Hyundai Recalls Sonata Sedans Over Fuel Tank Melting Risk

Hyundai has recently issued a recall for Sonata sedans due to an issue that can cause the gas tank to melt, according to Car and Driver.

85,043 Sonata vehicles are included in the recall, from the 2020–2023 model years. Only vehicles equipped with the non-hybrid turbocharged 1.6-liter four-cylinder engine are impacted, not the 2.0-liter hybrid powertrain.

Due to a defect in the purge control check valve, compressed air is able to backflow from the turbocharger and reach the fuel tank. This can lead to the tank to deform, potentially expanding and making contact with hot exhaust pipes. That could melt the tank and leak fuel, creating a fire risk.

Symptoms that drivers can look out for include a “pop” noise from the rear of the car, a flashing malfunction indicator light on the dash, a smell of fuel around the car, or the vehicle failing to start. Hyundai was aware of seven fuel tank leaks in the U.S. and Canada related to the recall.

Hyundai will begin notifying owners on Jan. 16, 2026. Dealers will inspect and replace the purge control check valve as needed, inspect and repair the fuel tank and surrounding components as needed, and update the ECU software. Hyundai will reimburse drivers who had any of the outlined services performed before the recall was filed.