NHTSA Complaint #11687974 — 2011 HYUNDAI SONATA

1. The car began to randomly stall and stop running. This happened while driving and it was extremely dangerous. Typically, the engine would restart after at least waiting 15 minutes. Any attempt to start the car before that time would fail. 2. When the stalls happened, the car acted as if it had run out of gas. The engine would simply stop running WITHOUT WARNING, at intersections, on city streets, and on the freeway at high speed. It did not matter how full the gas tank was. 3. My brother and I diagnosed the problem as intermittent loss of fuel pressure. 4. My brother and I replaced the FACTORY fuel pump, and to hour horror, when we unplugged the electrical connection/plug, one of the pins from the fuel pump came out with the plug/connector. 5. We inspected the fuel pump and discovered that parts of the electrical plug INSIDE THE FUEL TANK had become burned and melted. See Image SANY0135.JPG === This is a SAFETY DEFECT - either the internal fuel pump electrical connections were faulty from the factory or the problem developed over time. There have been other recalls for this model of car for random engine stalls but this is a NEW and DIFFERENT cause. A dealer with a relatively inexpensive Infrared camera could likely spot this problem with minimal vehicle disassembly. There was clearly a LOT of heat concentrated in the area of the electrical connection to the fuel pump. We hope this report triggers a recall and prevents extremely dangerous random loss of engine power events, fires, or worse. Please recall all the vehicles that used that fuel pump for inspection before there is a disaster.