Gas Recirculation Valve (egr Valve) problems of the 2011 Hyundai Sonata

Nhtsa in December 2015 the engine on our 2011 Hyundai Sonata failed while accelerating to merge into traffic on a very busy hwy 101 in the san francisco bay area. We brought our vehicle to the dealership where we had purchased it in may 2011. The following morning we were told by the dealership's service department that the engine had failed and that Hyundai north american has authorized them to replace the engine at no cost to us. Afterwards, we brought the vehicle back complaining of 1. A noise coming from the engine compartment, and 2. A toxic smell invading the passenger cabin seemingly coming from the engine compartment. We were told that they were unable to replicate either of these conditions while the vehicle was with them. After several return visits we were told that the sound and smell were due to a failed �motor assembly� needing to be replaced. We were charged approximately $575 despite our objectives asserting that the failed motor assembly was the result of faulty work when the engine was replaced lest the other 3 motor assemblies would also need to be replaced. We were eventually reimbursed but not my the dealership but rather by Hyundai n. A. . We again mentioned our complaint about the frequent toxic smell to Hyundai n. A. Requesting that they buy the vehicle back from us based on the aforementioned conditions. We were advised that our vehicle was not eligible for buy back, rather Hyundai n. A. Offered a settlement agreement for $2,000. We reluctantly accepted the settlement agreement and signed the release believing that there was no other forum for us to seek remedies except through the costly court system. We regret having accepted the settlement agreement each time the toxic smell invades the passenger cabin. After the recent news reports we are now fearful that our 2011 Sonata will burst into flames.

I was driving my car about 45 miles per hour. All of a sudden my engine just cut out. I began to pump the gas and there was no acceleration and no sound from the engine. It was completely dead. The lights were on and all other functions were working properly. The yellow engine light came on. I had to pull over and was hoping and praying that my brakes were still working. They did. There was no warming . No oil lights or coolant lights came on . It was about 75 degrees and a clear night with no rain. I have taken my engine in 2 other times due to weird sounds and odd issues for the recall. All time it has passed the "pressure test" . My car was towed into the dealer. They are admitting there is definite noise in the engine, but it is still passing this random test. I have had all my oil changes and am at the dealer enough that they know who I am. This could have killed me if I was on the freeway here in southern California. My dealer has been amazing. The corporation is giving me the run around. (please let me know if you need my dealer print out to show that it is in for service).

My steering wheel has become increasingly loose and shaky over the past months when driving or stationary. There is a very distinct (and getting worse over time) "clicking" or "knocking" sound when I back up and turn my wheel either way. I was told by my mechanic that something is wrong with my steering gear box/shaft sector and possibly some of my axles. He told me this was dangerous, and that the recall campaign number 097 should cover me. However, I was told by Hyundai that my specific car does not fall under this recall, even though I my car has the exact symptoms of the recall. I was also told that because of recent recalls, my warranty would be extended. However, Hyundai has now told me that my warranty extension only covers the sole engine, and not the axles though they are part of and covered by the initial engine warranty. Hyundai has told me there are "kits" to fix these problems, but I have to pay over $1000 for the kits to fix, even though these were faulty parts by Hyundai. The Hyundai service manager I spoke with told me flat out that my car had faulty parts, but that the kits could fix them. I asked him whose fault it was that they were faulty, and he said that all car companies deal with this and it wasn't because of my driving. But even still so, I have to be the one to pay for Hyundai's faulty parts and non-existent recall help. I'm beyond frustrated after reading so many reviews and forums online of people with the exact same car symptoms as mine who are unfortunately also not covered by the recall. If I cannot get a better response and answer from this, I will be contacting the main lawyer who others have also contacted about this and filing an official lawsuit. I expected way better from Hyundai and am disgusted and disappointed at the lack of service, truthfulness, and integrity from this company at this point.

This car is equipped with a smartkey. Recently it has developed a starting problem that is directly related to the outdoor temp. It has been serviced several times by the local Hyundai dealer. They have replaced the shift interlock switch and the brake light switch. It is below zero this morning (2/21/2015) just one day after the brake light switch was replaced, and again the car refuses to start. When the start button is depressed everything lights up on the dash board but the engine will not even turn over, it is completely dead. The engine imobilizer light also comes on after attempting to move the shifter and the brake pedal becomes nearly impossible to depress! the car will be out of warranty soon. This needs to be resolved. The car has refused to start dozens of times with the very same issues. The car has left me stranded (at home to date) numerous times. When it warms up outdoors later in the day and the temp goes up to 25 - 30 degrees the car starts virtually every time and will start without a problem for the rest of the day. I have researched this problem on this website and other websites and push button ignition problems are very common on this car. Hyundai needs to come up with a proper fix for this problem. Numerous people report having the same switches replaced as on my car their problems were not solved either. It appears that Hyundai has never been able to come up with a proper fix for this issue or it is just to costly to implement. They have continually swept it under the rug.

There is a smell of gas/engine fumes notable in the vehicle on occasion. The problem does not happen consistently, however there are some common factors to when the smell in noticeable. These factors include: 1) the engine must be hot, generally having been driven for at least 15 minutes or more. The smell is never noticeable when the engine is cold, such as after sitting overnight. 2) the vehicle must be either moving at very slow speeds of <25 m. P. H. , or sitting still. Examples would include driving through parking lots, sitting at an idle for a long period at a stop light, when first starting the vehicle after sitting in a parking lot for awhile, etc. 3) when the gas / fume smell is notable with greatest intensity, it seems to occur after a hot engine soak of 15~45 minutes at ambient temperatures of 30 degrees fahrenheit or above and in conditions of moderate- to high-humidity. Examples include during periods of heavy fog, rainy days, snowstorms, etc. On occasion, the smell is strong enough that it is no longer comfortable to remain in the vehicle. Rolling down a window at speeds >25 m. P. H. To clear out the cabin air, followed by activating the hvac recirculation button will lessens immediate recurrence the smell to some extent. Finding ways to "mask" the smell are of lesser concern than determining why the smell exists in the first place. The vehicle has been in for this concern twice, with neither trip to the service bay having resolved the concern. While it does not appear to be an issue causing immediate danger (no noticeable fuel leaks or signs of fire), the smell of gas and engine fumes entering the passenger cabin is a bit concerning, both from a potential fire hazard in the future, and/or exposure to carbon dioxide and other noxious fumes while operating the vehicle. I will return the vehicle for a third visit to resolve this concern.