2023 Hyundai Sonata Fuel System Problems

The contact owns a 2023 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue and informed the contact that parts were still not yet available. The manufacturer referred the contact to the NHTSA Hotline to report the issue. The contact had not experienced a failure.

Hello Sir/Madam, While driving on Interstate I-75 at approximately 70 mph, the yellow check engine warning light suddenly illuminated. Immediately afterward, the vehicle began to shake violently, lose engine power, and run extremely rough. The vehicle experienced a sudden loss of power, and pressing the accelerator pedal did not result in normal response or acceleration. The throttle input was significantly reduced, making it difficult to maintain speed and safely control the vehicle. At highway speed and in heavy highway traffic, if we had not been able to safely exit the roadway, this loss of control could have put not only the occupants of this vehicle but also other drivers at serious risk. Fortunately, we were already in the exit lane, and a McDonald’s parking lot was located immediately off the exit. This allowed us to leave the highway quickly. Otherwise, this situation could have been extremely dangerous in active, heavy highway traffic. As the vehicle continued to shake, a strong smell of gasoline and a burning odor entered the cabin, raising concerns about a possible fire hazard. We safely stopped the vehicle in the McDonald’s parking lot and then shut the engine off due to the severity of the symptoms. After shutting the vehicle off, we attempted to restart it, but the engine would not start. The vehicle had to be towed to a Hyundai service center for inspection. The Hyundai service center later confirmed that the failure was caused by a faulty fuel injector, and they have changed all 4 injectors as I attached receipt from Hyundai This failure created a serious safety risk due to sudden loss of engine power, reduced accelerator response, severe shaking at highway speed, and fuel and burning odors inside the cabin. Regards

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

While driving at highway speed, my vehicle suddenly lost power due to fuel injector failure and could not be restarted, creating a serious safety risk for myself and others in high-speed traffic. This is the second vehicle of the same year and model that I’ve owned to experience the exact same injector failure. In the first case, one injector was replaced under a Hyundai service bulletin before I sold the vehicle. This second occurrence confirms that the issue is not isolated and should be escalated to a formal safety recall. The most recent failure was diagnosed and repaired by Hyundai, confirming the problem (this time replacing all injectors). The vehicle has not been inspected by police, insurance, or other outside representatives. There were no warning lamps, messages, or symptoms prior to the failure—it occurred without any warning, significantly increasing the risk of a crash

The contact owns a 2023 Hyundai Sonata. The contact stated that after depressing the START/STOP button, the vehicle failed to start immediately. Additionally, there was smoke coming from the exhaust pipe. There was no warning light illuminated; however, an undisclosed message was displayed. The vehicle was towed to the dealer, who replaced the fuel injector; however, the failure persisted. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the VIN was not included in the recall. The manufacturer was made aware of the failure. The failure mileage was approximately 56,000.

Fuel injectors cause car to lose power while driving in traffic, on the highway which can cause accidents. This event happened twice one while entering the highway and one while going past a light. Neither caused an accident at the time. The car both times were taken to the dealership and the fuel injectors had to be replaced both times. The first time was in December 2024 at 12k miles

The contact owns a 2023 Hyundai Sonata. The contact stated that while driving at 35 MPH, the fuel mileage abnormally increased from 320 to approximately 431. An unknown message was displayed, and the contact received a notification on the Mobile App about a diagnostic trouble code for the EVAP sensor. The vehicle was taken to the dealer, where it was diagnosed, and determined that the EVAP system valve was stuck open. The dealer replaced the EVAP system, and the dealer then determined that the fuel tank was swollen due to the failure. The contact stated that the rear seat sensor was malfunctioning and was causing a warning light to illuminate erroneously, which the dealer related to the fuel tank swelling and lifting the metal underneath the seat. The dealer also replaced the fuel tank. The vehicle was repaired. The manufacturer was notified of the failure and covered the repairs. The failure mileage was approximately 73,245.

Failed fuel injector caused 3rd cylinder misfire car only has 30,000 miles I'm the second owner I've only had it 2 weeks and this issue happened.

The fuel injectors failed again, leaving me stranded on a busy road. The first time this happened, I had a little over 8,000 miles on my vehicle - 5 months after purchase. That was two years ago. Now, the injectors have failed for the second time and I am having to pay just north of $1,000 to get them replaced at my Hyundai dealership. It was a terrifying thing to experience and my safety was at risk due to my vehicle decelerating on a busy street. I had to call the police to help shield my vehicle from other drivers. The problem has been confirmed by a dealer upon inspection and diagnosis, and the police officer that was at the scene also could see that my vehicle would not start. This dealer works at the company that manufactures Hyundais. Prior to the fuel injection failure, there were brief moments where the 'check engine' light would illuminate but it would never stay on long. Directly before my vehicle shut off on the road due to the failure, there were no light/lamps/or other symptoms noticeable.

