Hyundai Sonata fuel leak 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 Sep 5, 2026 · Fuel system · AZ

The low-pressure fuel pump module assembly, located directly beneath the rear passenger seat cushion, experienced a plastic housing failure. A stress fracture on the upper plastic fuel outlet nipple caused raw liquid gasoline to actively weep and pool on top of the module inside the passenger cabin. This component is retained and available for inspection upon request. RISK TO SAFETY: Raw liquid gasoline pooling inside the interior passenger compartment creates an severe, immediate fire and explosion hazard. Additionally, vehicle occupants were exposed to toxic fuel vapors while driving. INSPECTION & DEALER CONFIRMATION: An authorized Hyundai dealership inspected the vehicle and confirmed raw fuel leaking at the top of the fuel pump module assembly. This exact module had previously been removed and disassembled during a 2024 manufacturer recall service to replace the internal fuel filter and tank seal. Stress applied to the plastic fittings during that recall service appears to have caused the plastic top-hat to fracture over time under line pressure. Hyundai Corporate was notified of the safety hazard and prior recall history, but refused assistance. WARNING SYMPTOMS: The failure began with a strong, persistent fuel odor inside the vehicle cabin. No dashboard warning lights, check engine lights, or diagnostic trouble codes (DTCs) triggered prior to or during the failure. SUMMARY: A stress-fractured plastic fuel pump housing allowed raw fuel to pool in the passenger cabin following a prior manufacturer recall repair involving the disassembly of the same component.

Filed Jul 23, 2026 · Engine · 172,000 miles · VA · fire

The contact owns a 2019 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, smoke started coming from the hood and the vehicle was pulled over into a parking space. While opening the hood, the contact saw that fire was coming from the top of the engine. The contact stated that the fire consumed the front of the vehicle, including the windshield and the dashboard. The smoke coming from the vehicle was dark gray and turned black afterwards. The contact called 911, and the Fire Department was able to extinguish the fire. There were no injuries reported. A vehicle parked next to the vehicle was damaged by the flames. The contact's vehicle was not inspected or officially deemed a total loss. The vehicle was towed to an independent mechanic where an oil change had been performed prior to the failure. The mechanic stated that there might have been a high-pressure fuel valve on top of the engine that possibly caused a gas leak, which started the fire. The vehicle was not diagnosed or repaired. The dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was 172,000.

Filed Jun 4, 2026 · Fuel system · 108,000 miles · GA

The contact owns a 2020 Hyundai Sonata. The contact received notification of the federal safety agency Campaign Number: 25V796000 (FUEL SYSTEM, GASOLINE). The contact stated that while driving 60 MPH, the vehicle was leaking fuel from the fuel tank. There was no warning light illuminated. The dealer was contacted and notified of the failure, and the vehicle was repaired. The contact stated that the failure was a recurring failure. The manufacturer was notified of the failure. The failure mileage was approximately 108,000.

Filed Mar 3, 2026 · Engine, Fuel system · MD

My 2013 Hyundai Sonata has a replacement 2.0T Theta II engine. Recently, it developed a fuel leak that identically matches the description of Hyundai recall Recall 22-01-047H (the federal safety agency #22V‑312). I have attached a description of my fuel leak as assesed by a Hyundai dealership alongside a .pdf of the federal safety agency safety recall report to demonstrate that the issue is identical. Hyundai corporate is refusing to acknowledge that this is an identical issue and that my exact VIN group for 2013 Sonatas should be included in this recall. This issue represents a serious risk to life and property that Hyundai is refusing to officially address. They have refused to cover repairs for this issue. Additional info: my car has 124,047 miles on the odometer, but this replacement engine only has about 26,000 miles on it.

Filed Feb 28, 2026 · Fuel system · FL

I am filing this complaint regarding Recall 25V‑796 (Hyundai Recall 286). On November 27th, while driving, my vehicle made a loud popping noise twice and then began sounding muffled. About a week later, while on a long-distance drive, I attempted to refuel and the gas would not go into the tank. At another gas station I was able to fuel it, but afterward the vehicle began rapidly leaking fuel while I was driving. The fuel gauge was also malfunctioning. It showed 53 miles remaining and then suddenly jumped to 200 miles. It was not accurately reflecting the fuel level. When I stopped again for gas, the same muffled noise occurred and the fuel level rapidly dropped again. Due to safety concerns, I took the vehicle directly to the dealership.I dropped the vehicle off on December 6th and it has remained at the dealership ever since. The vehicle is currently sitting in their lot with no remedy available. I am still making monthly payments on a vehicle I cannot use. Although Hyundai provided a rental vehicle, it has now been over three months of inconvenience, including having to exchange rental vehicles for service. This has caused disruption to my daily life and financial strain. Hyundai has offered to pay off my loan and provide 8% toward the purchase of another vehicle. However, I am a single mother who is currently rebuilding financially after losing my job in prior years, and my credit score has been affected. I do not believe I should be pressured into purchasing another vehicle due to an unresolved manufacturer safety defect. I also attempted to seek guidance regarding Florida Lemon Law, but was informed that I may not qualify because the vehicle was purchased in April 2023 and the issue occurred after the two-year period. However, this is a manufacturer recall involving the fuel system, and I believe it is unfair that I am left financially responsible for a vehicle with a serious safety defect and no available remedy. I am requesting investigation

Filed Jan 27, 2026 · Engine, Fuel system · TX

I had recall 162 - engine replacement completed in 2024 , now I have fuel leak at high pressure fuel pump, the pump that is a component of the engine has now failed which was installed during the engine replacement which can cause a major fire

Filed Sep 3, 2025 · Fuel system · NV

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.

Filed Aug 22, 2025 · Engine, Fuel system · 192,000 miles · TN

The contact owns a 2013 Hyundai Sonata. The contact stated that while her sister was driving at various speeds, there was an abnormal, fuel odor coming from the vehicle. Despite the odor, the contact's sister resumed normal driving operation and later refueled the vehicle. After fueling the vehicle, the fuel odor was stronger, and the tire pressure warning light was illuminated. The contact's sister pulled over to inspect the vehicle, but found no failure. The next day, upon starting the vehicle, there was smoke coming from under the hood of the vehicle. The vehicle was taken to an independent mechanic, where the mechanic immediately smelled a fuel odor and later discovered a fuel leak while inspecting the vehicle. The mechanic showed the contact the fuel leak and diagnosed the vehicle with a defective fuel system. Upon investigation, the contact linked the failure to the federal safety agency Campaign Number: 18V934000 (Engine, Fuel System, Gasoline); however, the VIN was not included. The vehicle was not repaired. The contact attempted to reach the manufacturer but was unsuccessful. The failure mileage was 192,000.

Filed May 29, 2025 · Fuel system · FL

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.