2015 Hyundai Sonata fuel system problems

Filed Oct 31, 2026 · Fuel system · FL

The vehicle is currently at Greenway Orlando Hyundai for a fuel-system-related repair. During the dealership’s inspection, the dealership identified a crack in the fuel pump housing and a fuel leak. The dealership also provided photographs documenting the crack and the leak, and the vehicle has a very strong fuel odor. My primary concern is safety. A cracked fuel pump housing with a fuel leak presents a potential fire hazard. I do not believe it is safe to drive or operate the vehicle in this condition. The vehicle is being serviced in connection with Hyundai TSB 23-FL-004H, “Fuel Pump Filter Warranty Extension (TXXS), Inspection and Replacement.” The Prior Approval/goodwill issue is particularly important in this case. Note 2 on page 2 of TSB 23-FL-004H states that when a part not covered by the TSB is found to require replacement while performing the TXXS procedure, and that part is out of warranty, the dealership should submit a Prior Approval request for goodwill consideration before performing the work. When Greenway Orlando Hyundai identified the cracked fuel pump housing and the fuel leak, I asked the dealership to pursue this solution with Hyundai. Initially, the dealership refused to submit the Prior Approval/goodwill request. Because of that refusal, I personally contacted Hyundai, opened a complaint/case, and informed the dealership about the situation. I also insisted that the dealership submit the Prior Approval request contemplated by Hyundai’s procedure. Only after my insistence did Greenway Orlando Hyundai submit the Prior Approval/goodwill request to Hyundai. That request was subsequently denied. Therefore, I want to make it clear that I am not simply disputing the cost of a part that I chose to replace. The damaged component was identified by the dealership itself while the vehicle was undergoing fuel-system-related service. I asked the dealership to pursue the solution provided for under Hyundai’s procedure, but I had to take action directl

Filed Oct 14, 2026 · Engine, Fuel system · MS

A franchise dealership performed a federally mandated safety recall service (ECM Software Update) and a knock sensor replacement on this 2015 Hyundai Sonata 2.0L Turbo. To perform these specific repairs, the technician had to work directly around the intake and turbocharger assembly workspace. Immediately after picking up the vehicle, it suffered a sudden and dangerous loss of power and refused to accelerate normally on the highway, creating a severe traffic hazard. Upon an immediate emergency inspection by the same service center 5 days later, the dealership documented in writing that the turbocharger intercooler hose clamps were completely off/unfastened. Because the technician left the clamps disconnected, the turbo lost sealed pressure, failed completely, and began dumping high-pressure engine oil backward through the air filter intake box. The service center is now refusing to take responsibility for the mechanical safety failure directly caused by their technician's recall repair negligence.

Filed Oct 11, 2026 · Engine, Fuel system · TX

I am filing this complaint regarding transmission and drivability problems with my 2015 Hyundai Sonata 2.4L following Hyundai Campaign 9C-2. My vehicle was running and driving perfectly before this update. I have always maintained it on time, followed proper maintenance schedules, and have records documenting its maintenance history. I never experienced these transmission issues before the update. The problems began immediately after the campaign was performed. In fact, I noticed the abnormal shifting before I even left the dealership after picking up my vehicle. Since the update, the vehicle has experienced poor and abnormal shifting behavior. I contacted the dealership to report the problem and also filed a complaint directly with Hyundai Corporate. I was told that Hyundai is aware of the issue, yet my complaint remains unresolved. I also located a document online indicating that Hyundai is aware of this problem. Additionally, I have seen numerous reports from other Hyundai owners describing similar transmission problems after receiving this same update. My vehicle has approximately 82,000 miles. The engine was replaced approximately one year before this complaint. Given the vehicle's excellent operation before the update, my documented maintenance history, and the immediate onset of the problems at the dealership, I am seriously concerned that Campaign 9C-2 caused or contributed to these transmission issues. I am requesting that the federal safety agency investigate whether this software update causes or worsens transmission shifting problems in affected Hyundai vehicles. Hyundai's awareness of the reported issue and the apparent number of similar owner complaints make this especially concerning. I believe this issue deserves investigation to determine its cause, assess any potential safety risks, and establish whether corrective action

Filed Sep 11, 2026 · Engine, Fuel system · VA

After receiving the Hyundai Service Campaign 9C2 update on my 2015 Hyundai Sonata on XXX, I have started having jerky acceleration when the car is first started and am driving. Also, while driving at highway speed (~65 mph)) and I take my foot off the accelerator to coast, the engine RPM drops suddenly, anywhere from 250 rpm to 750 rpm, then recovers abruptly to where it was at prior to the drop (typically around 2000 rpm). The engine rpm also drops while driving at slower speeds and recovers but is not as noticeable as it is at highway speeds. It was not doing this prior to the Service Campaign. There are no check engine lights or pending codes. I brought it back to the Hyundai dealer and discussed the issue with them on XXX. They acknowledged it was likely due to the Service Campaign and they did not want to keep the car to look at it and said no damage was being done and it was safe to drive. They said a fix was in the works but did not know how long until it was released and I should receive information in the mail on it. Video link [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Aug 19, 2026 · Fuel system · AZ

Issue- fuel pump/supply line causing fuel to leak and fuel smell around the outside of the car. This can cause a major fire, explosion, death for myself and others around me. Problem has been confirmed by auto repair shop. No warning messages on car dash board, just strong smell of gas. Replaced gas cap and smell is still there.

