Manifold/header/muffler/tail Pipe Problems of Hyundai Sonata

Hyundai Sonata owners have reported 29 problems related to manifold/header/muffler/tail pipe (under the engine and engine cooling category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Hyundai Sonata based on all problems reported for the Sonata.

1 Manifold/header/muffler/tail Pipe problem of the 2015 Hyundai Sonata

Failure Date: 01/22/2021

My car was under the Hyundai engine recall campaign the engine was replaced at 60k now have 113k the car star to giving issues and smoke for the engine cap and muffler and oil disptick the car was take to the dealership because was under the Hyundai extended warranty until 120k or life time after the dealer make the inspection they contact Hyundai and they ask for pictures the pictures was sended car was fine no oil deposited everything was clean Hyundai after 6 days o back and for they denied the engine claim demanding the the car was no under warranty if my car was under the extended how they said that without even give an explanation I attached the conversation between the dealership ans Hyundai dealer.

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2 Manifold/header/muffler/tail Pipe problem of the 2011 Hyundai Sonata

Failure Date: 10/21/2020

Ever since I had a new engine put in my car, my car hasn't been the same. It acts like it doesn't want to go when pressing the gas pedal right after (was told it was the eco mode), then my dash started to crack, now is extremely cracked which has an air bag, gas gage has a mind of its own, burning a severe amount of oil a week so there is no point in �changing the oil�, oil light never once comes on letting me know its low, no oil on my driveway or under the hood, interior dome light sometimes doesn't shut off, the brake lights short out on a monthly basis and get pulled over by the cops all the time. Now with only 50,000 miles on the �new engine�, I take it back to the dealership because its smoking when I crank it, doesn't accelerate sometimes going down the road when I press the gas, then starts smoking, headlights flicker, engine light stays on and low tire light stays on (even after getting new tires & alignment). Took it in yesterday, Hyundai is stating my oxygen sensors, catalytic converter & gaskets and intake manifold need to be replaced at $3,177. The car isn't even worth that much. This is not the reason why my car is using excessive amounts of oil, smoking when I crank it and acts like the engine is about to blow up. Then they come back to tell me it needs the above, plus an engine replacement but out of �goodwill� they will only charge me 20% ($2,000) with no loaner car. Its going on 3 weeks now. The corporate office is useless and very rude. I have a voicemail stating �this is the highest customer service department and once the decision has be made, those decisions are fianl and its up to you to decline or accept our offer. � it's the engine, again! which then lead to other issues! I will never buy another Hyundai again!! this car has caused nothing but money and time, complete waste of junk!.

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3 Manifold/header/muffler/tail Pipe problem of the 2015 Hyundai Sonata

Failure Date: 08/24/2020

Intatke manifold runner performance the engine light show up on dashboard. The dweller charged me #163. 14 just to block, and they want #563. 00 to replaced the DC motor.

4 Manifold/header/muffler/tail Pipe problem of the 2017 Hyundai Sonata

Failure Date: 08/01/2020

Car is consuming too much oil I have to put anywhere from 2 to 3 quarts of oil in car in between oil changes sometimes it acts like it has no power don't wanna go but then it just takes off my mufflers is black from the oil puffs of smoke come from my muffler sometimes there is never any oil on ground not sure where it's going but it's goin somewhere it's causing problems I have heard several other people say that their Sonata is doin the same thing.

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5 Manifold/header/muffler/tail Pipe problem of the 2015 Hyundai Sonata

Failure Date: 07/10/2020

While driving on a major highway with a 55 mph speed limit, the check engine light came on and the car hesitated and was difficult to maintain the speed limit. I took the car to and auto parts store that has a code reader and saw the manifold runner control was indicating a fault. The code, p200a is described in a Hyundai technical service report for 2015 - 2016 Sonatas however after taking the car into new port richey Hyundai I was told that the service bulletin didn't apply to my vehicle. It is a danger to drive with the control unit failing and may at any time cause the car to decellarate.