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.

The contact owns a 2023 Hyundai Sonata. The contact stated while driving at various speeds, there was a loud sound coming from the rear end underneath the floorboard like a part slamming on the undercarriage of the vehicle. The contact stated that the fuel gauge suddenly indicated that the fuel tank was EMPTY. The vehicle was taken to the dealer who diagnosed that the gas valve and electronic control unit (ECU) had failed. The contact stated that the gas valve was replaced, and the electronic control unit (ECU) was updated. After receiving the repair, the contact noticed that while attempting to accelerate, the vehicle downshifted before shifting to the desired gear and accelerating. The failure was most persistent while driving uphill. The check engine warning light was illuminated. The vehicle was taken to another dealer, All Star Hyundai (3950 Century Ct, Pittsburg, CA 94565) who was unable to diagnose the vehicle due to not having the tool necessary to detach the fuel tank. The vehicle was then taken to another dealer, San Leandro Hyundai a Carnamic Car Center (1066 Marina Blvd, San Leandro, CA 94577) who diagnosed that the pressure valve was swollen and the entire fuel tank and pressure valve needed to be replaced. The vehicle was not repaired. Due to the inconsistency of diagnostic results, the contact decided to take the vehicle to another dealer, Fremont Hyundai (43690 Auto Mall Cir, Fremont, CA 94538) who diagnosed that the pressure valve was swollen but had not diagnosed that the fuel tank needed to be replaced due to not finding a failure with the fuel tank. The manufacturer was not made aware of the failure. The failure mileage was approximately failure mileage was 75,000.

I was driving into work on a major road (about 45 mph) when my 2023 Hyundai Sonata stopped accelerating and my engine gave out. Initially I thought I was accidentally pressing on my break pedal but when I realized I wasn’t pressing the break, I had just enough time to turn on my hazards and get out of traffic and onto the shoulder of the road. I was stuck between a main exit and the major road. My battery, oil, and engine lights came on (no service lights had been on prior to this incident) and my car was just very slowly rolling before it automatically engaged my parking break - which makes me fearful of what would have happened if I had still been in busy traffic. I could gotten very badly rear-ended. My car only has just over 5600 miles and I never had any issues with it before and kept up with the general maintenance. I attempted to restart my car to no avail and about 30 minutes later I was able to restart my car but there was a very strong vapor smell in the cabin of my car. I got my car towed to a dealership and was informed one of my fuel injectors was misfiring/gone bad - similar to many other incidents on this site. I asked the dealership if they were able to view the state of my other fuel injectors and was told they were unable to do that, so I am unsure if other fuel injectors will go bad in the future.

Good afternoon. My issue is related to an existing recall that Hyundai Motor sent to me back during the beginning of January 2025 for a gas valve, tank inspection (replaced if necessary.) and ECU computer update. I've been to a total of 4 Hyundai Dealers and none of them have been consistent with this recall. The first Dealer is "Future Hyundai" in Concord, California. Initially, I'd took my car there for both recall and sound coming from the gas tank and my fuel level dropping. I was told by a service advisor by the name of Hayley, that it would cost a diagnostic fee to locate the issue. I didn't have the fees. But, seeing that the gas tank was part of the equation. It was free. The gas tank inspection was never done. I was told by Hayley that the fuel valve was replaced. But they mechanics only done a quick visual. I wasn't reassured that my issue was resolved. So I'd took it to a another Hyundai Dealer. This dealer told me that part of the procedure is to take off the tank and inspect it. I didn't get that far because I was told that a tool that was used is used to take off the tank was broken. A bleeder tool. Which doesn't make sense, because the tool is used for Bleeding out air from the fuel system. "Allstar Hyundai." The last two of the 4 dealers, "San Leandro Hyundai" and "Freemont Hyundai", told me that my fuel pressure hose in my gas tank and had swelled up. San Leandro dealer told me that my gas tank expanded. But the "Freemont Dealer" only mentioned the fuel hose. But never mentioned the gas tank. But decided to add it anyways. None of these dealers have been consistent regarding the recall. "Freemont Hyundai", the last of the 4, the service man told me that my tank is available. But his story changed from the time that I can get the job done 4 times. To having to have my car for two days before they can order the part. He'd order the parts, verified to me, when I was at my appointment. But now that conversation changed.

