2020 Hyundai Sonata Fuel System Problems

Which parts fail

• Storage › Auxillary tank
  1
• Delivery › Fuel pump
  1

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  19%
• 25k–50k
  327%
• 50k–75k
  19%
• 75k–100k
  545%
• 100k–150k
  19%
• 150k+
  00%

Owner reports

Selected complaints filed with NHTSA by 2020 Hyundai Sonata owners, lightly cleaned up (personal details are redacted by NHTSA).

My vehicle was at a manufacturer authorized dealership for a federally mandated recall repair. While the vehicle was in the dealership's exclusive care, custody, and control, it was struck by a third party cleaning vendor operating on dealership property and was declared a total loss. I did not hire or authorize this vendor. After the incident, the manufacturer informed me in writing that the dealership would repair the damage at their own expense, separate from the recall work. The manufacturer also stated they were covering the recall related repairs and were coordinating with the dealership. They provided weekly updates, monitored the recall repair, and escalated a backordered recall part. …

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed with the family inside the vehicle, a strong gasoline odor was inside the cabin of the vehicle. The contact stated that the fuel gauge was lowering quickly. Upon exiting the vehicle, the contact became aware of gasoline gushing heavily out of the vehicle onto the ground. Two months prior to the failure, the vehicle was taken to an authorized dealer due to an abnormal sound coming from the rear of the vehicle. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the recall repair was not performed because the part for the recall repair was not yet available. The vehicle was towed to a dealer where it was determined that the gas valve was not properly fixed. …

The contact owns a 2020 Hyundai Sonata. The contact stated that while attempting to start the vehicle, the vehicle failed to start. The battery and the key warning lights were illuminated. The contact stated that after several attempts, the vehicle started. The vehicle was driven to the end of the driveway and turned off. The contact was afraid of driving the vehicle due to the failure. The independent mechanic was made aware of the failure. The contact was informed of an open recall. The dealer was made aware of the failure and confirmed the open recall information. In addition, the contact was advised that the failure might be because of the unrepaired recall. The contact was advised to bring the vehicle in for diagnostic testing. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. …

The contact owns a 2020 Hyundai Sonata. The contact stated while driving at 35 MPH, the vehicle made a booming sound. There were no warning lights illuminated. The contact then started to hear the sound outside the vehicle and noticed that the vehicle was losing gasoline very quickly. The vehicle started to stall, and the gas tank was almost empty when the contact arrived home. The vehicle was then taken to a dealer where it was diagnosed with floor damage, and the floor damage showed deformation on the rear passenger's seat, and the fuel cover had popped off due to the deformation, which caused the noise in the cabin. The vehicle was towed to another dealer where the vehicle was repaired, with a new fuel pump cover, and the rear seats were replaced. On another occasion, the fuel pump failure reoccurred. The manufacturer was made aware of the failure. …

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, who retrieved a diagnostic trouble code for the check valve. The mechanic related the failure to NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline), associated with the VIN; however, the contact had not received notification of the recall. The vehicle was then taken to the dealer, who determined that the check valve had failed and the fuel tank was deformed. The contact was referred to the manufacturer. The vehicle was not repaired. The manufacturer was made aware of the failure, and a case was filed. The manufacturer offered to buy back the vehicle, but the contact declined the offer. The failure mileage was approximately 82,000.

The contact owns a 2020 Hyundai Sonata. The contact stated that the fuel failed to go into the tank. The seat failed to move. The engine light illuminated. The vehicle stalled. While driving, the fuel gauge went from full to empty. The contact received the NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline) after the failure. The vehicle was towed to the local where it was diagnosed that the fuel tank had expanded. The vehicle was repaired approximately eight months later. The contact called another local dealer. Ourisman Hyundai Bowie, 2404 Crain Hwy A, Bowie, MD 20716, who was unable to schedule an appointment. The manufacturer instructed the dealer to keep the vehicle due to it being a fire risk. The manufacturer was contacted regarding a buyback. The failure mileage was approximately 80,000.

The contact owns a 2020 Hyundai Sonata. The contact stated while driving at an undisclosed speed, there was an abnormal gasoline odor inside the vehicle. The contact then heard a loud pop and pulled over to the shoulder of the roadway. After a visual inspection, the contact observed gasoline leaking from the fuel tank filler neck, even though the access door and gas cap were both securely closed. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed a failure with the canister purge valve, causing the fuel tank to swell, resulting in damages to the fuel pump. The vehicle was not repaired. The manufacturer was notified of the failure, and a case was opened. The failure mileage was 47,000.

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, there was an abnormal gasoline odor inside the vehicle, after which the vehicle lost motive power. The contact pulled over to the shoulder of the roadway, moved the rear seat, and observed that the fuel pump was protruding upwards. The check engine warning light was illuminated. The vehicle was towed to the dealer, who diagnosed a failure with the purge valve, resulting in damages to the fuel pump and fuel tank. The vehicle was repaired, but the failure reoccurred. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 47,000.

The contact owns a 2020 Hyundai Sonata. The contact stated while driving approximately 65 MPH, there was a booming sound heard and suddenly there was an abnormal fuel odor inside the cabin of the vehicle. The vehicle was towed to the local dealer who replaced a fuel sensor. The contact stated that later, while driving, the rear seats started to raise up, and became extremely hot. The contact parked to inspect the vehicle and discovered that the fuel tank had expanded underneath the vehicle. Due to the failure, the rear seats became burned and melted. The cause of the failure was not yet determined, and the vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 52,000.

While stopping at a major highway intersection on [redacted] for a red light vehicle stalls and will not start back up while everyone else continues at a 55 mph mile an hour passing me on each side! This happened more than 6 times . While you're stuck in intersection,you have to keep trying to start the car eventually it will start . Apparently it is EGR valve and is a very common problem. IT IS NOTED IN THE common problem for this year making model and the repair cost is in the range of $1600 even the dealership said it is a very common problem. They have been experiencing it.

Related recalls

Fuel System complaints in other Sonata years