6 Manifold/header/muffler/tail Pipe problem of the 2016 Hyundai Sonata

Failure Date: 07/02/2020

Hello I purchased a 2016 Hyundai Sonata 4/8/2020 with 110,743 miles on it with now 116,000. About a month ago my check engine light came on with no symptoms to the naked eye . Maybe a week later I could feel the difference in the speed control the air intake seemed very sluggish it won't take off from the line it will drag before it decides to pick up speed . Now the issue is that this is a common problem with these specific cars with no recall on them. This is an expensive fix that I should not be responsible for. Code p200 intake manifold . . It's not safe to drive a vehicle that you cannot control its initial speed . . .

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7 Manifold/header/muffler/tail Pipe problem of the 2012 Hyundai Sonata

Failure Date: 01/31/2020

My car stalls, lags and shuts off while driving and has a strong scent of exhaust and uses an awful amount of oil but there are no visible oil leaks. There are no check engine lights on. I have taken it to the muffler shop who states no exhaust leaks are found. My local gateway and mike morgan hyuandi says it throws no codes when put on the diagnostic machine so I cant find out the issue. From research I see this is a common issue with this model cars and I feel this should be looked into because it is a hazard especially when it kills in the midst of traffic.

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8 Manifold/header/muffler/tail Pipe problem of the 2011 Hyundai Sonata

Failure Date: 11/07/2019

This vehicle has stalled on me while driving on the highway and streets. I've taken it into the shop for the problem was told the pc module is going out. The price to fix this a 2300. 00. This should be covered on a warranty. They've me told that it's not. This is a major componet for these vehicle it should be cover. This has happened several times prior. When the vehicle accelerated there is smokes for the tail pipe.

9 Manifold/header/muffler/tail Pipe problem of the 2015 Hyundai Sonata

Failure Date: 08/08/2019

The check engine light is illuminated and when coming to a stop, the vehicle lunges/surges forward as if the brakes are failing and I'm going to hit the vehicle in front of me. I took the the vehicle to 2 local jim click Hyundai dealers, the fault code is p200a and they stated the issue is most likely replacing the intake manifold which would not be covered by the powertrain warranty and my mileage is 85,000 presently. I would think that it would be a warranty item because the intake manifold is bolted to the engine and connected to the engine with wires. Now I'm stuck with a $1000 repair bill.

10 Manifold/header/muffler/tail Pipe problem of the 2017 Hyundai Sonata

Failure Date: 07/08/2019

Engine cuts off in the middle of traffic would not allow me to move gear shift reported issue since October 2018. Car recently had 3 recalls that were repaired however engine is still shutting off and gear shift won't move and engine light is on and off. I got a diagnostic and it had 3 codes of intake manifold and valve. I bought the car like this.

11 Manifold/header/muffler/tail Pipe problem of the 2007 Hyundai Sonata

Failure Date: 05/18/2019

I had been driving on the turnpike for almost an hour when I started to hear a clicking noise. I was driving about 70 mph and pressed down on the accelerator. When I did so, there was a loud bang and suddenly, smoke filled under the hood and also came out the exhaust pipe. I also saw debris flew out from under the car, looking like it was coming from the tail pipe. I pulled over and opened the hood to find oil everywhere, more smoke flooding out of the hood and bits of metal debris all over. Oil was leaking all over the side of the road. The mechanic has judged that the engine burst while I was driving it.

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12 Manifold/header/muffler/tail Pipe problem of the 2013 Hyundai Sonata

Failure Date: 02/10/2019

Engine recall - I did an oil change at glendale Hyundai CA. , and the vehicle is now blowing thick white smoke through the tail pipe. The engine is knocking, and the oil is sludgy and it sized up on me while driving on the city streets. My vehicle only has 36k miles on it. . . I did some research and noted that the model that has recalls on the engine for sludgy and knocking and worn-out bearings are Hyundai Sonata from the 2011 and 2012 model years it has either the 2. 0-liter turbo or 2. 4-liter version of the 4-cylinder theta ii engine. Im taking it to the dealer today and see what and how theyll handle the situation.

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13 Manifold/header/muffler/tail Pipe problem of the 2014 Hyundai Sonata

Failure Date: 11/20/2018

When accelerating past 3500 rpms there is a clanging sound coming from the engine and you can't accelerate anymore. There has been at times a large plume of white thick smoke coming from the tail pipe when trying to accelerate.