Filed Aug 6, 2026 · Electrical, Fuel system · MA

1.) Following Hyundai's 9C2 Campaign update for the ECU that was completed back on May 27th, 2026, my 2015 Sonata went into limp mode [solid check engine light present] while I was accelerating up an on-ramp on the 2nd drive cycle since the update was performed. I was already far away from the dealership so I was forced to limp it to my local shop that I regularly use to have it checked out. It was confirmed that the code on the vehicle was P200A for intake manifold runners. Since the update was for smog regulation, the code was cleared in order to see if it would come back. Since then, it has not, however the vehicle continues to have one persistent problem. The RPMs will dramatically dip and then surge back upwards while the car is coasting (no gas and no brake applied). 70% of the time, you can feel the car violently jerk as it appears to try and correct itself. 2.) I've brought this car to multiple dealerships, have a case open with corporate and have also found that this is a systemic issue with this specific update in these cars. All and all, nothing has been done. I'm repeatedly turned away over and over again because their techs are only permitted to look into it once they have hard evidence of a fault. In this case, that would be a dashboard light. I'm told that I may only return if the check engine light comes back, which as I mentioned previously, posed a HUGE safety risk to myself the first time it appeared. If I can only go 55mph down the highway, I am at risk of being rear-ended or struck in some way. 3.) The problem has not been reproduced by the dealer as they will not test drive it to see the dip and spike. However, the code was still pending for awhile in the vehicle before it cleared it on its own, so that was acknowledged by at least one place. 4.) Vehicle has not been inspected by anyone but a dealership and local mechanic. 5.) No other signs prior to the vehicle limping out on me other than some acceleration concerns on May 27th, 2026.

Filed May 1, 2026 · Brakes, Engine · WI

I have the 2015 Hyundai sonata with the 2.5 GDI engine that eventually will seize due to internal damaged caused by manufacture design flaws. My Hyundai threw a P0010 code which causes my car to idle high and causing low vacuum affecting my brakes. I had a diagnostic test done at a Hyundai dealership that told me it was a cvvt cam sprocket issue and that it was the beginning of the end of the engine, They quoted me 3700.00 but the engine was to far gone and this repair would only accelerate the engine to seize. They said since the engine isn't seize Hyundai will not cover the cost to repair or exchange the engine, I contacted the Hyundai customer service who stated since the repair that is needed wasn't the root cause of the problems associated with the engine swap warranty they were not going to help me even though I explained to them that the cars high accelerating and the braking system been jeopardized and been told the engine is beyond repairs I feel Hyundai should reconsider their decision and help a loyal customer. I have purchased 12 Brand New Hyundaj since 2001. The customer Representative was Extremely un Professional even suggesting I scrap my car, Also I contacted My Hyundai service Technician who said Hyundai customer service never contacted them about my car, When they said they spoke with the technician. Also I received an Extended warranty on the 2.4 GDI engine from Hyundai who many Hyundai customers are or have dealt with.I also purchased an Extended warranty Which I believe should have been extended as well Thank You

Filed Feb 17, 2026 · Engine, Fuel system · SC

Component/System Failed: Engine – connecting rod bearing failure consistent with Hyundai Theta II engine defect subject to federal recalls and Consent Orders. The vehicle previously received Recall Campaign 953 (KSDS software update), intended to detect premature rod bearing wear. The engine is currently knocking and has been diagnosed as requiring replacement. The vehicle and engine are available for inspection upon request. Safety Risk: Rod bearing failure can cause sudden engine seizure or stall while driving, creating a significant crash risk due to loss of power steering and braking assist. Engine failure DID occurr despite prior recall software update, indicating potential recall remedy ineffectiveness. Sudden stalling in traffic placed myself and others at risk of collision. Dealer Confirmation: Hyundai of North Charleston confirmed through warranty history a prior engine replacement request (PA) was submitted by a previous owner but denied. The recall repair was never performed. Current diagnostic findings indicate engine failure consistent with known recall defect. However, Hyundai has refused to perform further inspection or goodwill repair solely due to the vehicle’s salvage branding. Inspection History: The vehicle has been inspected by a Hyundai dealership. No engine replacement was completed. Hyundai Customer Care has updated case notes but is declining remedy based on title status rather than mechanical condition. Warning Lamps/Symptoms: The vehicle previously received KSDS software update. Engine knocking developed consistent with rod bearing wear. The software did not provide effective prevention of engine failure. The engine now requires replacement. Hyundai is refusing recall-related remedy due to salvage title (predates my wonder ship by many years), despite federal recall obligations applying to the vehicle VIN. This complaint concerns potential failure of recall remedy effectiveness and denial of defect-related inspection.

Filed Dec 2, 2025 · Fuel system · 55,300 miles · FL

The contact owns a 2015 Hyundai Sonata. The contact stated that while driving at 45 MPH, the vehicle suddenly stalled. The vehicle was parked on the side of the road and failed to immediately restart. The vehicle was later restarted and driven to the residence. The vehicle was taken to the local Auto Zone, but the cause of the failure was not yet determined. The vehicle was then taken to the local dealer to perform a diagnostic test. No further info was available, and the vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 55,300.

Filed Aug 19, 2025 · Engine, Fuel system · TX · fire

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.