Hyundai Sonata fuel system problems, 2016–2027
319 of the 2,997 complaints owners filed with NHTSA about the Hyundai Sonata 2016–2027 name the fuel system (NHTSA’s “Fuel/Propulsion System” heading — fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors). The loudest years: 2020 (59), 2023 (47), 2017 (46). Filed under the same heading across these years: 2 manufacturer bulletins, 2 recall campaigns. Every figure is a linked federal record; none is a failure rate, none a repair cost, and none a verdict on one car.
Hyundai Sonata fuel system problems by model year
Source: NHTSA complaints, recalls, investigations and manufacturer communicationsOne row per model year on file, newest first. A year marked in depth has its own page: the complaints, the owners’ words and every document under this heading for that year.
| Model year | Complaints naming the fuel system | Share of the year’s | Typically at | On file under the heading | |
|---|---|---|---|---|---|
| 2027 | 0 | — | — | — | the year → |
| 2026 | 0 | — | — | — | the year → |
| 2025 | 2 | 7% | — | — | the year → |
| 2024 | 0 | — | — | — | the year → |
| 2023 | 47 | 46% | — | 6 TSBs · 1 recall | the year → |
| 2022 | 32 | 29% | — | 9 TSBs · 2 recalls | the year → |
| 2021 | 39 | 21% | — | 6 TSBs · 2 recalls | the year → |
| 2020 in depth | 59 | 30% | 80k | 1 recall | the record → |
| 2019 | 17 | 10% | — | — | the year → |
| 2018 | 34 | 9% | — | — | the year → |
| 2017 | 46 | 5% | — | — | the year → |
| 2016 | 43 | 5% | 66k | — | the year → |
Two things the counts carry that are not the car: how many of each year were sold, and how long each has been on the road — an older year out-counts a newer one before anything is wrong with it. The share column is the honest comparison across years: what part of that year’s complaints named the fuel system. Nothing here is a rate.
When the fuel system complaints were filed, and at what mileage
Source: NHTSA complaint databaseFiled per calendar year, every model year together: 2017: 5 · 2018: 6 · 2019: 6 · 2020: 11 · 2021: 7 · 2022: 19 · 2023: 35 · 2024: 64 · 2025: 80 · 2026: 86
Across the model years, half of the 69 owners who gave an odometer reading reported the fuel system problem between 39,000 and 92,000 miles. A median of reports, not the life of a part.
In owners’ own words
Source: NHTSA complaint databaseFiled with NHTSA by the people who own these cars, about the fuel system, from the model years with the most to say. Quoted as written, with anything identifying removed; unverified reports — what was said, not a finding that it was true.
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.
Riding down the road June 30, 2024 and heard a loud boom coming from the back of my car. I pulled to the side of the road and walked around but saw no damage to outside of car. When I was approximately 30 miles from home my gas started dropping tremendously.
Hello, I have Hyundai Sonata 2023. The fuel tank of this car is expanded on . I have never heard about this issue to any cars. I took my car to dealership they said they don’t know why this happened and they said they cannot fix it, my car at the dealership more than a month.
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.
Supplemental Information to Existing NHTSA Complaint involving a 2017 Hyundai Sonata Plug-in Hybrid (VIN: ) While traveling at approximately 70 MPH on a heavily traveled highway, the vehicle suddenly and completely lost propulsion without warning.
What is on file about the fuel system, across the years
Source: NHTSA recalls, investigations and manufacturer communicationsRecall campaigns filed under this heading, any model year
- 25V796000 CriticalNov 17, 2025 · 85,043 vehicles
- Hyundai Motor America (Hyundai) is recalling certain 2020-2023 Sonata vehicles. A damaged check valve can allow air to enter the fuel tank, causing it to expand and contact hot exhaust components, melting the tank.
- 21V524000 CriticalJul 9, 2021 · 15,752 vehicles
- Hyundai Motor America (Hyundai) is recalling certain 2021-2022 Santa Fe and Sonata vehicles equipped with 2.5L turbocharged engines. Fuel may leak at the pipe connection between the high-pressure fuel pump and fuel rail.
2 manufacturer bulletins filed under this heading, any model year
- Jun 3, 2026
- Some Sonata Hybrid (DN8 HEV) vehicles may display a Check Engine light and store one or more of the DTCs listed below due to an abnormal air-fuel ratio in a specific cylinder. This bulletin provides instructions to update the Engine Control Module (ECM) to resolve the air-fuel ratio logic.
- Jan 7, 2026
- Some vehicles equipped with a 2.5L GDI Theta III engine (non-Turbo) may exhibit one or more misfire DTCs due to the GDI fuel injectors leaking internally. This may be caused by internal filter breakage in the injector. Follow the procedure in this TSB to replace all 4 injectors on affected vehicles, using the kit in the Parts Information section.
Every one filed under the heading is listed. Quote the document number at a service desk — it is a diagnosis the maker has already written down.
Other systems with a record on the Hyundai Sonata
Source: the same files- engine problems
- electrical problems
- steering problems
- transmission and drivetrain problems
- brake problems
Every system, every model year: Hyundai Sonata problems by year →
Common questions
Source: NHTSA complaint database, recalls and manufacturer communicationsWhich Hyundai Sonata years have the most fuel system complaints?
2020, 59; 2023, 47; 2017, 46. Raw counts, and an older year has had longer to collect them; by share of each year's own complaints the loudest is the 2023 (46%).
Is there a recall for the fuel system on the Hyundai Sonata?
Yes — 2 campaigns are filed under this heading across these model years: 25V796000 (2023), 21V524000 (2022). A recall is matched by VIN, and applies to specific years; check yours at nhtsa.gov/recalls.
When do fuel system problems show up on the Hyundai Sonata?
Owners who gave an odometer reading reported it at a median of 70,000 miles across the model years; half of them between 39,000 and 92,000. That is when reports cluster, not the life of a part.
What does NHTSA's "Fuel/Propulsion System" heading cover?
Fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors. Owners choose the heading when they file, so it says which area of the vehicle the complaint is about, not which part failed.