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14 Manifold/header/muffler/tail Pipe problem of the 2016 Hyundai Sonata

Failure Date: 11/12/2018

Got an engine light at 37k miles. Took the car to dealership initially told was vcm motor, replaced, left dealer and light came back on, told they forgot to update software after replacing vcm motor, left dealer and light came back on. Went back to dealer for third time and after they called Hyundai engineering the discovered that the entire manifold needed to be replaced as it was somehow wedged into the engine. Was covered by warranty as should be. This somewhat helped my acceleration issues but was told it was a safety issues because if anything from the plastic manifold broke off in engine it would cause the rods to bend and could cause engine to seize and catch on fire.

15 Manifold/header/muffler/tail Pipe problem of the 2011 Hyundai Sonata

Failure Date: 11/20/2017

Tl the contact owns a 2011 Hyundai Sonata. The contact stated that the engine was hesitant and there was excessive smoke emitting from the tail pipe. The dealer (ciocca Hyundai, 550 s west end blvd, quakertown, PA 18951, (215) 536-2700) indicated that the vehicle was previously repaired per NHTSA campaign number: 15v568000 (engine and engine cooling). The contact was uncertain that the oem defective part was replaced with the new engine assembly. The vehicle was not diagnosed again by a dealer. The vehicle was not repaired. The manufacturer was notified of the failure and provided no remedy. The approximate failure mileage was 139,000.

16 Manifold/header/muffler/tail Pipe problem of the 2013 Hyundai Sonata

Failure Date: 09/14/2017

The contact owns a 2013 Hyundai Sonata. When the contact started the vehicle, black smoke emitted from the tail pipe. The contact also heared an abnormal knocking noise coming from the engine. The vehicle was taken to nalley Hyundai (7909 mall pkwy, lithonia, GA 30038, (678) 509-8248) to be diagnosed. The contact was informed that there was no debris found in the engine oil. Additionally, an oil change and oil filter replacement were performed. The vehicle was included in NHTSA campaign number: 17v226000 (engine and engine cooling). The vehicle was not repaired per the recall. The manufacturer was not notified of the failure. The approximate failure mileage was 77,361.

17 Manifold/header/muffler/tail Pipe problem of the 2013 Hyundai Sonata

Failure Date: 05/19/2017

The contact owns a 2013 Hyundai Sonata. While driving 45 mph, the vehicle emitted large amounts of smoke from the tail pipe. In addition, when switching from gear to gear, the vehicle made a loud bumping noise. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 91,000.

18 Manifold/header/muffler/tail Pipe problem of the 2016 Hyundai Sonata

Failure Date: 04/25/2017

I was driving the car and the car started spitting and did not want to go. Then white smoke came out of the tail pipe. I cut the car of and waited in traffic with my baby in the car , then turned the car back on. The engine light came on and the car drove like it had no energy. I was on my way to my new job for the first day.

19 Manifold/header/muffler/tail Pipe problem of the 2008 Hyundai Sonata

Failure Date: 03/06/2017

On the 3. 3l engine there is a fault in the intake manifold gasket that causes oil to leak onto the alternator causing premature alternator failure. If the vehicle loses power while driving this can increase the risk of a crash. This problem has happened on other vehicles with this same engine such as the veracruz and a recall has been initiated. For some reason the recall does not extend to the Sonata as it should. The following is from the veracruz recall involving the same engine. "Hyundai motor company (Hyundai) is recalling certain model year 2007-2012 veracruz vehicles manufactured from December 26, 2006, through July 24, 2012. The affected vehicles may experience an oil leak from the front cylinder bank valve cover gasket. If there is a sufficient amount of oil dropped onto the alternator, the alternator will be damaged causing the charging system to become inoperative. " my alternator has failed twice now, once while driving and I experienced a total loss of vehicle power. I was able to force the vehicle to the side of the road without incident but it easily could have gone bad on me as I was on the freeway in traffic. Once my alternator and subsequently my battery died I was left without control of the vehicle and without lights on the vehicle to warn other drivers of my situations.

