Hyundai Sonata Has Another Fuel Leak Problem

Recall / 9 Comments

The first recall yielded a fix that did not last.

Automotive recalls happen all the time, but they don't always lead to the intended outcomes. Hyundai recalled more than 200,000 Sonata sedans in 2020 for a leaking low-pressure fuel hose but didn't solve the issue entirely at the time. Now, the automaker is recalling all of those vehicles and then some for the same problem.

The recall covers 215,171 vehicles, including Sonata models built between November 2012 to February 2014. Sonatas equipped with a turbocharged 2.0-liter four-cylinder engine or the 2.4-liter engine are included in the recall. The NHTSA says that leaked fuel in the engine compartment could cause a fire, and notes that vehicle occupants may notice a fuel smell with the problem.

Hyundai
Hyundai

The first recall occurred in 2020 and covered 206,896 vehicles, but the documentation reads like a carbon copy of the more recent paperwork. The first time around, the fix was to replace a leaking fuel hose or install heat-protective tape if no damage or leaking was found. The NHTSA says that vehicles that did not receive a new hose during the 2020 recall will now need a replacement. Before the first low-pressure fuel hose recall, Hyundai recalled the high-pressure fuel pipe in 2018 over concerns that it had been improperly installed at the factory and could leak.

The NHTSA reviewed warranty claims reporting leaking fuel on select Sonata models that received the earlier tape solution. Hyundai's corporate sibling, Kia, had already recalled 2013-14 Optimas that were similarly repaired, so the NHTSA opened an investigation into Hyundai's issues.

Hyundai
Hyundai
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A closer look revealed "varied conditions in which the tape and zip-tie were applied in Recall 189's remedy, as well as fuel tubes with the remedy components missing." The NHTSA report also stated that it observed leaking in vehicles where the tape and zip-ties were used correctly.

Unsurprisingly, tape and zip-ties aren't the most elegant or permanent solution, so a replacement is in order for owners who received the fix in 2020. The new hose component is manufactured with a new material that should improve durability and heat resistance. Owners and dealers will be notified by July 5, and Hyundai will conduct repairs at no cost to the owner. The automaker will also reimburse owners for any expenses incurred during the process. Hyundai's newest EVs are excellent and don't leak fuel, so maybe it's time for a switch for owners of a decade-old Sonata.

Hyundai
Hyundai

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