A recall for Hyundai Sonata fuel tanks has been announced for nearly 91,000 vehicles with gas tanks that can expand and melt.
Hyundai says the Sonatas are equipped with 1.6-liter turbo engines.
The recall involves 2020-2023 Hyundai Sonata fuel tanks that may have damaged check valves that could allow air to enter the fuel tanks.
This can cause the gas tank to swell and come into contact with hot exhaust components, causing the tank to melt and fuel to leak. Leaking fuel can cause a fire.
According to Hyundai:
“The check valve of the bleed control system can gradually wear out and fail, causing a backflow of compressed air from the turbocharger to enter the fuel tank.”
Hyundai had issued emissions service campaign SC9B1 in November 2024, and thanks to repairs during this campaign, Hyundai discovered the fuel tank problems.
Hyundai is aware of at least seven complaints about leaking gas tanks in the US and Canada, but there have been no reports of accidents or injuries.
The Hyundai Sonata fuel tank recall affects 5,616 vehicles in Canada.
Hyundai dealers will replace the bleed control system check valve and inspect and replace any damaged fuel tanks or components. Dealers will also update the engine control unit software.
Recall letters for the Hyundai Sonata fuel tank are due January 16, 2026. But if you have any questions about the recall, call Hyundai at 855-371-9460 and ask for recall number 286 for the fuel tank.
In January, a Hyundai Sonata class action lawsuit was filed over swelling gas tanks, a lawsuit that blames the purge check valves.
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