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20 Manifold/header/muffler/tail Pipe problem of the 2011 Hyundai Sonata

Failure Date: 12/08/2016

The contact owns a 2011 Hyundai Sonata. While driving 20-30 mph, smoke billowed from the engine compartment. The dealer diagnosed that a high pressure oil line leading to the turbo charger fractured, which caused oil to leak onto the exhaust manifold and engine compartment. The vehicle was repaired. The manufacturer was notified of the failure. The approximate failure mileage was 38,678.

21 Manifold/header/muffler/tail Pipe problem of the 2015 Hyundai Sonata

Failure Date: 10/20/2016

Leased 2015 Hyundai Sonata se trim in 05/2015. 1) in 02/16 --> sluggish acceleration reported to dealer and he applied software update to ecm. 2) 10/05/2016 ---> while driving car started to sputter , shudder and heavy smoke (mostly white) coming from tail pipe. Car was not accelerating at all. It was very dangerous situation and felt that car was not under control. Finally it came to stop. After few minutes, tried to start and succeeded in 3rd/4th attempt. Took it to nearby Hyundai dealer, and as per them, they updated ecm (engine control module) software. 3) 10/20/2016 --> issue appeared again with same symptoms. Car is with dealer and he is looking into it. I am very concerned about safety.

22 Manifold/header/muffler/tail Pipe problem of the 2015 Hyundai Sonata

Failure Date: 06/26/2016

While driving my car loses power. What causes this is a leaking manifold. My friend has a 2015 Sonata with the same issue.

23 Manifold/header/muffler/tail Pipe problem of the 2011 Hyundai Sonata

Failure Date: 07/01/2015

2011 Hyundai Sonata. Consumer writes in regards to muffler noises, fuse outlet replacement, loose window handle and engine replacement repair issues. The consumer was informed the baffles in the muffler were coming apart. Also, the vehicle suddenly stalled while in the midst of driving and it would not re-start. The vehicle had to be towed to the dealer. The dealer stated the engine needed to be replaced. However, it would have to be taken apart to see what caused it to happen. The dealer informed the consumer the connecting rods were bad and a recall had been issue on the engine due to concerns of metal debris entering the engine compartment causing the connecting rods to fail. The engine was replaced. However, when the consumer went to retrieve the vehicle, the other problems were not fixed. When the consumer drove off the lot, the vehicle began to shake violently and the check engine light illuminated. The dealer informed the consumer the engine they put in was bad, and it would be months before they could get another one.

24 Manifold/header/muffler/tail Pipe problem of the 2011 Hyundai Sonata

Failure Date: 04/30/2015

I had problems with the engine starting in April 2015, with an unexplained noise. I brought car to dealer and was told it was the muffler. They said I could wait 3 months. By June 25, 2015 the noise was extremely loud while the car was running, moving or not. I could not drive the car the 80 mile round trip to work the next day and Hyundai had the car towed to the same dealer. They kept the car for 2 1/2 weeks finally replacing the short block on it. Trust me they looked to not cover it under warranty. By August 24, the car had only been driven 800 miles, having been off for the summer. I checked the oil before starting to commute again and it was down a qt. Of oil. I brought it back to the dealer and was told the oil pan had leaked, even after their warranty work. Note there was no oil drippings in my driveway ever! I no longer trusted the car or the service from the dealer. Again, I have an 80 mile per day commute. So I had no choice but to trade the car back to that dealer, so I would have a reliable vehicle. Having purchased the car I had hoped to pay off the last few payments of the car and have no car payments for awhile. It seems Hyundai and the dealer had other plans. The car was not even finished for another 10 days, I know this because service, from the same dealer I leased a new car from, called to tell me to pick up the 2011. I would not have even been able to trade it to another dealer knowing about the short block problem at that time and weeks before Hyundai sent an interim recall letter to me! I have all service records for this car. The first time warranty work was done on the car, I was never told what the cause of the problem was. I found out when I went to get new tires and mentioned it. That business told me about the problem with the 2011 Hyundai Sonatas.

