The Recall Desk
Our severity:SevereNHTSA·25V796000·Announced 2025-11-17

Hyundai Sonata fuel tank can expand and melt against hot exhaust

Hyundai is recalling certain 2020-2023 Sonata vehicles because a damaged check valve can let air into the fuel tank, causing it to expand, contact hot exhaust components and melt.

What this means for you

Our assessment, not the agency’s: severity 4/5 (Severe).

The hazard poses a serious risk of illness, injury, or structural failure. Stop using the product immediately and contact the manufacturer for a refund or repair.

Our severity reasoning: Rubric level 4 covers structural vehicle defects: the tank physically deforms and melts against the exhaust, which is a failure of fuel containment rather than a theoretical hazard.

Plain-English summary

Hyundai Motor America is recalling certain 2020-2023 Sonata vehicles. About 85,043 units are potentially affected.

A damaged check valve can allow air to enter the fuel tank, causing it to expand and contact hot exhaust components, melting the tank.

NHTSA states that a melted fuel tank can leak, increasing the risk of a fire.

Dealers will inspect and replace the check valve, inspect the fuel tank assembly for damage and replace it if necessary, and inspect and update the engine control unit software. All repairs are free of charge. Owners may contact the NHTSA Vehicle Safety Hotline at 1-888-327-4236.

The recalled product

Product
HYUNDAI SONATA
Brand
HYUNDAI
Manufacturer
Hyundai Motor America
Category
Vehicle — Fuel system
Hazard
Affected units
85,043

Is your product affected?

Check your packaging against the codes below. If any of them match, the product is part of this recall.

Model numbers (1)

  • SONATA

Distribution

Distributed nationwide across the United States.

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