I bought the new car on 11/21/22. There have been two incidents with the same cause. Incident #1: On 1/25/23, while I was on a six lane highway with high speed traffic and rush hour level traffic, the car began to fail, with 'bucking', failure to respond to the gas pedal, loss of power, and difficulty steering. At that time, the check engine light also went on (it had not been on previous to the event starting). I was able to get the car off the highway, where it completely died - it would not move. It was towed. Mileage at this time was 1,330 miles - the car was 2 months old. It was diagnosed that "Cylinder #3 fuel injector is stuck open causing drivability issue". The likelihood that I would have been hit, by another car on that multi-lane highway with cars at high speed, and hurt or even killed is extremely high, if not certain. I did not file a report with NHTSA about the first incident (I was not aware of this service.) Incident #2: On 12/7/24, while I was again on a six lane highway, high speed traffic, night darkness, rain, and rush hour level traffic, the car began to fail in the exact same way as in 2023, 'bucking', failure to respond to gas pedal, slowing, difficulty steering, etc. I was able to get off the highway before it completely 'died'. It was undriveable and had to be towed. There was no warning light prior to the event occurring. Mileage at the time was 21,091. The probability, considering the rain, the dark, and the fact that I was on a 'super highway', that I could have been hit, hurt or even killed is extremely high. The diagnosis was 'TSB indicated #3 Fuel Injector be replaced." I do not have any of the old fuel injectors. In addition, I routinely - multiple times a week - have small children in this car. These events could have happened when I had a carful of small children with me. My routine schedule means there was also the high probability of others being hurt.

The contact owns a 2023 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer several times, and the dealer reset the check engine warning light. In addition, the vehicle remained with the dealer for 32 days but was not repaired. The vehicle was not repaired, and the failure reoccurred. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the parts were not available for the recall repair. The manufacturer was made aware of the failure. The contact was informed that parts were not yet available. The failure mileage was approximately 28,000.

Fuel injection systems failed At 5000 miles cell 2 At 15000 miles cell 3 Under warranty but although tech said other two would fail prematurely Hyundai would not replace cell one and 4 As these failures happen suddenly without warning while driving I feel this is a serious safety hazard

On 3 separate occasions the vehicle decelerated, lights flickered and stated to produce a burning smell through the engine. Each time the car would not allow me to accelerate and eventually stalled out. The car would no immediately start. After a few minutes it would start but not accelerate. After about 30 minutes it would start and would drive about 5-15 mph, enough to get me to my location. On the first occasion I was coming home late in the evening after working a 12 hour shift and had to have a family member get me after being stranded by the side of the road. The second time I was taking my 4 to son to his planned surgery in a bigger city and it broke down on the way. It was not safe driving in the city barely being able to excel but we did it for my son. The third time I was in a larger time in traffic and missed an appointment as I tried to stear my decelerating vehicle out of multiple lanes of traffic to a safe location. I could not use the air conditioner while I attempted to let it rest in 100°+ heat. Each time the lights would flicker and dim. There would be a smoke from the exhaust. After the first 2 occurrences we took it to the dealership but they were not able to replicate the problem or identify a causative code. During the last occurrence we were able to get it to the dealership very slowly and they deemed it to be the fuel injector malfunctioning. This was fixed after about a week or so of being in the shop . About a week or two after the fuel injector was fixed the check engine light came on. We took it back into the service department and they "reset" the system thinking it was an error. The light came back on in less than 24 hours. The vehicle has been running a little harder, not as fast or responsive as normal. A service/evaluation date was scheduled and the code was checked indicating it was likely the catalytic converter. We scheduled another service appointment once the part was in which is 2 weeks from the evaluation appointment.

Had been traveling for approximately 2.5 hours in a winter storm, pushed on brake to slow down and park and the car started to chug. Turned car off and then back on again. Car would not start and had to be towed to nearest Hyundai dealership. There were no warning signs at all, car just suddenly quit. We were later informed that it was the fuel injectors. We were very fortunate that this did not occur in a place with no cell service on a very frigid, stormy night.

I was traveling on the freeway when I began experiencing erratic acceleration, around which time the check engine light came on. I took the next exit, and continued to experience the same symptoms, as well as rough idling, and a bit of smoke. The car was towed to the nearest Hyundai dealership where the fuel injector was replaced under warranty.

Took a trip to the grocery store, and started up my car when I got back. The engine turned over but after a few seconds, it stalled. Tried this again, but lightly pressed the accelerator. This raised the RPM, but it dropped quickly and stalled the engine again. Made a couple more attempts after and eventually, the engine light came on. Shortly before this incident, I had about 10-15% of gas left in my tank. After this happened, bluelink reported that I had 1% left. Got the vehicle towed to the dealership, where they confirmed the condition and found that the fuel injector for cylinder 3 needed to be replaced. I consider myself lucky that this happened while my vehicle was parked. This would've been a huge safety concern if it happened out on the road.