2015 Hyundai Sonata Fuel system Problems

1.) Following Hyundai's 9C2 Campaign update for the ECU that was completed back on May 27th, 2026, my 2015 Sonata went into limp mode [solid check engine light present] while I was accelerating up an on-ramp on the 2nd drive cycle since the update was performed. I was already far away from the dealership so I was forced to limp it to my local shop that I regularly use to have it checked out. It was confirmed that the code on the vehicle was P200A for intake manifold runners. Since the update was for smog regulation, the code was cleared in order to see if it would come back. Since then, it has not, however the vehicle continues to have one persistent problem. The RPMs will dramatically dip and then surge back upwards while the car is coasting (no gas and no brake applied). 70% of the time, you can feel the car violently jerk as it appears to try and correct itself. 2.) I've brought this car to multiple dealerships, have a case open with corporate and have also found that this is a systemic issue with this specific update in these cars. All and all, nothing has been done. I'm repeatedly turned away over and over again because their techs are only permitted to look into it once they have hard evidence of a fault. In this case, that would be a dashboard light. I'm told that I may only return if the check engine light comes back, which as I mentioned previously, posed a HUGE safety risk to myself the first time it appeared. If I can only go 55mph down the highway, I am at risk of being rear-ended or struck in some way. 3.) The problem has not been reproduced by the dealer as they will not test drive it to see the dip and spike. However, the code was still pending for awhile in the vehicle before it cleared it on its own, so that was acknowledged by at least one place. 4.) Vehicle has not been inspected by anyone but a dealership and local mechanic. 5.) No other signs prior to the vehicle limping out on me other than some acceleration concerns on May 27th, 2026.

NHTSA ID

11755317

Incident

May 27, 2026

I have the 2015 Hyundai sonata with the 2.5 GDI engine that eventually will seize due to internal damaged caused by manufacture design flaws. My Hyundai threw a P0010 code which causes my car to idle high and causing low vacuum affecting my brakes. I had a diagnostic test done at a Hyundai dealership that told me it was a cvvt cam sprocket issue and that it was the beginning of the end of the engine, They quoted me 3700.00 but the engine was to far gone and this repair would only accelerate the engine to seize. They said since the engine isn't seize Hyundai will not cover the cost to repair or exchange the engine, I contacted the Hyundai customer service who stated since the repair that is needed wasn't the root cause of the problems associated with the engine swap warranty they were not going to help me even though I explained to them that the cars high accelerating and the braking system been jeopardized and been told the engine is beyond repairs I feel Hyundai should reconsider their decision and help a loyal customer. I have purchased 12 Brand New Hyundaj since 2001. The customer Representative was Extremely un Professional even suggesting I scrap my car, Also I contacted My Hyundai service Technician who said Hyundai customer service never contacted them about my car, When they said they spoke with the technician. Also I received an Extended warranty on the 2.4 GDI engine from Hyundai who many Hyundai customers are or have dealt with.I also purchased an Extended warranty Which I believe should have been extended as well Thank You

NHTSA ID

11735056

Incident

Apr 17, 2026

Component/System Failed: Engine – connecting rod bearing failure consistent with Hyundai Theta II engine defect subject to federal recalls and Consent Orders. The vehicle previously received Recall Campaign 953 (KSDS software update), intended to detect premature rod bearing wear. The engine is currently knocking and has been diagnosed as requiring replacement. The vehicle and engine are available for inspection upon request. Safety Risk: Rod bearing failure can cause sudden engine seizure or stall while driving, creating a significant crash risk due to loss of power steering and braking assist. Engine failure DID occurr despite prior recall software update, indicating potential recall remedy ineffectiveness. Sudden stalling in traffic placed myself and others at risk of collision. Dealer Confirmation: Hyundai of North Charleston confirmed through warranty history a prior engine replacement request (PA) was submitted by a previous owner but denied. The recall repair was never performed. Current diagnostic findings indicate engine failure consistent with known recall defect. However, Hyundai has refused to perform further inspection or goodwill repair solely due to the vehicle’s salvage branding. Inspection History: The vehicle has been inspected by a Hyundai dealership. No engine replacement was completed. Hyundai Customer Care has updated case notes but is declining remedy based on title status rather than mechanical condition. Warning Lamps/Symptoms: The vehicle previously received KSDS software update. Engine knocking developed consistent with rod bearing wear. The software did not provide effective prevention of engine failure. The engine now requires replacement. Hyundai is refusing recall-related remedy due to salvage title (predates my wonder ship by many years), despite federal recall obligations applying to the vehicle VIN. This complaint concerns potential failure of recall remedy effectiveness and denial of defect-related inspection.