25 Manifold/header/muffler/tail Pipe problem of the 2013 Hyundai Sonata

Failure Date: 04/20/2015

Driving down the freeway, we heard a clicking sound then a loss of power, but it came back after a few seconds. The clicking and loss of power happened again the next day while driving on a surface street, again for just a few seconds. The next thing that happened while accelerating onto the freeway, a red light flashed on the instrument panel, but did not stay on, unable to determine the light at that time. The next thing that happened was a puff of smoke came out of the tail pipe, which at that time we decided to take the vehicle to the dealer. The next day, the dealer informed me that the vehicle had no oil in the engine, and that it had goop in the oil pan. The dealer then said that the rings are burnt up and that the engine needed to be replaced. We had no warning that the engine had no oil - no warning lights stayed on. We also have a bluelink report that says everything is operating as normal.

26 Manifold/header/muffler/tail Pipe problem of the 2011 Hyundai Sonata

Failure Date: 03/30/2015

My wife was driving the car than all of a sudden she thought she heard a muffler sound like a rattling sound. She checked the muffler but the muffler was intact. Than as she was driving the car idled low as if it wanted to die. Than she got out at a parking to investigate the sounds turns out the engine is knocking bad. I call to get vehicle towed to Hyundai. Before they received the vehicle a service employee tried to tell me that the maintenance of the vehicle is determined also by the previous owner and how well he maintained it in order for the warranty to be valid (my vehicle is precertified it has 44487 miles and oil change is due at 44906) and the vehicle will not be looked at for a week. I called another dealership because I knew the employee was lying to me and the other employee at the different dealership assured me that the warranty starts with me and the previous owner has nothing to do with it. So I am waiting to hear back to see what they will do regarding the warranty. I know a knocking engine is a severe matter and the fact they lied to me before looking at the car already seems as if things are to just get worst in regarding with dealing with them.

27 Manifold/header/muffler/tail Pipe problem of the 2000 Hyundai Sonata

Failure Date: 10/19/2006

Frame of 2000 Hyundai Sonata was found during oil change to be severely rusted to the point where vehicle was unsafe to drive. Went to dealership where we were told to contact Hyundai corp. After 2 week period we were told Hyundai would do nothing to correct problem. Went back to dealership and after 3 days were again told nothing would be done to fix problem. The car only had 88,000 miles on it when problem was discovered and still had original muffler. Does frame usually rust out before muffler? eventually because of need for vehicle were forced to have vehicle fixed out of pocket. Repair shop told us they had repaired several Hyundai Sonatas over the last year with rust all in the same spot on the frame and that some couldn't even make it to the shop without a tow. We paid to have a refurbished frame put on the car, at the cost of $1150, not to mention the inconvenience caused over the course of 3 months it took to get it fixed. We had pictures taken of the frame on the car and as it came off.

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28 Manifold/header/muffler/tail Pipe problem of the 2006 Hyundai Sonata

Failure Date: 01/01/2006

I purchased a 2006 Hyundai Sonata in October 2005. The vehicle has developed a high pitched whine at 60-69 mph (2,000 rpm). I have taken the vehicle to my Hyundai dealership and they have been informed by Hyundai engineers that the noise comes from a design flaw dealing with the variable intake manifold. They are apparently aware of this matter but are doing nothing to rectify it. The noise is loud enough and high pitched enough that it could and does cause a driving distraction.

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29 Manifold/header/muffler/tail Pipe problem of the 2005 Hyundai Sonata

Failure Date: 12/09/2004

Bought 2005 hyuandi on 12/8/04. Experienced vibration on 12/9/05 took car back to dealership in cleveland tennessee, they said nothing was wrong, but they thought that the bolts that hold the motor in car needed to be tightened. Took car back 3 days later for the same problem vibration, they said that the bolts needed to be tightened again. Took the car back on three other occasions and they continued to tighten the bolts that hold the engine in the car. Finally a representative was called in to look at the car he had me to drive the car and told me that it was normal for the car to have a vibration when sitting still and that nothing was wrong with the car. Also, he said that the bolts needed to be tightened that hold the engine in.

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