2022 Hyundai Sonata Fuel system Problems

RECALL REMEDY FAILURE AND MANUFACTURER COERCION My Certified Pre-Owned 2022 Hyundai Sonata Limited has been held completely out of service at an authorized Hyundai facility since June 2, 2026, due to severe fuel tank expansion under active NHTSA Safety Recall 25V-796 (Hyundai Campaign 286).The dealership confirmed that the defective expanding plastic fuel tank ballooned with enough force to structurally warp and buckle the unibody center floor pan and frame rails. Rather than providing a safe, timely remedy under federal recall guidelines, Hyundai Corporate and the dealership are attempting to coerce me into an unfair, non-statutory "voluntary trade-in" that simply pays off my remaining loan balance ($22,000) while completely wiping out the $9,000 in cash equity ($3,000 down payment and $6,000 in monthly payments) I have invested into the car. Upon rejecting this predatory trade-in offer, the manufacturer immediately threatened an additional 6 to 8-week delay to attempt a massive structural frame and unibody pull, which would bring the total out-of-service time to over 90 to 110 cumulative days. Furthermore, the dealership is actively withholding the internal diagnostic write-ups and structural alignment prints from me. I am requesting that the NHTSA investigate this recall remedy failure. Hyundai is using extreme delays (90+ days) and structural frame threats to force consumers to abandon their financial equity rather than issuing lawful, purchase-price repurchases for vehicles deemed structurally unsafe due to a manufacturing defect. I can't provide any documents as they have refused being able to provide me with any. Was told I would be emailed a copy from the dealership several times and they never end up sending over any information.

NHTSA ID

11754635

Incident

Jun 2, 2026

The contact owns a 2022 Hyundai Sonata. The contact received notification of NTHSA 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 not made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11746780

Incident

Jun 26, 2026

The vehicle’s fuel tank system failed catastrophically. The vehicle is currently grounded and has been inspected at the Hyundai dealership service center where it was towed. My safety and the safety of everyone on the road was put at extreme risk due to a severe fire and explosion hazard. Additionally, the defect caused the vehicle to suddenly lose power, sputter, and threaten to stall out while driving on a major interstate, creating an immediate risk of a high-speed rear-end collision. When attempting to add fuel, the pressurized tank forcefully spit gasoline back out of the filler neck, creating an active chemical and fire hazard at a public gas station. I was able to drive it home and called via Hyundai Roadside Assistance to have it towed to an authorized Hyundai dealership service department. On June 15th, 2026, the dealership service technicians officially confirmed the failure, stating that the fuel tank had expanded, the back floor base of the car was melting, and the vehicle was on the verge of exploding.

NHTSA ID

11744661

Incident

Jun 9, 2026

Our 2022 Hyundai Sonata experienced multiple issues related to recalls affecting the vehicle’s reliability and operation. Due to these ongoing problems, the vehicle was taken to a dealership and has remained out of service and in dealership possession for approximately 90 days. The issues were confirmed by the dealership, and Hyundai Motor America was involved in the case. As a result, Hyundai approved a full buyback of the vehicle, indicating the problems could not be resolved in a reasonable timeframe. Despite this, the vehicle remains out of service and unusable. Hyundai has failed to complete the buyback process and has not provided a resolution within a reasonable time. There have been repeated delays and missed timelines. The extended period without a functioning vehicle creates reliability concerns and potential safety risks, as the vehicle could not be safely depended on for regular use prior to being removed from service. The vehicle is currently still in dealership possession and unavailable for use.

NHTSA ID

11735677

Incident

Feb 7, 2026

I brought this car 2022 Hyundai Sonata with 41k miles on it and only had it for 6 months. It has cut off 3x so far after putting gas in the tank. Always the same thing, oh nothing is wrong. Obviously there is and I see there is a recall on this car however my VIN isn’t coming up as a recall. This has to be fixed.

NHTSA ID

11735239

Incident

Dec 23, 2025

The Full stereo system with cameras and most sensors and the car is currently at the dealership as 03/09 @11:00 am and I took It to them as well so that they can repair the other pending recall I have at the moment and they stated that It was a " point to point check recall " and that they would change it whether it would need to be or not and I raised concerns about another possible recall on the car and if they could check it out which is my stereo system they tried to charge me almost $200 and " the symptoms or warnings " was that sometimes it would happen but Instead of It going out completely I was able to troubleshoot it by pressing on the little button under the volume button

NHTSA ID

11722956

Incident

Mar 9, 2026

The contact owns a 2022 Hyundai Sonata. The contact stated that while his daughter was driving at an undisclosed speed, the vehicle failed to accelerate as intended. The vehicle was taken to the local dealer, who determined that the failure was associated with NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the vehicle was not repaired. The manufacturer was contacted and opened a case. The failure mileage was approximately 100,000.

NHTSA ID

11722271

Incident

Feb 7, 2026

Mileage

100,000 mi

The contact owns a 2022 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 contact stated that while the vehicle was idling, and while driving at various speeds, the engine revved unintendedly, and the vehicle jerked. The ABS, traction control, and several unknown warning lights were illuminated. The message "Front Collision Avoidance Deactivated" was displayed. The vehicle was taken to the dealer, where a valve and gasket were replaced. The vehicle was repaired; however, the dealer informed the contact that the recall was not completed because the part was not yet available. The contact expressed concerns due to a fire risk associated with the recall. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the failure. The failure mileage was approximately 60,000.

