daily the car was a higher risk of a ticking time bomb stated by the Hyundai service center technicians. This is an nere to miss accident narrowly avoid catastrophe.

See all problems of the 2021 Hyundai Sonata 🔎.

Something went wrong in the fuel tank that caused it to become so pressurized that the tank expanded up and out so far that it pushed the exhaust pipe down and my back seat of out place. The only issue I had was the car was accelerating slower than usual but it wasn’t even enough of a difference for someone who didn’t drive it every day to be able to tell. It did this for two days then the check engine light came on and it just read “powertrain”. Began slow acceleration on 06. 08. 2025. Check engine light came on the night of 06. 09. 2025. I took it to the dealership 06. 10. 2025. I immediately took it into the dealership and they told me the car could have exploded. There was a previous recall for the fuel pump that I had replaced at the dealership. After seeing my car, they said their techs and the techs at hma have never seen one this bad and that maybe after replacing the recall part the system update failed in my vehicle and the issue was never actually resolved.

Engine light is blinking and put safety of my family in danger. I called the close huyndai dealer also I have a case number. However, it takes forever for them to answer. I only have this car. I am driver and this how I make living. I have no choice in driving this recall vehicle and kill my self and my family. No body care!.

See all problems of the 2014 Hyundai Sonata 🔎.

My car stalled while driving through an intersection and nearly caused a t-bone collision. The car would not start afterwards and towed to dealership. The car currently has 32000k miles on it. The inspection report stated leaking fuel injectors causing misfires. This was covered by warranty. The parts are currently backordered with no eta on possible repair indicating it might be a widespread issue. There were no warnings or lights prior to incident. The car had just been serviced at 30k miles by the dealership with no indication of possible failure given to me by maintenance department. The dealership is out of loan vehicles and I’ve been without a vehicle for 6 days now causing work and personal issues.

Oil consumption was ridiculously high, changing oil/topping off oil constantly. Car would not accelerate over 30 mph without sputtering and rumbling. I had mechanic diagnose bad sparks plugs due to sitting in oil from leaking. After I had them repaired/replaced the car drove great for 1 day, then decided to die in the middle of a busy intersection while I had my teenage son in the car with me. My son and I had to push it out of the busy intersection onto a side street to get out of the way! I had it towed to Hyundai dealer who said the spark plugs were bad and that the fuel pressure sensor and gdi pump were faulty and needed replacement. Left front lower control arm/ball joint assembly also requires fix. To the tune of $3000 + . It’s been at dealer for past few months until I can afford the repairs including the 2nd diagnostic and tow it took to get it to dealership.

See all problems of the 2018 Hyundai Sonata 🔎.

Multiple critical mechanical and safety issues have occurred with my 2018 Hyundai Sonata sport. The vehicle has experienced persistent engine misfire, a severe oil leak, emissions system failure, and extensive paint deterioration. A certified technician confirmed an active oil pan leak with no dashboard warning lights, posing a fire and stalling hazard. To prevent further damage, I replaced the entire oil pan and spark plugs at a personal cost of approximately $800 at firestone complete auto care. The check engine light revealed diagnostic code p0420 – catalyst system efficiency below threshold (bank 1). An o’reilly emissions scan confirmed the catalytic converter failure, and emissions status was marked “red. ” the vehicle will not pass an obd-based emissions test. At 149,219 miles, Hyundai refused warranty coverage due to mileage. A certified Hyundai dealership quoted $3,722 to replace both the catalytic converter and valve cover gasket, which remains unaffordable and unrepaired. In addition, the factory-applied white paint began peeling severely from the hood and roof. Although Hyundai issued a warranty extension for this known defect, the dealership refused to repaint the hood, citing a minor dent — even though the peeling is clearly unrelated. The exposed metal has started to rust, risking structural deterioration. All concerns have been evaluated by certified Hyundai service and independent professionals. These combined mechanical, emissions, and exterior failures raise serious safety and durability concerns. I am filing this report to document manufacturer-related defects that may affect other owners of this model and year.

I had engine issues back in 2021. I had to pay $600 for a part to be installed to fix the problem . The engine failed, the idle was violently lurching forward and would randomly shut down. Recently the car shut down without warning again. Its scary.

See all problems of the 2016 Hyundai Sonata 🔎.

