Recall 25V796 affects 85,043 2020-2023 Hyundai Sonata vehicles for check-valve damage that can melt the fuel tank. Repair is free at any franchised Hyundai dealer.
Hyundai is recalling 85,043 2020-2023 Sonata sedans because a damaged check valve can let air enter the fuel tank, expand it, and push it against hot exhaust parts. A melted tank can leak and increase fire risk; the Hyundai dealer repair will be free once it is available.
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What's wrong?
The purge control system check valve on 2020-2023 Hyundai Sonata vehicles with the 1.6-liter turbocharged engine is part of the fuel vapor control system. Its job is to control flow between the engine's intake system and the fuel tank area, so fuel vapors move the right direction and pressure in the tank stays controlled.
On affected Sonatas, the check valve wears and stops sealing as designed. That lets compressed air from the turbocharger flow backward toward the fuel tank. The tank can expand, move out of position, and contact hot exhaust parts. Repeated contact can damage or melt the tank, leading to a fuel leak.
Owners can hear a pop from the rear of the vehicle, see the malfunction indicator light, smell fuel, or find that the vehicle will not start. Those are warning signs to treat as fuel-system symptoms, not normal drivability issues.
Who's affected?
Covers four model years using the same PCSV check valve assembly in the fuel system.
| 2020 Hyundai Sonata | fuel system |
|---|---|
| 2021 Hyundai Sonata | fuel system |
| 2022 Hyundai Sonata | fuel system |
| 2023 Hyundai Sonata | fuel system |
| Units affected | 85,043 |
| Field incidents | NHTSA has logged 7 field incidents to date. |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific sedan is included.
What's the safety risk?
A melted fuel tank can leak fuel and increase the risk of a fire. Watch for a pop from the rear, a fuel odor, a malfunction indicator light, or a no-start condition. If any of these appear, park safely and call a Hyundai dealer for guidance. Repair will be free at any franchised Hyundai dealer once available.
What should I do?
- Check your VIN to confirm your 2020-2023 Hyundai Sonata is included in this recall.
- Watch for Hyundai's owner letter if you have not received it yet.
- Call Hyundai customer service at 1-855-371-9460 with questions and reference recall number 25V796 when you call.
- Contact a franchised Hyundai dealer about the free check-valve, fuel-tank, and engine-software inspection that fixes the fuel-tank expansion and leak risk.
- Keep the car away from ignition sources and contact Hyundai or the dealer right away if you smell fuel or see a fuel leak.
What happens at the repair
Once the dealer repair is available, a Hyundai technician will inspect and replace the check valve, inspect the fuel tank assembly for damage, replace the tank assembly if damage is found, and inspect and update the engine control unit software. Parts and labor are covered under the recall. Hyundai used its standard reimbursement plan for this campaign, so documented out-of-pocket repairs tied to this issue can be submitted through Hyundai customer service or the dealer service desk. Keep repair invoices and payment records.
| Reimbursement | Reimbursement available |
|---|
Timeline
| November 17, 2025 | NHTSA published the recall |
|---|---|
| November 19, 2025 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| January 15, 2026 | Interim owner notification (was planned for this date) |
| January 16, 2026 | Dealer notification began |
| January 16, 2026 | Dealer notification ended |
| March 9, 2026 | Owner notification mailed |
Frequently asked questions
What is recall 25V796?
Recall 25V796 covers 85,043 2020-2023 Hyundai Sonata vehicles with a damaged check valve that can let air enter the fuel tank. The tank can expand, contact hot exhaust parts, and melt. Hyundai dealers will inspect the check valve, fuel tank assembly, and engine control unit software for free.
What should I do if my 2020-2023 Hyundai Sonata is on this recall?
Check your VIN to confirm your specific Sonata is included in recall 25V796. If it is, contact a franchised Hyundai dealer and reference recall 25V796 or Hyundai recall 286. The dealer will inspect the check valve, fuel tank assembly, and engine control unit software for free.
Is the recall repair free?
Yes. Federal recall law requires Hyundai to fix this defect at no cost to the owner. Hyundai dealers will inspect and replace the check valve, inspect the fuel tank assembly for damage, replace it if needed, and update the engine control unit software for free.
What is the safety risk?
The safety risk is fire. A damaged check valve can allow air into the fuel tank, which can make the tank expand and contact hot exhaust components. If the fuel tank melts and leaks, the leak increases the risk of a fire.
When did Hyundai notify owners about recall 25V796?
Hyundai mailed owner notification letters beginning March 13, 2026. A mailed letter is not the final word for a used vehicle or a recently moved owner. Check your VIN, then call a franchised Hyundai dealer with recall 25V796 or Hyundai recall 286.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V796000 |
|---|---|
| Hyundai customer service | 1-855-371-9460 |
| NHTSA recall # | 25V796 |
| NHTSA recall # (full) | 25V796000 |
Source documents
-
Download Recall Report (PDF) - Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Recall Document (PDF) (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 19, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →