2015 Hyundai Sonata: fuel pump failure

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 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 5, 2026 · Engine · CA

Engine / Short block assembly / Connecting rod bearing seizure. The engine suffered a sudden, catastrophic seizure while I was actively driving on a steep incline mountain road with a cliff on one side and forest on other. The vehicle experienced an immediate, total loss of motive power, forcing an emergency maneuver onto the shoulder in 5 seconds with no power steering or power brakes, creating an extreme collision hazard on a high-speed incline. The rod bearing melted due to a manufacture defect and could have also possible caught fire in heavy fire country. The fuel pump was also leaking recently and just replaced. They are nearly $1800 for a new pump because of price gauging because they are in "high demand". The Check Engine Light was solid (not flashing) for a thermostat code (P0128) due to extreme internal friction/heat from the failing bearings. There were no flashing KSDS warnings or physical signs of engine overheating. My car was denied a new engine under a Federally Mandated Warranty explicitly stating the exact symptoms of internal engine defect that happened in my car under "owner neglect" even though I have changed my oil regularly and even before the manufacture recommended time frames to do so. I've changed the valve covers, 02 sensors, thermostats, and plenty more on this car than any other car I have ever owned proving I'm actually an exceptional owner. I remained nice to all corporate staff during this process while they denied my car proper care under a Federal Mandate. I bought this car to believe that Hyundai was a superior company in regards to warranties, price, and function as opposed to the more expensive counterparts of the same class. Which in the end has cost me way more, and almost my life. This car is dangerous and the company has done everything in their power to try to cover it up while placing blame on the very consumers that are believing in them to do better.

Filed Dec 16, 2025 · Electrical, Engine · GA

i've had my 2015 hyundai sonata now for A year. i took it to the hyundai place to have recalls on the security fixed. and told them about the valve cover gasket leaking. they said they fixed it. however every since i took it to the dealership i have had nothing but problems. my car makes a rattling noise when i accelerate, i smell a strong gas smell occasionally at random times but always while driving. my driver brake light has never worked, my driver headlight keeps blowing, my airbag light is now coming on randomly, my car has a bag vibration while going down the road, when i let off the gas it stops and i have replaced tires and still it won't go away no matter what i have done to fix it , and there has been many times after i return home the smell of something burning as off something is on fire is coming from my car. i have even been in panick thinking something today home was on fire but the smell was coming from my car. and others have even stated they smelled it as well. i've already taken out two loans to fix the valve cover gasket and the fuel pump filter, i can not keep taking out loans to fix problems that appears to be problems from the manufacturer and same problems others have had due to malfunctioning issues. i have children that ride in my car, i would hate for someone to get hurt or worse bc of manufacturing problems. then hyundai would have a bigger problem on their hands.

Filed Jul 18, 2025 · Fuel system · TX

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.

Filed Mar 19, 2025 · Fuel system · FL

The low pressure fuel line connector to the high pressure fuel pump failed and sprayed fuel over the hot engine. This could have easily cause a vehicle fire and death. This is a KNOW ISSUE and is covered by a safety recall on 2013-2014 Hyundai Sonatas (Hyundai Technical Service Bulletin 20-01-030H). The same issue occurred on this 2015 Sonata that was built in June 2015. A temporary repair had to be made until Hyundai could inspect it. Vehicle was taken to Holler Hyundai in Winter Park, FL and inspected. Results were forwarded to Hyundai Motors America and the repair was declined because the 2015 models were not included in the recall. It is our belief that the same connector was also used on some 2015 Sonata models prior to the issue being discovered.

Filed Mar 18, 2025 · Fuel system · 85,000 miles · FL

The contact owns a 2015 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, there was an abnormally strong gasoline odor inside the vehicle. There was a warning light illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the fuel pump. The contact was informed that the fuel pump was leaking and needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 85,000.

Filed Sep 29, 2024 · Engine · PR

Engine turned off running. Car was at Hyundai Dealer, Puerto Rico for 5 months. The car belongs to campaign lots 21-01-066H and 19-01-006H-2, which establishes alternative transportation service, or rental car coverage, the transportation service was denied. In addition, Hyundai PR did not provide me with a warranty period for the new or remanufactured engine, fuel pump and starter. A complaint was filed with DACO (government agency) and it was found in favor of the defendants Hyundai de PR and Sojitz (Cataño, PR) since they did not issue documentation reporting that it was covered under the campaign, they argue that it was as a courtesy (good will) which they also did not present evidence of. After repaired (200 miles) the car presented low voltage, code P0234-P0236 overboost condition, the unit was verified presenting broken cables from one tail of the map sensor. I incurred transportation and crane expenses, and the repair of the cables, and the replacement of the map sensor.

Filed Dec 8, 2023 · Engine, Fuel system · IL

In the first incident(2020) after the check engine light was on, the car was towed and needed the valve cover and fuel pump gasket replaced due to leakage. In November of 2023, the check engine light kept flashing and again the car was towed to the dealer. The valve cover was removed and we were told a new engine was needed, but we would have to pay for it. We were old that we have neglected to keep oil in the vehicle.

Filed Oct 2, 2023 · Acceleration, Engine · MO

I am 86 years old. I bought the car brand new so I am the original owner. I have kept the car perfectly maintained and garaged from the day I bought it. My wife is also 86. She and I are the only ones that drive the car. To date, it has 73,822 miles on it. The main issue I am having is random, unpredictable stalling and hesitation when trying to accelerate. We have also had unintended acceleration. This always happens at the worst times which causes grave concern for our safety. We have taken the care to the dealership here in Cape Girardeau, MO called Chris Auffenberg Hyundai. They've charged me $130 only to tell me nothing is wrong. I have continued to try to work with them and they now have decided a new fuel pump will fix this which is $730. I have noticed there are already hundreds of complaints on the 2015 that all say they have the same exact issues I am having but this dealership doesn't seem to care. Here is what I have read. "The most common issue in the 2015 Sonata lies with its faulty throttle control system, which can cause stalling, hesitation, and even unintended acceleration. Currently, there is no fix from Hyundai." My dealership will not acknowledge this even though it is public information. I feel like they are going to keep replacing parts and are taking advantage of me. [XXX] is the Service Manager at this dealership and I am not happy how he is handling this. Please let me know if there is any additional information I can provide. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Sep 11, 2023 · Fuel system · AR

Noticed a smell of gasoline in the passenger compartment and took it to my local mechanic. Upon his inspection he found that the gas smell was caused by a crack on the plastic connector for the fuel line on top of the fuel pump. He showed this to me and recommended replacing the fuel pump as the connector is built into the pump and there was no proven way to fix the leak. Said leak caused gasoline fumes to fill the passenger compartment and therefore a risk of igniting a fire in the passenger compartment.

Filed Aug 18, 2023 · Fuel system · 163,402 miles · AZ

Strong gas Odor from inside the vehicle low pressure fuel pump is leaking from underneath the back seat of the vehicle down the side of fuel tank onto the exhaust it can cause a fire fuel pump is cracked on nipple the pressure line connects to that runs to the motor on the vehicle repair cost is over 1000 dollars to replace the fuel pump to fix the issue