In early may 2025 while driving around 40mph, I heard a very loud pop which startled me. Pulled over and looked back and noticed my backseats were push up out of place. I attempted to put the seat back into place but it wouldn’t fit into the latch anymore. The framing underneath the seats looked pretty damaged so I took it to a local mechanic. After doing some research, he found information for a check valve/fuel tank recall (service campaign 9b1) and then advised me to go a Hyundai dealership. I attempted to take it to the dealership, whom sent me away after I advised them of what happened. I came back the next day asking them to take a look at while informing them about the recall that could be related. Later that evening, they called and said the issue was directly related to the recall and the repairs would be covered. My car was in their possession for from 5. 12. 25 to 7. 25. 25 without any updates or instructions on what is happening. I was told they’re waiting to hear back from Hyundai manufacturer on how to proceed. They returned my car to me on 7. 25. 25 stating everything was repaired. On 7. 31. 25 they called me back stating my tank needs to be replaced and bring the car back ASAP. My car was again being repaired and was returned to me on 8. 25. 25. Now my vehicle will not start randomly sometimes. At this point, I’m under the impression my vehicle is no longer safe as all the issues I’ve been facing are fuel related.

Burns oil fast. 900 miles from an oil change the car oil stick was empty. There are no signs of oil leaking. Every 1000 miles you have to place oil back into it. I’m not the only one complains of this issue. I was reading on reddit and it’s thousands of people having the same issue.

Unknown, caught fire. ??.

See all problems of the 2013 Hyundai Sonata 🔎.

Fuel lines and connections / fuel tank band / fuel tank vapor vent system hoses [xxx]: my check engine light illuminated. I immediately returned to Hyundai riverdale. They advised me it could be the fuel tank and stated they needed to keep the car for 5-7 business days. May 1, 2025: I dropped off my car for inspection, having made arrangements for a personal rental car. May 7, 2025: I received a text message (no phone call) indicating the inspection was complete and was presented with a $3500 bill to replace the entire fuel tank. May 9 or 12, 2025: marilyn from Hyundai riverdale called me regarding my vehicle. She explicitly suggested I "contact your insurance company, advise them you hit something on the road, pay the deductible, and they will pay for the repairs. " she then stated, "I know you hit something after April 9th because your fuel tank is now damaged. " I denied hitting anything. During this call, she mentioned a "recall" related to fuel tanks on all Hyundai Sonatas, which I was never previously made aware of. I questioned why I was being charged if there was a recall for the exact issue I was experiencing. She claimed my car was previously checked and the fuel tank was fine, therefore the cost fell to me. May 14, 2025: merilyn called to inquire if my insurance would cover the repairs. I informed her I was picking up my vehicle as another Hyundai dealership in newnan was willing to perform the recall repairs for free. Upon arrival at riverdale, I faced resistance but demanded my car be released. I was then charged a $200 inspection fee, which I refused to pay. Marilyn then provided my keys and, upon learning I planned to drive to newnan, stated, "I wouldn't feel right letting you drive this car off the lot and something happening to you. Your vehicle at any moment can blow up due to the fuel tank. It's very dangerous to drive and suggest you get a tow truck. " April 11-may 1st I drove that vehicle w/no idea it had the potential to blow up. Information redacted pursuant to the freedom of informati.

I received a notice in the mail my car needed a software update. I went to the dealership to have the update performed. They informed me there was a service campaign for an expanding fuel tank due to pressure. They were unable to return my car to me at that time stating they were awaiting direction from Hyundai motor of America for the fix. The fuel tank expanded so much it bent the body of of the car underneath the backseat. It also broke the support straps. The dealership stated it was a known issue with a vent valve. Causing the fuel tank to swell so much it damaged the body. They have had my vehicle for 9 weeks with no direction as to what to next.

On [xxx] at approximately [xxx], my [xxx] daughter was using my car to go to work. When she called us and informed my husband that the car did not start. At that point he asked to video call him so that he can visually see what was going on. She was directed to turn on the car again at and that point, the car started then smoke was noticed from coming out of the hood. My daughter managed to open the hood where flames emerged from the center of the engine. She then ran in the house to get a fire extinguisher and managed to put it out and it reignited. She then made a second attempt with another fire extinguisher where it briefly subsided and then grew larger. At that point the fire dept arrived and successfully extinguished the fire and deemed the car totaled after the fire marshall carefully inspected the car. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

See all problems of the 2012 Hyundai Sonata 🔎.

