2019 Hyundai Sonata

The low-pressure fuel pump module assembly, located directly beneath the rear passenger seat cushion, experienced a plastic housing failure. A stress fracture on the upper plastic fuel outlet nipple caused raw liquid gasoline to actively weep and pool on top of the module inside the passenger cabin. This component is retained and available for inspection upon request. RISK TO SAFETY: Raw liquid gasoline pooling inside the interior passenger compartment creates an severe, immediate fire and explosion hazard. Additionally, vehicle occupants were exposed to toxic fuel vapors while driving. INSPECTION & DEALER CONFIRMATION: An authorized Hyundai dealership inspected the vehicle and confirmed raw fuel leaking at the top of the fuel pump module assembly. This exact module had previously been removed and disassembled during a 2024 manufacturer recall service to replace the internal fuel filter and tank seal. Stress applied to the plastic fittings during that recall service appears to have caused the plastic top-hat to fracture over time under line pressure. Hyundai Corporate was notified of the safety hazard and prior recall history, but refused assistance. WARNING SYMPTOMS: The failure began with a strong, persistent fuel odor inside the vehicle cabin. No dashboard warning lights, check engine lights, or diagnostic trouble codes (DTCs) triggered prior to or during the failure. SUMMARY: A stress-fractured plastic fuel pump housing allowed raw fuel to pool in the passenger cabin following a prior manufacturer recall repair involving the disassembly of the same component.

For the past several years, this vehicle has experienced a recurring and unresolved engine malfunction that creates a safety hazard. The problem manifests as follows: Symptoms when check engine light illuminates: • Idle RPM elevation to approximately 1500 RPM (normal idle: 800 RPM) • Sudden unintended forward acceleration when foot is removed from brake pedal • Significantly reduced acceleration performance during normal driving • Vehicle becomes difficult to control safely The malfunction occurs intermittently but follows a consistent pattern. This is not an isolated incident but a recurring defect that has persisted for years. Multiple diagnostic and repair attempts have been unsuccessful: • Coconut Creek Hyundai service center - unable to diagnose [DATE(S)] • Independent mechanics - unable to resolve [DATE(S)] • Issue remains unresolved despite multiple service visits Despite multiple attempts by qualified technicians, the root cause has not been identified and the defect has not been corrected. This malfunction creates a significant safety hazard: • Unintended acceleration increases risk of collision • Reduced acceleration capability limits ability to merge or accelerate safely • Check engine light indicates undiagnosed system failure • Problem is intermittent and unpredictable, making it unsafe to drive I am concerned this may represent a defect pattern affecting multiple 2019 Sonata vehicles. NHTSA should: 1. Investigate whether this represents a defect pattern in 2019 Hyundai Sonata vehicles 2. Determine if a safety recall is warranted 3. Contact Hyundai Motor America to address this systemic issue

On April 14, 2026, my 2019 Hyundai Sonata was parked at a retail store parking lot. Returning from the store, I attempted to start the car, and it did not start. I attempted to start it again, and I saw smoke coming out from under the hood. I immediately exited the vehicle and opened the hood. I saw open flames coming out of the engine area, about 4” high. I called 911 and waited about 10 minutes for the fire department to arrive. During this time, the flames engulfed the entire engine compartment and extended vertically above the hood height. The hood eventually melted and fell back onto the engine area. The fire department came and put out the fire. The car is totaled. There were no injuries, thank God!

My 2019 Hyundai Sonata has been experiencing excessive oil consumption since I purchased it. The vehicle requires oil to be added approximately every two weeks, which indicates a serious internal engine issue. Recently, the check engine light turned on, and I took the vehicle to a dealership for inspection. I was told that the engine is “operating normally,” despite the ongoing oil consumption problem. I was also informed that the engine would only be replaced under warranty if it fails completely, such as through connecting rod bearing damage. This means I am expected to continue driving a vehicle that may suddenly fail without warning. I drive daily with my children, and I am concerned about the risk of sudden engine failure, loss of power, or engine seizure while driving, which could lead to a serious accident. I believe this is a known issue with these engines, and it represents a significant safety hazard that should be addressed before a catastrophic failure occurs.

Car has 39,495 miles. First owner of vehicle. Have advised dealership since 2024 that there was a oil issue as i have only went to them for oil changes. I advised that as they can see the car is barely driven and the oil is disappearing. They claimed nothing was wrong and made me pay for a oil change again. Come this year, I advise again there is a issue, they tried to have me pay for a oil change again and I advised something else needs done. They argued I was not the first owner and the car was not in warranty however I bought the car from their lot and I am the original owner. Then they stated I had to pay for another oil change for the oil consumption. Then they claimed they would just do the oil consumption and then to drive 1,000 miles and bring it back. After the oil consumption engine light is on. I drove 1,000 miles, brought it back and the engine failed the test. The dealership changed the engine. 5 days later engine light is on, car is stalling and brake locked up, then car would not start and was smoking under the hood. Car was then towed to the dealership. They claimed nothing is wrong and they reset the code for the engine light to go away. They stated evap code was on but was not persistent so it's fine. Few days later engine light comes on again and once the car has been running, you shut it off go to start it again it won't start unless you have it sit for a while. I Take it back to the dealership they point next to the engine saying a purge valve, but the wants money for a diagnostic. They do the diagnostic and still provide maybes, as they claim the filler neck is rusted and corrosion. I take the car to another place who states the filler neck is fine.

I have had issues with oil consumption in this vehicle for about 4 years. I started getting a "Knock Sensor" code. I replaced the knock sensor and still had problems. Hyundai had a recall and they reprogrammed my computer board. A year later I was having the same issues. My car started stalling out. Took back to the dealership they said my engine had sludge and now they're saying that there is a hole in my engine. Hyundai is saying that I don't qualify for assistance.

What component or system failed or malfunctioned, and is it available for inspection upon request? Since april 2025 i’ve been having low oil readings in my vehicle despite regular oil changes I took it into the dealer since my vehicle was still under warranty, which they stated only one part was under warranty. I had to pay $800 after this was replaced. I started having engine light come on. This engine light when I paid a diagnostic fee I learned that the cylinder three was misfiring. It was suggested that I have an oil change and get the oil level checked again within a week. This was done and it was determined that it was burning too much oil. I submitted this to the insurance and was told that this was not covered that there must be another reason why this was not working the way it should. 3 weeks ago Then I was asked to replace the spark plugs and coils. These were replaced for an additional cost of approximately $300. After replacing this, the check engine light gave the same condition of third cylinder damage.. And the oil level continue to decrease The vehicle was left with the dealer for approximately 10 days. They stated that the engine needed to be cleaned due to possible carbon buildup for about $800 then they stated that the spark plugs and coils needed to be replaced with a specific brand and not the type that Was previously used. Then my vehicle was returned to me, performing sluggishly with the check engine light returning with the same condition of third cylinder misfire. An inspection is available. How was your safety put at risk? The possibility engine failure away from hom Has the problem been reproduced or confirmed by a dealer or independent service center? Yes twice Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Yes frequently over the last 2 months