A new serious conundrum is looming for the Korean giant Hyundai. The company has been forced to launch a large-scale recall of a total of 85,043 Sonata sedans due to a critical manufacturing defect that can cause the fuel tank to deform, expand and even melt. The reason is simple, but extremely dangerous - a defective valve that can turn the fuel tank into a potential time bomb.
This alarming development was announced after a recall application was filed with the US National Highway Traffic Safety Administration (NHTSA). The recall covers Sonata models manufactured between 2020 and 2023 that are equipped with a 1.6-liter turbocharged gasoline engine. It is important to note that hybrid versions with a 2.0-liter unit are not affected by this problem.
The problem is rooted in the incorrect operation of the canister purge control valve. Due to its failure, compressed air from the turbocharger can be injected directly into the fuel tank. As a result, the plastic tank cannot withstand the pressure and begins to deform and expand.
When the tank changes shape, it can come into contact with hot elements of the exhaust system. This contact creates a high risk of melting the plastic and, even more frightening, fuel leakage, which increases the likelihood of a fire many times over.
How to recognize the problem?
According to NHTSA documents, owners of affected vehicles should be alert to several possible signs of a malfunction. These include:
A loud “cracking“ coming from the rear of the vehicle.
A malfunction indicator on the dashboard illuminates.
A distinct smell of fuel appears.
The engine is difficult or impossible to start.
At the time of filing the report, Hyundai has registered seven cases of fuel leaks in the United States and Canada. Fortunately, there have been no reports of accidents, injuries or, God forbid, deaths, but the risk is real.
Owners of affected Sonatas should contact an authorized Hyundai dealer immediately. Service centers are committed to conducting a thorough inspection and, if necessary, replacing the defective valve, as well as inspecting the condition of the fuel tank and adjacent components. They should also update the engine control unit software to prevent future problems.
The company has stated its readiness to compensate all customers who have fixed this defect at their own expense before the official recall. Hyundai will begin sending official notification letters to owners and dealers starting January 16, 2026. Each owner can check whether their car falls under the scope of the recall on the NHTSA website by entering their VIN code.