NHTSA ID

11718641

Incident

Feb 6, 2026

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.

NHTSA ID

11702439

Incident

Nov 28, 2025

Mileage

55,300 mi

I had a standard oil change done on my car and it was running fine afterwards. Later that evening, my car started smoking and spontaneously burst into flames from the hood. The fire originated in the hood of the car and melted the entire front of my car as well as the entire inside. It burned a lot of fuel and oil, which leaked onto the ground and continued burning on the ground. My car was overtaken by flames in a matter of a few minutes. It burned so fast that there was nothing I could do to stop it. I was not aware of anything wrong with my engine or fuel lines, or anything like that. However, something was very wrong for the engine area to catch fire like that spontaneously.

NHTSA ID

11681712

Incident

Aug 1, 2025

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.

NHTSA ID

11674506

Incident

Jul 17, 2025

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.

NHTSA ID

11649349

Incident

Dec 15, 2024

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.

NHTSA ID

11649010

Incident

Jan 21, 2025

Mileage

85,000 mi

Gas smell on the passenger side front seat

NHTSA ID

11643054

Incident

Dec 20, 2024

Approximately five weeks ago, my 2015 Hyundai Sonata showed a check engine light. I took it into the dealer and paid a diagnostic fee which revealed the third cylinder misfire in the engine. I paid to have the engine cleaned yet the light continues to stay on and the car has been Running low on oil every time it gets checked the dealer states that the engine needs to be replaced

NHTSA ID

11632108

Incident

Nov 10, 2024

Hybrid system failure leading to complete power loss while driving.

NHTSA ID

11613315

Incident

May 7, 2024

I was driving on the highway and my engine violently started to shake and I pulled onto the shoulder and the engine shut off. I’ve had oil leak and engine problems with this car for 2 and a half out of 3 years! I’ve had to buy countless gallons of oil. Multiple spark plugs, coil packs, etc. You can’t drive the car for one whole minute without it stalling in traffic and almost causing accidents. So I can’t drive it!

NHTSA ID

11605266

Incident

Jul 22, 2024

The car has been having problems with oil consumption. The problem became known in 2022, but the dealer/service department (Frank Hyundai, National City, CA 91950) did not care for the issue or safety. The dealer told me, "Your car is OK." On 7/3/2023, the engine light came on. A second round of oil consumption tests began along with a 90,000-mile service, including replacements of filter assy and gasket, four new tires and front and rear brakes, spark plugs, suspension/steering repair, shaft assy, engine repair, cooling system service, and fuel induction service. Shortly after, the car slows down even when my foot is on the accelerator. It feels like the vehicle will stall/stop (while driving in the middle of the road). I can see the rpm gauge erratically going up and down. The car lurches or jerks. I reported the jerky problem to the dealer at the second 1000-mi oil consumption test, but the dealer did not make any diagnostic tests or repairs because, per the dealer, "it did not jerk while we test-drove it." The problem continues.