Car is a Sonata hybrid limited equipped with a solar roof which charges the hybrid battery. Vehicle began to cut off battery power while parked, requiring the use of a factory equipped 12v override switch in March 2025 after approximately 3. 5 years of ownership. This occurred multiple times, often when the car was parked in the sun but independent of how long it had been driven prior or how long it had sat without being started. Evaluated by two Hyundai dealers; second dealer found a fault in the "solar dcdc converter" as well as the hybrid battery bulging. Battery module replaced. Unclear if this resolves the issue or it will recur again. Am speaking to Hyundai regarding battery warranty extension as vehicle had 88000 miles on it at the time of the issue starting. Online fora (e. G. , reddit, facebook) note other customers who have had similar problems with similar fixes. - [xxx] - [xxx] - [xxx] - one individual in this thread had complete power loss while driving down the highway this issue potentially risks stranding customers, and if the hybrid battery continues to bulge increases the risk of fire which could lead to property damage, personal injury, or death. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

So my car started to stall when I started it an when I started goin down the road like it wanted to die. Then I started to smell gas very strong so had a code tester put to my car an I have 6 permanent codes. An not only that im smelling oil strong an noticing big oil spots under my car. So I look under the hood an behind the turbo I see oil behind an underneath the turbo. I definitely didnt feel safe driving but now its not even drivable. I purchased it couple months ago from an individual an I cant belive the amount of problems this car has. Im a single mom an trying to support my family an its hard to now with a non running car. I've put quite a few parts hoping it would fix some of the problems an nothing has. I absolutely love the car an very beautiful but unfortunately to many problems with it. Eninge, gas leaks, timing.

My wife and son experienced a terrible situation on the way home from training. They had to stop at the nearest gas station due to the vehicle showing extremely low gas in the tank during a short drive home. The fuel gauge initially showed about half a tank but drastically dropped on the way home. They stopped at a gas station to add fuel but during the process, fuel starting spewing out of the tank. The vehicle was scheduled to be dropped off at a later date for an open recall (service campaign 9b1). I called the dealership and told them I needed to get the vehicle in right away due to the incident. After bringing the vehicle to Hyundai, they told me that the fuel tank exploded causing the tank to swell all the way around. Because the tank is located under the rear seat, we constantly heard air coming in due to the rear seat not seating properly. The check engine also was on and we smelled fuel while driving the vehicle. Hyundai representatives has been avoiding my calls to the point where I had to go in person for an update. Apparently, a district manager had to come inspect the vehicle to advise the dealership how to write up the request to send to corporate.

Unknown cought fire under the hood was engulfed within minutes.

Service campaign 9b1 that my gas tank has explanded/exploded due to the issue noted in the subject line. As you can see the whole bottom of the backseats have been raised up imcluding the part that connects to the gas tank itself. My car is immobilized and not drivable during this time. What is the next step to take?.

I have had this car checked out 3 times and on my way to the 4th appointment. I can be in the middle of the road or pulled up in my driveway the rpms go crazy shuts off every light comes on then clicks and I have to waite and try to restart. This car has been a problem since we bought it brand new even the chrome has come loose on it. Took to 1 dealership they said it's not throwing a code so nothing they can do I pulled out of the dealership onto the busy highway and the rims went crazy lights came on and it died called the mechanic that said nothing was wrong he came out got it running took it back came back said nothing showing up so there was nothing he could do. I'm driving another 3 hours away hoping I make it to another dealership that said they would look at it after I sent pictures and a video to the mechanic. I will never buy another Hyundai again and definitely tell anyone I know not to.

My 2018 Hyundai Sonata (approx. 60,000 miles) began consuming excessive oil, and the engine started smoking while driving. My wife barely made it to the dealership — the car was unsafe, struggled to stay running, and visibly smoked from under the hood. Hyundai acknowledged the oil issue but refused to cover engine replacement. Instead, they approved a one-time combustion chamber cleaning and requested we drive the car 1,000 miles to "see if it gets better. " this is a major safety concern. The vehicle is part of a group of Hyundai models known to have defective theta ii engines that have led to engine failure, fire risk, and recalls. This issue is widespread, and Hyundai is not taking proper responsibility for defective engines in cars like mine.

I experienced an issue where the gas tank in my 2020 Sonata began to swell and emit loud popping noises while the vehicle was parked. I took it to the dealership, and Hyundai corporate eventually acknowledged the issue and agreed to buy out my loan. However, no official recall has been issued for this model year. This problem has had a major impact on my life. I lost my job due to not having transportation for over two months, and the stress of not knowing whether my vehicle was safe made it even worse. I had to upgrade my insurance for a loaner I never received, take financial hits, and go into deeper credit trouble—all while also recovering from a serious injury from a previous car accident. I now have to start over with a new loan while my credit is already damaged. I’m submitting this report not just for myself, but to ensure that other 2020 Sonata owners are protected and made aware of this issue. I believe this is a serious defect that warrants official investigation.

Fuel system expanded back seat.

