2020 Hyundai Sonata fuel, hybrid & EV propulsion problems

Related recalls

• Recall 25V796000Nov 17, 202585,043 vehicles
  FUEL SYSTEM, GASOLINE

  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.

  Risk: A melted fuel tank can leak, increasing the risk of a fire.

  Remedy: Dealers will inspect and replace the check valve. The fuel tank assembly will be inspected for damage and replaced if necessary. Additionally, dealers will inspect and update the engine control unit software. All repairs will be performed as necessary, free of charge. Owner notification letters were mailed beginning March 13, 2026. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 286. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on November 19, 2025.

What owners say

1. Filed Oct 6, 2026FLBody & StructureBrakesFuel, Hybrid & EV Propulsion

   Fuel system recall (NHTSA 25V796; Hyundai 286/23HYZ2 "Fuel Tank Expansion") on a 2020 Hyundai Sonata, plus the fuel-tank heat shield and rear floor pan area. On 4/21/2026 (110,423 mi.) a Hyundai dealer's recall test FAILED; no warning lamps or symptoms beforehand. The repair order says Hyundai "is declining the repair at this time and is calling the customer to offer assistance." Hyundai's advisory: "Do Not Drive, Park Outside." Hyundai's recall filing says heat…

   NHTSA complaint #11769249 · source
2. Filed Jul 30, 2026FLBody & StructureFuel, Hybrid & EV PropulsionSeats & Seat Belts

   Car was taken to dealership for inspection. Upon inspection, it was determined that the fuel tank had expanded and pushed towards the heat shield, and expanded upward pushing up the back seats of vehicle. It was determined to not safe to drive. Manufacturer contacted me and offered a buyback. Upon their offer of a buyback, it was determined that I would owe the manufacturer approximately $2,000. I have requested that they fix it, and they have refused to give me the…

   NHTSA complaint #11753819 · source
3. Filed Jun 22, 202689,000 miAZTowedBody & StructureFuel, Hybrid & EV Propulsion

   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…

   NHTSA complaint #11745596 · source
4. Filed Jun 10, 2026TXFuel, Hybrid & EV Propulsion

   Hyundai Motors America has failed to comply with its statutory obligations in conducting the recall campaign 25V796, and is instead engaging in behavior substantially similar to that which has been previously censured by NHTSA. My Sonata suffered irreparable damage related to this campaign as confirmed by HMA. 49 U.S.C. § 30120(a)(1)(A) allows HMA to choose one of three remedies: repair, replacement, or refund. However, they 1) say it cannot be safely repaired, 2) will not…

   NHTSA complaint #11743103 · source
5. Filed Jun 4, 2026108,000 miGAFuel, Hybrid & EV Propulsion

   The contact owns a 2020 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 25V796000 (FUEL SYSTEM, GASOLINE). The contact stated that while driving 60 MPH, the vehicle was leaking fuel from the fuel tank. There was no warning light illuminated. The dealer was contacted and notified of the failure, and the vehicle was repaired. The contact stated that the failure was a recurring failure. The manufacturer was notified of the failure. The failure…

   NHTSA complaint #11742138 · source
6. Filed May 8, 202680,000 miMDTowedEngineFuel, Hybrid & EV PropulsionSeats & Seat Belts

   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…

   NHTSA complaint #11736639 · source
7. Filed May 7, 202682,000 miCAFuel, Hybrid & EV Propulsion

   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…

   NHTSA complaint #11736326 · source
8. Filed Apr 22, 2026FLFuel, Hybrid & EV Propulsion

   NHTSA Complaint Statement Subject: Stop‑Drive Recall – Vehicle Held Since March 5, 2026 – No Remedy, No Transportation, Buyback Delayed I am filing a complaint regarding a stop‑drive safety recall that has left me without access to my vehicle since March 5, 2026, and the manufacturer has not provided a timely remedy, transportation assistance, or a completed buyback. My vehicle has been at the dealership since March 5 due to a manufacturer-issued stop‑drive recall. The…

   NHTSA complaint #11733167 · source
9. Filed Apr 3, 2026ARFuel, Hybrid & EV Propulsion

   Vehicle subject to NHTSA Recall 25V796000 (fuel system defect). In July 2025, while driving, a loud explosive sound came from the rear of the vehicle followed by raw gasoline fumes entering the cabin. Vehicle was towed to a Hyundai dealership and held approximately 120 days before being returned as repaired. In December 2025, the exact same defect recurred. A third-party diagnostic scan (performed before drop-off) confirmed DTC Code P14EE — Fuel Tank Check Valve /…

   NHTSA complaint #11728980 · source
10. Filed Mar 16, 2026OHFire1 injuredAirbagsEngineFuel, Hybrid & EV Propulsion

    It was smoking from the engine, I immediately stopped the vehicle. My safety was put at risk immediately while being in the vehicle when the air bags deployed hitting me in the face and causing my face to swell. The safety of others was put at risk due to others being right next to me and putting others at risk of engine blowing up. Yes, the vehicle has been inspected by police. There were no warning signs on the vehicle.

    NHTSA complaint #11724672 · source
11. Filed Feb 20, 2026FLEngineFuel, Hybrid & EV Propulsion

    On 2/19/2026 while driving, my 2020 Hyundai Sonata Limited 1.6T began making several loud explosive / popping sounds. At the same time, the fuel gauge on the display screen appeared to rapidly drop, as if the vehicle was losing gas. Immediately following this, the vehicle began to hesitate and lose power while accelerating. The hesitation felt like the engine was misfiring or struggling to maintain consistent performance. There were multiple explosive sounds before and…

    NHTSA complaint #11719504 · source
12. Filed Feb 12, 2026PAFuel, Hybrid & EV Propulsion

    The contact owns a 2020 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 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. The contact had not experienced a failure.

    NHTSA complaint #11717557 · source

Source: U.S. National Highway Traffic Safety Administration (NHTSA) Office of Defects Investigation public data. Complaints are submitted by owners and are not verified by NHTSA or by us; a complaint does not prove a defect exists. View this vehicle on NHTSA.gov Methodology