Fuel tank can expand, contact hot exhaust and melt (recall 25V796)major
The generation-wide fuel-tank recall reaches the 2023 as its final model year. Hyundai states that a damaged check valve can allow air into the fuel tank, causing it to expand and contact hot exhaust components, melting the tank — and a melted tank can leak, raising the risk of fire. The remedy is a free check-valve inspection and replacement, fuel-tank inspection and replacement if damaged, and an engine-computer software update. VINs became searchable on 19 November 2025 and letters went out from 13 March 2026, so many 2023s will still be waiting. One 2023 owner filed against it after the failure spread: recall 286, as Hyundai numbers it internally, causing a heat-module failure, a cylinder-two misfire and high-pressure fuel trouble. Check the VIN before you view the car.
Sources: NHTSA complaints and recalls, 2023 Sonata / Sonata HEV (pulled 2026-07-30) · NHTSA manufacturer communications, Hyundai Sonata (2.5L GDI Theta III injector filter breakage, 8-speed wet DCT oil pump and judder, EHRS coolant leak and DTC P00B7 logic, fuel-tank check valve P0451, Idle Stop & Go)
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Recall 25V796 check valve, tank and software