2015 Hyundai Sonata Fuel System Problems

The contact owns a 2015 Hyundai Sonata. The contact stated that while driving at 45 MPH, the vehicle suddenly stalled. The vehicle was parked on the side of the road and failed to immediately restart. The vehicle was later restarted and driven to the residence. The vehicle was taken to the local Auto Zone, but the cause of the failure was not yet determined. The vehicle was then taken to the local dealer to perform a diagnostic test. No further info was available, and the vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 55,300.

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.

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.

Gas smell on the passenger side front seat

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.

Component : High pressure fuel pump Is being fixed as speak ; can provide statement and diagnostic from mechanic. 2. The first time the fuel pump failed it went out on the freeway, I was accelerating onto the freeway and I hear a big pop sound , the whole car went into limp mode . Leaving to cruising on the freeway. No warning , no check engine . I had children in the car . The issue was deemed ; a faulty fuel pump . Second time mechanic let me know there was a crack in the pump ( had been replaced less than a year ago ) . Because of the crack , gas & fumes filled the cabin of the vehicle , to the point where you could not operate without having all windows down . The vehicle could have caught fire ! Me and my family could have been hospitalized because of these fumes coming through the vents. Again, no check engine , nothing ! That repair is being fixed as we speak . Another $1,200 job . 3. No the vehicle has not been inspected by insurance or law enforcement . Only by licensed mechanic shops . 4. There were no warnings , Both times the high pressure fuel pump failed . No prior signs of the issue the first time & the second time the gas smell was so unbearable , that was the indication .

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.

Strong odor of gasoline noticed after driving vehicle and smell remained present for a few hours after ending the drive. Found out that many drivers for the Hyundai Sonata and Kia Optima have had same complaints and the issue is a component of the fuel pump that is cracked. Traced it back to my vehicle, and that in fact is the problem. Since gas is combustible, this is a seriously dangerous defect.

I reported a fuel leak while the vehicle is in motion to the dealer on 9/12. They had the vehicle 3 days and could not find the leak although the service manger agreed he smelled fuel when the vehicle was brought in. They released the car without repair.

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

The top of the low pressure fuel pump in the fuel tank was cracked. A strong fuel smell was present near the rear of the vehicle. When the vehicle was placed on jack stands, leaking fuel was visible on the sides of the fuel tank. The rear seat was removed, fuel pump access cover was removed, ignition was turned on and fuel was observed leaking from cracks on the top of the low pressure fuel pump. This is a huge safety concern due to fuel leaking from the fuel tank. I know for a fact this is not an isolated incident, you can watch YouTube videos of others with the exact same problem. The dealers want $1K+ to repair. I was an ASE Certified mechanic for 20+ years experience, I purchased an OEM fuel pump through an online retailer for ~$600 and replaced it myself. Problem solved, but for how long? There were no warning lamps or messages, the only sign was the strong smell of fuel.

Anytime the car needs a repair on something (fuel pump, inhibitor switch, etc.) in the middle of driving the car will flash "hybrid system warning safely stop and do not drive" and then either slow to 40mph then die, or just die completely. This has happened 3 times before I took it in to be fixed. A few months later, it happens again. It doesn't matter what is wrong with the car, the car just senses an issue and dies in the middle of driving. Very unsafe!

While driving POV from work, I began smelling fuel in the air conditioning system from external intake. Upon further discovery, the high pressure fuel pump was found to be dislodged from the engine, due to a sheered bolt. This allowed fuel to spill out on the manifold and engine, also reducing power for acceleration. This issue could have caused a vehicle fire that could have engulfed the cabin if ignited.

The contact owns a 2015 Hyundai Sonata. The contact stated that while driving at 20 MPH, the vehicle inadvertently stalled. The check engine warning light illuminated. The contact was able to veer to the side of the road. The contact stated that the vehicle restarted independently after a few minutes and she continued to drive. The dealer was notified of the failure and informed the contact that the vehicle was not included in any open recalls. The vehicle was taken to a local Pep Boys who diagnosed that the fuel system and fuel pump had failed. The contact stated that the failure reoccurred while driving on the highway at an undisclosed speed. The contact was able to push the vehicle to the side of the road with assistance. The vehicle was towed to the contact's residence. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 137,438.

I took my vehicle to the dealership to have recommended service completed which included the fuel tank air filter. To complete this operation, the mechanic performed an M.P.I which showed that the fuel pump was leaking. I'm not an expert on anything, but I can't imagine a time that fuel leak is good. What's really concerning is that if I hadn't had the vehicle in for routine maintenance, this problem wouldn't have been found which could have led to catastrophic issues. I find it hard to believe that it's typical that a fuel pump fail with under 60,000 miles on the vehicle- who knows how long the fuel pump had been leaking. My tech at the dealership told me that they have seen this same problem with other 2015 Sonatas so I am certainly not the only one to experience this issue. I had to return the car to the dealership a few months ago for a recall that involved a fuel leak. I wonder if all of the fuel leak issues have been dealt with, fuel leak wise, with this vehicle. The sub total for this repair was $817.66. Thank you, [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

Heavy odor of gas in backseat and truck. Noticed odor in garage while parked and when driving had to roll down windows! I took to mechanic. He found a crack in fuel tank. My Hyundai had been at the dealership that week with them changing the oil and rotating tires but they did not acknowledge it! Mechanic informed me that this could be a very dangerous situation and should not be driven. Dealership no help.

The vehicle has a very strong smell of gasoline and has been taken to the repair shop after spark plug flooding. Vehicle still smells like gas after repair but runs now.

TL* THE CONTACT OWNS A 2015 HYUNDAI SONATA. THE CONTACT STATED THAT WHILE DRIVING AT AN UNDISCLOSED SPEED, THE VEHICLE LOSS MOTIVE POWER AND STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO ANTWERPEN HYUNDAI CATONSVILLE (6440 BALTIMORE NATIONAL PIKE, BALTIMORE, MD 21228, (410) 747-3333) TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE ENGINE AND THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

TL* THE CONTACT OWNS A 2015 HYUNDAI SONATA. THE CONTACT STATED THAT THE FUEL DOOR FAILED TO OPEN FROM DEPRESSING THE UNLOCK BUTTON INSIDE OF THE VEHICLE. THE EMERGENCY LEVER TO OPEN THE FUEL COVER IN THE TRUCK OF THE VEHICLE WAS ALSO INOPERABLE. THE DEALER OURISMAN HYUNDAI OF BOWIE 2404 CRAIN HWY, BOWIE, MD 20716 (866) 295-4674, WAS ABLE TO FORCIBLY OPEN THE FUEL DOOR. THE CONTACT STATED THAT A PART DETACHED INSIDE THE UNLOCKING MECHANISM. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 89,000.

Please refer to prior complaint #11505068 I want to add the fact that this vehicle's engine was replaced on or around Sept 1, 2019. This dealer asked me who replaced the fuel pump, and I responded it was replaced by Rick Case Hyundai where the car was brought to with the seized engine.