NHTSA ID

11718520

Incident

Sep 17, 2025

Mileage

60,000 mi

The contact owns a 2022 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 contact stated that while driving at various speeds, the vehicle stalled. The vehicle was restarted and taken to the dealer, where it was diagnosed, and it was determined that the spark plugs had failed. The dealer replaced the spark plugs; however, the failure progressively worsened. The vehicle failed to restart and became undrivable. The vehicle was towed to the dealer on several occasions, and the dealer cleared the diagnostic trouble codes; however, the failure persisted. The manufacturer was notified of the failure and informed the contact that the part for the recall repair was not yet available. The failure mileage was approximately 50,000.

NHTSA ID

11717187

Incident

Feb 11, 2026

Mileage

50,000 mi

I have noticed puddles under/near rear side door/tire, the smell of gas after filling up tank. And a reduced MPG lower than normal with same driving habits.

NHTSA ID

11715181

Incident

Jan 30, 2026

My 2022 Hyundai Sonata Limited had a recall issued on the vehicle. I took my vehicle to a dealership and the recall issue was taken care for my fuel tank. Months after this issue was supposedly resolved, my fuel tank exploded and the car has been totaled.

NHTSA ID

11711052

Incident

Nov 24, 2025

My 2022 Sonata has had to have its fuel injectors replaced two times in the 3 years I've had it. On 12/18/2025 My car started to become very slow and could not reach over 20mph, and started to smell like gasoline and shake slightly. I had to get it towed to the hyundai dealership and there they told me that the fuel injectors need replacing. I had the same exact problem with this car before where I had to get the car towed to hyundai and then they had to replace the fuel injector.

NHTSA ID

11706285

Incident

Dec 18, 2025

Car keep cutting off and fuel injection is not right

NHTSA ID

11701358

Incident

Oct 7, 2025

Car has been running great. We ave had the car almost 3 months. My wife drove the car to church. On the way home the car engine started acting up. She pulled over and called me. I went to where she was about 1 mile from home . My son and I got the car started it would not hardly run we got it home. It was running roughly and smelled like gas making white smoke. A rollback truck picked it up the next day. Took it to the closest dealer in cape Girardeau mo. It has been in the shop3 weeks found out today it will be over another week before Hyundai gets in touch with the dealer about the problem. (Injectors)

NHTSA ID

11700679

Incident

Aug 20, 2025

I was driving the car home from Massachusetts when, after 6 hours of driving, the car started to shake and would not accelerate. It was also emitting a burning smell. I exited the highway and called for a tow truck. I was told by the Hyundai dealership that, at 4,100 miles, a fuel injector and high pressure rail had failed.

NHTSA ID

11697227

Incident

Oct 19, 2025

In November of 2024, I had a Check Engine Light for a Cylinder 2 misfire and a fuel to air mixture ratio. Had it towed to a Hyundai Dealership. Got a call the next day saying it was fixed. Picked the car up and 50 miles later it popped back up. Had it towed back again. They said my fuel injector was cracked. They had to order the fuel injector directly from Korea. Took 5 days to get the part and it installed. Fast forward to September 2025, Cylinder 2 misfire showed up again(same cylinder the fuel injector was replaced) and now the car shakes violently when accelerating and stalled at a stop light. Massive safety concern due to risk of an accident. Car to be towed to another dealership for the same issue less than a year apart.

NHTSA ID

11684409

Incident

Sep 2, 2025

The fuel tank expanded/swelled up causing frame damage to the vehicle.

NHTSA ID

11679597

Incident

Jun 25, 2025

Fuel Lines and Connections / Fuel Tank Band / Fuel Tank Vapor Vent System Hoses [XXX]: My check engine light illuminated. I immediately returned to Hyundai Riverdale. They advised me it could be the fuel tank and stated they needed to keep the car for 5-7 business days. May 1, 2025: I dropped off my car for inspection, having made arrangements for a personal rental car. May 7, 2025: I received a text message (no phone call) indicating the inspection was complete and was presented with a $3500 bill to replace the entire fuel tank. May 9 or 12, 2025: Marilyn from Hyundai Riverdale called me regarding my vehicle. She explicitly suggested I "contact your insurance company, advise them you hit something on the road, pay the deductible, and they will pay for the repairs." She then stated, "I know you hit something after April 9th because your fuel tank is now damaged." I denied hitting anything. During this call, she mentioned a "RECALL" related to fuel tanks on all Hyundai Sonatas, which I was never previously made aware of. I questioned why I was being charged if there was a recall for the exact issue I was experiencing. She claimed my car was previously checked and the fuel tank was fine, therefore the cost fell to me. May 14, 2025: Merilyn called to inquire if my insurance would cover the repairs. I informed her I was picking up my vehicle as another Hyundai dealership in Newnan was willing to perform the recall repairs for free. Upon arrival at Riverdale, I faced resistance but demanded my car be released. I was then charged a $200 inspection fee, which I refused to pay. Marilyn then provided my keys and, upon learning I planned to drive to Newnan, stated, "I wouldn't feel right letting you drive this car off the lot and something happening to you. Your vehicle at any moment can blow up due to the fuel tank. It's very dangerous to drive and suggest you get a tow truck." April 11-May 1st I drove that vehicle w/no idea it had the potential to blow up. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATI

NHTSA ID

11670726

Incident

Apr 11, 2025

Driving on the highway ih35N at 75 mph, my car's engine randomly started violently jerking and then shut off and wouldn't start back up. Had it towed to Hyundai (2022 Hyundai Sonata ~33k miles) took a few days but they repaired it under warranty saying it was bad fuel injectors and they replaced all 4. My car just dying on the highway could of caused a bad accident at that speed. Moving to present day (June 28th, 2025) car is at 56,400 miles and its starting to jerk at low speeds and is getting terrible gas mileage again. I'm taking it back in as I am still under warranty but everything points to fuel injectors again. Only warning lights I get was when the car died on the highway. Just a check engine light.

NHTSA ID

11669971

Incident

May 3, 2024

First owner, sporadic acceleration problems reported from approx 6k miles. Documented with dealership.. “couldn’t reproduce” issue every time I brought it in after an occurrence. Dangerous when entering highway, as I never knew when it would fail/stall. Eventually broke down on busy interstate highway, replaced 1 fuel injector, and guilt tripped me into “needing” to have fuel injector cleaning because the others might fail as well. 27k miles was the first breakdown. 38k was the second breakdown and almost caused a serious accident when I was unable to accelerate. Replacing all 4 fuel injectors but not covering the oil change due to their faulty fuel injectors.

NHTSA ID

11666438

Incident

Jun 10, 2025

Car keeps jerking also it’s something going on with the fuel injections I’ve had to get them replaced twice. Please help

NHTSA ID

11661682

Incident

Mar 3, 2025

The contact owns a 2022 Hyundai Sonata. The contact stated while driving at an undisclosed speed, there was an abnormal sound coming from underneath the vehicle. No warning light was illuminated. The vehicle was taken to a local dealer and was repaired for a fuel valve failure. The vehicle was repaired; however, shortly after the repair the check engine warning light illuminated. The vehicle was taken back to the same local dealer where it was diagnosed with the fuel valve failure. The vehicle was repaired; however, the failure had reoccurred. The vehicle was taken back to the same local dealer where it was diagnosed with a fuel valve failure. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 92,000.

NHTSA ID

11653249

Incident

Mar 15, 2024

Mileage

92,000 mi

My car has been experiencing air defects when it would randomly stop working. Last month my car air stopped working after I picked my pet up from the groomers and all together on the service road my car shut down. After being towed to Hyundai dealership I was being demanded that I ride on E and that it could’ve been my fuel injector. After realizing it was not that they claimed it was a failed fuel pump. After paying and recording my car back not even 8 hours later my car would not turn over again with no air causing me to get towed a second time. The dealership couldn’t diagnose what’s wrong with my car so they tried to throw false accusations as to my old gas can that stays in my truck that the smell of gas is the reason why they can’t properly diagnose my car. After getting my car back and driving it home, after turning it off and back in case duplicated the same problems with me. Wouldn’t turn over or produce air. Dealership refuse to comment on the paperwork if the problems they ran into but rather called me. After keeping my car a week to drive it the problem didn’t duplicate. I’ve had my car for about 3 weeks now and the air still give me problems and don’t want to come on every now And then

NHTSA ID

11604047

Incident

May 27, 2024

****Answers to questions above**** The dealership determined the fuel injector of cylinder 2 to be malfunctioning and replaced it. My safety was put at risk because my car lost all drive power and I could not get out of other people's way.(I was only going 40 but imagine if it happened at 80 mph on an interstate) The dealership reproduced the issue and fixed it. The dealership also stated that several models of Hyundai using the same fuel injectors had come in with the same failures.(10+ cars) Not all on the same cyclinder either. My vehicle has only been inspected by the dealership at this time. There were no warnings leading up to the failure. ****Full Story**** I was driving at about 40 mph through town and experienced total loss of drive power. The vehicle had electric, but little to no response from the gas pedal. I manged to limp the vehicle about 200 yards to a stop light. The rpms dropped to under 300 and the engine began to idle very rough. I shut the car off while at the red light to save it from any potential internal damage. When the light turned green, I almost could not get the car to start and stay running. There was a very strong gas smell at this point, which I had assumed was coming from the engine. I had to put the gas pedal to the floor to keep it running and ride the brakes through the intersection to not hit the vehicle in front of me. After getting through the intersection, I limped it into the parking lot on the other side. This is when I noticed the check engine light had come on. There was no leaking fluids under the hood or the car. I had the vehicle towed to the nearest Hyundai dealership.

NHTSA ID

11590031

Incident

Apr 25, 2024

GDI fuel injectors are faulty and causing engine misfires in multiple cylinders.

NHTSA ID

11585143

Incident

Mar 8, 2024