The affected component is the engine/rod bearing (theta ii 2. 4l). My 2011 Hyundai Sonata stalled and the engine locked up twice in live traffic (March 2025 and July 2025). The vehicle is available for inspection if needed. This created a serious safety risk to me and others on the road, as the stall occurred on [xxx] at highway speeds. This failure could have been catastrophic had it happened on the DC/baltimore beltway or another high-traffic roadway. Hyundai’s system shows recall 132 was marked complete at very low mileage (around 32,000 miles), but my vehicle later developed oil consumption and stalling consistent with rod bearing failure. Capitol heights Hyundai noted a warranty pre-authorization (PA) in March 2025 and told me Hyundai needed my mailing address “for the claim,” but later said it was a typo and that no record exists. The dealership charged me for a diagnostic but did not inspect the vehicle for rod bearing failure, despite symptoms consistent with recall 132. Annapolis Hyundai, where the car was purchased as a cpo, has admitted they have no documentation that recall 132 was ever performed (no repair order, mileage, or technician notes). Yet Hyundai’s system shows recall 132 marked “complete. ” without proof that the ksds software or bearing inspection was done, I belive this recall should be considered open. Hyundai consumer affairs has stated that I must pay for towing and diagnosis before they will investigate, with possible reimbursement later. This conflicts with federal law (49 u. S. C. § 30120), which requires recall diagnosis and repair at no cost to the consumer. Prior to the failures, my vehicle had a history of oil consumption and “no oil on dipstick” findings, which are known precursors to rod bearing failure. No warning lamps appeared before the stalls. I am requesting NHTSA’s assistance in requiring Hyundai to provide documentation or reopen recall 132 and perform a no-cost inspection/repair to ensure this vehicle is safe to operate information redacted pursuant to the freedom of.

See all problems of the 2011 Hyundai Sonata 🔎.

The car would excelerate while in park. While I was pressing the brakes the car would jerk forward, it would not just quietly idle. While driving the car would randomly speed up or slow down. Sometime it would sound like it was going to shut off and start vibrating.

On [xxx], in washington, d. C. , my 2013 Hyundai Sonata experienced sudden engine failure, leaving the vehicle inoperable. My goodwill repair request was denied within 30 minutes, without a proper inspection of the rod bearings (a known failure point covered under the txxi extended warranty) or the fuel pipe recall—a known issue that could pose a fire hazard. Hyundai cited suspected maintenance neglect, but I have documentation of regular synthetic oil changes. Despite having over 200,000 miles, a firestone inspection from September 2024 confirmed the vehicle was in good condition prior to the failure. Additionally, Hyundai theta ii engines are widely known to suffer from excessive oil consumption, a defect that can lead to premature engine failure even in well-maintained vehicles. Hyundai has replaced engines in vehicles with similar mileage under the same extended warranty, yet in this case, no proper inspection was conducted before denial. Safety concerns: the fuel pipe recall was not inspected, raising concerns about whether unresolved recall defects are leading to engine failures or fire risks. The airbag clock spring, covered under Hyundai’s txxa extended warranty, was not inspected, despite the airbag light being illuminated, potentially affecting airbag deployment in a crash. The vehicle failed without warning lights or error messages, creating an unsafe situation. Hyundai’s failure to inspect recall-related issues before denying repairs could impact other affected vehicles on the road. I request that the NHTSA: ensure Hyundai properly inspects recall-related components before denying repairs. Investigate whether Hyundai is improperly denying warranty and recall-related repairs, even in cases where similar vehicles have received replacements. Determine if the unresolved fuel pipe recall and airbag clock spring defect pose broader safety risks. This issue has been reported to Hyundai corporate, but no proper inspection has been performed. Information redacted pursuant to the freedom of informatio.

Car keeps jerking also it’s something going on with the fuel injections I’ve had to get them replaced twice. Please help.

I took my car in for a standard oil change and tune up. They found out that the fuel tank had expanded to the point where it caused significant damage to the metal frame. The Hyundai dealership sent it to the local body shop for an estimate for the frame, they sent it back because the dealership hadn't removed the gas tank, then the dealership sent it back to the body shop. It's been 3+ weeks, my car is still in the shop, and I haven't received any indication of whether my car is able to be fixed. The dashboard never displayed any warning messages and there were no symptoms of the problem. I had no idea the gas tank had expanded and could've caused an explosion or fire.

Took my car in February 10 for a recall that pop up on the app and today is June 22 and I’m getting all the run around and different dates for my car to be ready but everything it’s time to pick up my vehicle something comes up and they told me they took my car back to the body shop for the recall issue. All the information are added on the file.