Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2012 Hyundai Sonata owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2012 Hyundai Sonata. The contact stated that after fully refilling the gas tank at the gas station, and driving at 40-55 MPH, he smelled a strong gasoline odor inside the vehicle. There were no warning lights illuminated. The contact was able to continue to drive the vehicle. Upon investigating the failure, the contact noticed that each time he fully refilled the gas tank, in addition to the smell, the vehicle would shudder for 3-5 min while driving. Additionally, the contact noticed that gas was leaking onto the driver's side rear wheel well whenever the gas tank was fully refilled. The check engine warning light was illuminated. The vehicle was taken to the dealer where it was diagnosed with evap failure. The dealer informed the contact to check his gas cap; however, the contact stated that the fuel cap was new and was a manufacturer-approved gas cap. …
On the morning of April 15, 2024, at around 6 a.m., our 2012 Hyundai Sonata Hybrid unexpectedly caught fire and exploded in front of our house. This incident occurred shortly after I started the car and left it to warm up. Smoke and flames emerged from under the hood, quickly escalating until the front of the vehicle exploded, shattering the windows and extensively damaging the driver and passenger sides. Previously, we had noticed a fuel odor emanating from the hood, which we suspected was related to a known fuel recall issue. We brought the vehicle to the manufacturer's attention, hoping for a resolution under the recall. Unfortunately, the manufacturer did not address the fuel smell as part of the recall services and instead billed us for unrelated repairs. …
On [redacted] at approximately [redacted], my [redacted] Daughter was using my car to go to work. When she called us and informed my husband that the car did not start. At that point he asked to video call him so that he can visually see what was going on. She was directed to turn on the car again at and that point, the car started then smoke was noticed from coming out of the hood. My daughter managed to open the hood where flames emerged from the center of the engine. She then ran in the house to get a fire extinguisher and managed to put it out and it reignited. She then made a second attempt with another fire extinguisher where it briefly subsided and then grew larger. At that point the fire dept arrived and successfully extinguished the fire and deemed the car totaled after the Fire Marshall carefully inspected the car.
The contact's daughter owns a 2012 Hyundai Sonata Hybrid. The contact stated that while his daughter was driving at an undisclosed speed, the vehicle lost motive power with the hybrid system message displayed. The vehicle was towed to the dealer; however, no error codes were retrieved and the dealer was unable to duplicate the failure. The vehicle was then towed to Gray Epperson Hyundai (4100 APD 40, Cleveland, TN 37311) where it was diagnosed that the transmission needed to be replaced. The vehicle was last towed to an independent mechanic, who replaced the transmission; however, the failure recurred. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to take the vehicle to the dealer. The failure mileage was 140,266.
The contact owns a 2012 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 18V934000 (Engine, Fuel System, Gasoline). The contact stated that while driving 20 MPH, the vehicle stalled. There was an abnormal knocking sound coming from the vehicle. While driving at an undisclosed speed, the vehicle stalled after five minutes. The engine and the ABS warning lights were illuminated. The vehicle was towed to the residence. The contact called the local dealer and was informed that the maintenance records were needed. The contact was using an independent mechanic for maintenance and did not have the records. The vehicle was not diagnosed or repaired. The manufacturer was contacted and opened a case. The failure mileage was approximately 100,000.
The contact owns a 2012 Hyundai Sonata. The contact stated while driving at an undisclosed speed, the contact became aware of smoke coming from the engine compartment. There was no warning light illuminated. The contact stated that there was an abnormal gasoline odor coming from the vehicle. The vehicle was taken to the dealer where it was determined that the fuel pump control module had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was opened. The failure mileage was approximately 126,561.
The contact owns a 2012 Hyundai Sonata. The contact stated while driving 60 MPH, the vehicle stalled with the key symbol warning light displayed. The contact pulled over to the side of the highway and was able to use a trailer to tow the vehicle to the residence. Neither the dealer nor the manufacturer was notified of the failure. Upon investigation, the contact discovered NHTSA Campaign Number: 18V934000 (Engine, Fuel System, Gasoline) which she linked to the failure. The vehicle was not repaired. The failure mileage was approximately 180,000.
About 1 month after I bought this vehicle, late December 2021, a warning light came on the hybrid screen, it read "Hybrid System Warning! Safely Stop And Do Not Drive!" The accelerator was not working I pulled over and turned the vehicle off. I waited a couple minutes and restarted it up again and went on my merry way. About a month later it happened again!! It's happened about every 5 weeks until June 16th at about 5pm, it now permanently chimes and beeps with the Hybrid screen warning me of the same, my foot brake goes to the bottom and makes a grinding noise. I am not able to drive it more than 100 yards or so then the accelerator fails again. …
The contact owns a 2012 Hyundai Sonata Hybrid. The contact stated that once car has warmed up, while driving at low speed or starting to move after a stop, she vehicle hesitated and stalled while depressing the accelerator pedal. This is a serious risk hazard as the car barely moves at intersections where it is a risk of getting hit by incoming cars. There was no warning light illuminated. The contact had taken the vehicle to multiple independent mechanics as well as hyundai dealerships who were all unable to diagnose the failure due to no warning lights illuminating on the instrument panel and no codes getting registered in the ECU. The contact then got the car evaluated by another Hyundai dealership in order to exchange it for a new vehicle and mentioned this problem. …
Steering has a clunking/clicking sound when turning left or right. It has gotten worse from when I noticed it. At first I could hear a faint rattling sound when going over bumps in the road (more noticeable in colder time of the year). Now for the past 2-3 years it's very noticeable and makes clunking like noise every time turning even when parked. When I first heard the faint noise my mechanic couldn't hear it. He said I have to hear it to know for sure but said it's possibly the steering column And at that time he priced it at $500 I'm sure it's more now with this economy. I didn't get it fixed bc he wasn't sure and I didn't want to pay to get it fixed if that wasn't the problem. I had no idea I could file this complaint otherwise I would have done it sooner! This problem started January 2019. Also the gas gage will blink and say I have no gas even tho I filled up. …
Fuel System complaints in other Sonata years
Frequently asked questions
How common are fuel system problems on the 2012 Hyundai Sonata?
NHTSA has 117 complaints about the fuel & propulsion system of the 2012 Hyundai Sonata, 8% of the model year's 1,558 complaints. The component named most often is fuel injection system (1 mentions).
Is there a recall for 2012 Hyundai Sonata fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2012 Hyundai Sonata, though it has 8 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2012 Hyundai Sonata fuel system problems start?
Half of the complaints with a recorded mileage happened before about 96,000 miles, and 14% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 9 fires and 2 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.