2006 Hyundai Sonata: fuel pump failure

Filed Aug 29, 2019 · Fuel system · 5 miles · MN

While driving our 2006 I noticed after stopping at a store and got back in it was hard to start. It finally did start, this had never happened before. As I was driving I noticed the gas gauge had moved from 3/4 of a tank to 1/2. I thought maybe I just looked at it wrong. But by the next stop light I was down to 1/4 tank. By this time I was closed to home, so when got home and got of the car I noticed a trail of gas behind me. I looked under the car and gas was pouring down from the gas tank on top of exhaust. How it didn't catch on fire I have no idea. I found that the gad line from the fuel pump to the main gas line had rusted and under pressure it blew. Thank god we dint give this car to our granddaughter as we were in the process of doing.

Filed May 28, 2014 · Fuel system · 118,000 miles · MO

Fuel pump failed when starting the vehicle. The repair shop has reported scorch marks on the fuel pump assembly, and a melted/fused screen. He tells me that the failure/short could have caused an explosion.

Filed Jan 16, 2013 · Fuel system · 67,400 miles · AZ

Driving from bakersfield, ca to auburn, ca on 12-20-12. Filled with fuel about 15 miles before auburn. Parked in auburn, car would not start about 3 hrs later. Towed to garage on 12-21-12, started at garage, could find no problems. Drove from barstow, ca to payson, az on 12-27-12. Would not start next morning. Mechanic came on 12-30-12, car started. Had mechanic come on 1-16-13 to check fuel pump. Started to replace the electric fuel pump, found that the power connector from the pump to the connector at the top of the fuel tank had burnt, corroded. Discolored connections. This is inside the fuel tank! Have had to order a new pump assembly from hyundai. Don't if it is an upgraded part.

Filed Mar 27, 2012 · Fuel system · 36,000 miles · NY

2006 hyundai sonata. Vehicle was parked overnight . The vehicle would not start in the morning and was towed to a repair facility. An independent mechanic examined the vehicle and stated that the fuel pump had no pressure, that the housing was melted/burned and had a faulty/worn connection. As such, the pump was inoperable causing the failure. Hyundai of huntington, ny stated backorder of fuel pumps with no eta from the manufacturer and housing was also unavailable. The dealership offered no assistance as "not covered by powertrain warranty." independent mechanic having difficulty finding suitable replacement/new part(s). The failure mileage was approximately 36,000.

Filed Sep 9, 2011 · Fuel system · 67,000 miles · CO · fire

Tl* the contact owns a 2006 hyundai sonata. The contact was driving approximately 10 MPH when the vehicle stalled. The vehicle would not restart and was towed home. An independent mechanic examined the vehicle and stated that the fuel pump was burned, causing the failure. The vehicle was not repaired. The manufacturer was made aware of the failure and offered no assistance. The failure mileage was 67,000.

Filed Oct 7, 2009 · Fuel system · 68,263 miles · DE

This issue involves the combustion of a plastic fuel pump power supply connector inside the fuel tank of a 2006 hyundai sonata. A pin on the outer connector was also burnt. The pump actually still works - it only quit because the connectors burnt - including the connector inside the tank to the point that an electrical connection could not be made. If the fuel pump motor wore out after several thousand miles (usually well over 100k in most cars - not 68k) then I may understand an argument for the hyundai service manager's contention that this is "normal wear". I believe that a connector burning inside a fuel tank is not "normal wear" and is also likely to be a safety hazard. Hyundai motors and the dealership have both been notified of my concerns and they show no indication of doing anything to correct it other than to replace the pump at my expense - undoubtedly with one of the same design. I took the old pump from their shop and I am keeping it for future evidence. The incident occurred when trying to re-start the vehicle after it had been parked. I don't plan on keeping the vehicle for another 68k miles because I'm concerned that we may need an undertaker instead of a tow truck the next time.