NHTSA ID

11562727

Incident

Nov 21, 2022

The car has been having problems with oil consumption. The problem became known in 2022, but the dealer/service department (Frank Hyundai, National City, CA 91950) did not take care of the issue and did not care about safety. The dealer told me, "Your car is OK." On 7/3/2023, the engine light came on. A second round of oil consumption tests began along with a 90,000-mile service, including replacements of filter assy and gasket, four new tires and front and rear brakes, spark plugs, suspension/steering repair, shaft assy, engine repair, cooling system service, and fuel induction service. Shortly after, the car slows down even when my foot is on the accelerator. It feels as though the vehicle will stop. I can see the rpm gauge erratically going up and down. The car lurches or jerks. I reported the jerky problem to the dealer at the second 1000-mi oil consumption test, but the dealer did not make any diagnostic tests or repairs because, per the dealer, "it did not jerk while we test-drove it." The problem continues.

NHTSA ID

11562726

Incident

Nov 21, 2022

In the first incident(2020) after the check engine light was on, the car was towed and needed the valve cover and fuel pump gasket replaced due to leakage. In November of 2023, the check engine light kept flashing and again the car was towed to the dealer. The valve cover was removed and we were told a new engine was needed, but we would have to pay for it. We were old that we have neglected to keep oil in the vehicle.

NHTSA ID

11559205

Incident

Nov 28, 2023

The driver's seatbelt does not retract. The engine is burning oil.

NHTSA ID

11547040

Incident

Jan 2, 2023

Car stalls intermittently. When at a stop sign or red light, then when my turn to go I step on gas peddle, car starts to go, then stalls. I have to let off gas pedal and step on it again to get car going. This is dangerous as it leaves me in intersection and vulnerable to oncoming traffic. I had a mechanic check it out and they cleaned Throttle body, but that did not fix problem. No trouble codes showing up apparently.

NHTSA ID

11546838

Incident

Sep 26, 2023

Hybrid car with various hybrid system failures that results in sudden loss of power while driving. this has occurred 3 times to me while on the highway (I-75 in South FL). Car suddenly loses power, could not accelerate but I was able to get off the highway safety. This has been reproduced at the dealer and they first replaced the hybrid generator then the hybrid battery and ECM and now it occurred again yesterday while I had 2 children with me and now they blame the transmission. This is a dangerous car that should be recalled and investigated for the true cause of sudden and unpredictable power loss.

NHTSA ID

11544187

Incident

Sep 11, 2023

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.

NHTSA ID

11543962

Incident

May 15, 2023

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

NHTSA ID

11539274

Incident

Aug 17, 2022

Mileage

163,402 mi

I have taken my car to mechanic and they have told me that my car is leaking gasoline. They recommended that I go to the dealer. When I called the dealer they told me that I would have to pay for the diagnosis. This is obviously concerning as gasoline fumes are toxic. There has been no warning lamps turned on this whole time but can definitely smell it when I finish my ride.

NHTSA ID

11538046

Incident

Jul 28, 2023

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 .

NHTSA ID

11538023

Incident

Aug 8, 2023

Engine failure due to a problem with the type of engine. Hyundai denied warranty and class action settlement claim, due to exceptional neglect. All oil changes etc were accounted for. the car with no warning, had been driving great, lost all power and left me and my two grandchildren on the side of the road. The Hyundai dealership confirmed that the engine was blown. There were no warnings

NHTSA ID

11535820

Incident

Jul 3, 2023

Hyundai is having failed engine problems after certain amount of mileage. The engine is burning oils with no leaks anywhere in the engine. You change engine oil after a week we will see the engine light flashing on your dashboard.This is my 2nd vehicle with the same problem. Thank you

NHTSA ID

11533824

Incident

Jul 18, 2023

My 2015 Hyundai Sonata has issues when switching from eco-to standard to sports, it constantly shakes when approaching a red light or stop.. my vehicle is constantly stock and vandalize and stole. Need you to easy assessability by thieves. this constitute higher insurance for me and consistent problems

NHTSA ID

11526312

Incident

Oct 1, 2022