Hyundai Sonata fuel pump 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 22, 2026 · Fuel system · AL

The vehicle experiences a severe delayed start/extended crank condition before finally starting. This is caused by a loss of fuel pressure prime due to the defective fuel filter housing leaking internally, creating an unpredictable and unsafe vehicle operation hazard. The dealership is denying coverage under the 15-year/150,000-mile extended warranty (Campaign TXXS), claiming the issue is a standard fuel pump failure while completely ignoring that the integrated fuel filter housing defect causes this exact failure."

Filed Oct 22, 2026 · Fuel system · LA

The fuel tank assembly became pressurized with compressed air due top worn purge control system check valve. This caused the tank to deform and the deformation of the tank led to the fuel pump being pushed out and the back seat of the car was completely unattached and no longer secured. There was a strong presence of gas smell in the car as well. The check engine light came on and the car began to drive poorly. It was taken directly to a Hyundai dealership where it remains as of today. This could have resulted in the car catching on fire and potentially killing everyone in the car. My [XXX] daughter and 2 friends was driving the car from Louisiana to Mississippi when this occurred. The dealership in MS told her she needed to call and find someone to come and get her because the car was not safe to drive. My daughter was stranded in another state and had a college friend come and get them since I did not have a car and I was in Louisiana. After several hours her friend was able to pick them up which she remained stranded in MS for an additional 4 days. I had to get a friend to meet them halfway and bring her home because the dealership said there was nothing they could do to assist with transportation. This occurred on [XXX]. My car remains at this dealership in MS with only the testing to say the gas tank test failed and the car could not be driven. I was told Hyundai would offer a buyback on my vehicle because the repair was costly and time consuming. I have not been reimbursed for my transportation expenses through Uber as of today. I was told I could rent a car and they would reimburse my expense after I submitted a receipt and waited several weeks to process and then at least 2 weeks for the payment to clear. Either way I have received nothing. There was not any warning and the dash lights and poor engine running all happened at once. She drove straight to the dealership on [XXX]. We have not been treated fairly with this situation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S

Filed Oct 15, 2026 · Engine, Fuel system · NY

Summary of Event: This vehicle was brought to an authorized Hyundai dealership for a mandatory safety recall engine replacement under the Theta II Engine Recall Campaign. The dealership successfully installed a replacement engine provided by the manufacturer. However, the dealership and Hyundai Motor America are now refusing to return the vehicle to me in a functional, safe condition. Safety Hazard & Defect: The dealership states that the replacement engine shipped by Hyundai is mechanically and physically incompatible with the vehicle's original, factory-installed high-pressure fuel pump (HPFP). In an official written correspondence from a Hyundai Motor America Corporate Case Manager, Hyundai explicitly documented that: "dealership stated that it is not safe to drive the vehicle with old fuel pump." Despite acknowledging that the vehicle is now in an "unsafe to drive" condition due to the mismatched replacement parts provided by the manufacturer, Hyundai Corporate and the dealership are refusing to complete the safety recall remedy unless I pay $1,500 out-of-pocket for a new, compatible fuel pump.

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 Sep 4, 2026 · Fuel system · TX

My car stalls while driving and then I try to restart it but nothing happens. After reading online about the fuel pump issues and extended warranty related to the fuel pump I took the car in for repair. My car has 75,000 miles and the extended repair on this is for 150,000 miles/15 years. The dealer is refusing the repair because my car has a branded/ theft title. The car wasn't damaged just stolen. This is creating a serious safety concern and should be repaired by the dealer. Thank you for your time.

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 18, 2026 · Electrical · NJ

The AC/heating blower motor circuit on my 2020 Hyundai Sonata failed intermittently due to extreme electrical resistance overheating and melting the terminal pins inside the engine fuse box. I took it to the dealership and they inspected it said it was out of warranty but it needed part number 18980-09910-FFF and wiring kit 91300L1000-FF to repair at a cost of 780.00 including parts, tax, and labor. This matches the severe design defect acknowledged in Hyundai TSB #25-EE-002H or alternative TSB-24-EEOO-1H. I filed case number 43138757 with Hyundai corporate. For now this just affects my air conditioning. However, the root failure is a known design defect that presents a severe vehicle fire hazard and potential loss of windshield defrosting capability, lights, etc. if the whole electrical system should fail. As you should know the engine bay fuse box (which currently has melted parts) is the "brain" for the car's electrical distribution. It doesn't just power my AC fan; it holds the fuses and relays for the cars fuel pump, engine control module (ECM), headlights, and electronic power steering. If left unfixed and over time as the plastic melts, copper wires will cross and touch each other, causing a massive short circuit. My engine could suddenly cut out and stall while I am traveling at 70 mph on the highway, instantly killing my power steering and power brakes and putting me in extreme danger. Again not to mention the fire hazard this situation is likely to cause. This should be addressed via a mandatory safety recall, so that I don’t have to pay for a known engineering design defect and in case the TBS bulletin fails or further unknown damage has already occurred.

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 Jul 24, 2026 · Fuel system · 92,000 miles · MS

The contact owns a 2018 Hyundai Sonata. The contact stated that while operating the vehicle, there was an abnormal fuel odor inside the vehicle. The vehicle was taken to the local dealer and was diagnosed with an inoperable low-pressure fuel pump. The contact was informed that the low-pressure fuel pump needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure. The contact stated that the manufacturer had issued an extended warranty coverage for the failure. The failure mileage was 92,000.