Three problems related to gas recirculation valve (egr valve) have been reported for the 2017 Hyundai Sonata. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2017 Hyundai Sonata based on all problems reported for the 2017 Sonata.
This is the seventh occurrence of complete loss of power while driving on the interstate. The hybrid system warning activated, followed by the engine shutting down, and all dashboard lights illuminated with alerts indicating "shut off engine/hev. " an 18 wheeler was pulling out from the shoulder as I was losing power and barely missed getting crushed. The former problems have all been at interstate speeds with similar accident avoided. The service history clearly demonstrates that Hyundai has repeatedly attempted to address this issue by replacing numerous critical components, including the engine, transmission, knock sensor, battery (three times), integrated brake actuation system, and Smart cruise control, among others. Despite these extensive repairs, the problem persists. On this latest occasion, less than 4,000 miles and four months since the last major incident, the dealership has proposed replacing the intake manifold, egr valve, hsg belt, and spark plugs. The belt was changed less than 20k miles ago. And I believe the spark plugs were as well. Each time my vehicle experiences this issue, it is out of commission for weeks or even months at a time, causing significant inconvenience and raising serious safety concerns. I no longer trust this vehicle and I don't believe the many recalls have successfully addressed the root cause of issues with the 2017 hybrids.
Egr cooler leaks and slowly burns off engine coolant resulting in the car overheating while driving, forcing a quick exit from the road, or stopping in traffic not to damage the engine. Google search shows this is a very common issue with these hybrids.
While driving on a highway at ~60 mph, the check engine light came on (plus other indicator lights) and the car immediately dropped to ~45 mph. ~20 seconds later, while trying to pull into a school parking lot, the hybrid system fault warning came on and the car dropped to ~5-10 mph and then became extremely difficult to control. The car was towed ~80 miles to my home dealership and it was diagnosed as a partially blocked egr tube. ~1 month later, on the next longer drive I had to make (all other drives were short distances), ~70 miles into the drive, the car started making a knocking sound and then suffered the same failure under the same kind of conditions. This was diagnosed as a failed knock sensor. One week later I tried to drive it a long distance to see if the problem would happen again (but closer to home) and while traveling on an interstate highway the same issue occurred. This time it was diagnosed as oil in the wiring assembly for the just replaced knock sensor. The dealership tried to give me the car back but I demanded that they do a long test drive. It took 4 days to get them to do what I asked and then they had it break down on them in the same way. I'm not 3+ weeks after that and still don't have the car back (now they're planning to replace the egr assembly and intake manifold). Each breakdown has thrown the p1326 trouble code but Hyundai refuses to admit that the issue may be the engine itself (related to the recall). It took until the 3rd breakdown and a lot of demands to get a loaner vehicle. I don't know if this is the known engine issue, something else or new but don't feel that Hyundai is taking it seriously. If nothing else, the programming that was added to put the car in safe mode and prevent fires is too aggressive and in each case has made the car undrivable in less than 1 mile. I have gotten lucky in all cases that a safe place to stop was nearby but it is not safe to drive in many areas due to lack of safe pull off location.