Other Fuel System Problems of Hyundai Sonata - part 1

Description of safety defect & immediate hazard:my 2021 Hyundai Sonata sel is currently exhibiting the most severe, catastrophic symptoms of the fuel tank expansion defect covered under NHTSA campaign 25v796000. The fuel tank has expanded so drastically that it physically warped the structural interior of the cabin, violently popping the rear passenger seat completely out of its assembly while the vehicle was in motion. Furthermore, there is a constant, heavy, raw gasoline odor inside and around the vehicle. The vehicle is a documented, active fire, explosion, and vapor inhalation hazard. It is currently physically located at sterling Hyundai in lafayette, la. Description of manufacturer non-compliance & refusal to remedy:Hyundai motor America and sterling Hyundai are in direct violation of their legal obligation to provide a safe, accessible remedy or interim safety accommodations under federal recall guidelines. An executive case manager from Hyundai corporate has officially refused to provide a direct-billed rental vehicle or a dealer loaner. Initially, a third-party rental vehicle was provided. However, that vehicle was compromised in an accident and wrecked through absolutely no fault of my own. Despite my lack of fault, Hyundai corporate and the dealership are now explicitly using that accident to refuse any further direct-billed rental accommodations or dealer loaners. Instead, they are demanding that I pay out-of-pocket for a rental vehicle at a rate of $60/day for a repair process expected to take multiple weeks, knowing I do not possess the upfront financial means to cover these costs. By imposing this insurmountable financial barrier due to an accident I did not cause, Hyundai has effectively stranded me. Because I must maintain my livelihood and have no other means of transportation, Hyundai’s bad-faith refusal to direct-bill an accommodation is actively forcing me to retrieve and operate a verified, explosive fire hazard. Remedy sought:I request that the nh.

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My car stalls while driving and then I try to restart it but nothing happens. After reading online about the fuel pump issues and extended warranty related to the fuel pump I took the car in for repair. My car has 75,000 miles and the extended repair on this is for 150,000 miles/15 years. The dealer is refusing the repair because my car has a branded/ theft title. The car wasn't damaged just stolen. This is creating a serious safety concern and should be repaired by the dealer. Thank you for your time.

See all problems of the 2018 Hyundai Sonata 🔎.

After receiving the Hyundai service campaign 9c2 update on my 2015 Hyundai Sonata on xxx, I have started having jerky acceleration when the car is first started and am driving. Also, while driving at highway speed (~65 mph)) and I take my foot off the accelerator to coast, the engine rpm drops suddenly, anywhere from 250 rpm to 750 rpm, then recovers abruptly to where it was at prior to the drop (typically around 2000 rpm). The engine rpm also drops while driving at slower speeds and recovers but is not as noticeable as it is at highway speeds. It was not doing this prior to the service campaign. There are no check engine lights or pending codes. I brought it back to the Hyundai dealer and discussed the issue with them on xxx. They acknowledged it was likely due to the service campaign and they did not want to keep the car to look at it and said no damage was being done and it was safe to drive. They said a fix was in the works but did not know how long until it was released and I should receive information in the mail on it. Video link [xxx] information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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I took my vehicle in for the safety recall due to an expanding fuel tank on 08/03/2026. I received my vehicle back on 8/12/2026. Hyundai performed an improper repair on the vehicle that will not correct the fuel tank expansion. They replaced the same check valve that was replaced last time I brought the vehicle in for recall on 11/20/2024 repair order # 107221 at jones Hyundai of belair. This valve did not and will not correct the fuel tank expansion issue. The expansion issue is caused by fuel getting past the check valve and entering the purge control system. The correct repair is to replace the fuel tank and the purge control system, as the check valve has already allowed fuel to bypass it and enter the system causing the expansion issue. . Replacing the valve that failed & allowed fuel into the system & caused the tank to expand will not correct the issue caused by the failed valve. My fuel tank has not decompressed. I still have the same problem I brought the vehicle in for because the repair Hyundai advised NHTSA on was not performed.

Gas tank expansion and pcv melted. Car smells like gas when I was driving earlier, and my garage was flooded with the fumes of gasoline.

Issue- fuel pump/supply line causing fuel to leak and fuel smell around the outside of the car. This can cause a major fire, explosion, death for myself and others around me. Problem has been confirmed by auto repair shop. No warning messages on car dash board, just strong smell of gas. Replaced gas cap and smell is still there.

Vehicle stalled in traffic due to recall defect. Manufacturer recall remedy is delayed beyond reasonable timeframe, creating ongoing safety exposure.

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Engine revving at a complete stop. Surging engine while braking. I was forced to put into neutral when stopping. I had check engine prior that read p049d85. It went away. The Hyundai dealer said to be the egr valve. Nick hayes at d'arcy Hyundai and Hyundai motor America (hma) agreeing to a 75% goodwill split of cost to repair.

Diagnosed 07/20/2026 with catastrophic oil ring failure requiring engine replacement. Engine can stall due to oil degradation/absence of causing uncontrolled vehicle handling and fire. This would put myself and others at risk. It has been diagnosed at dealership. Complaint narrative: the subject vehicle is experiencing its third total engine failure due to an inherent manufacturing and design defect, presenting a severe and repeating highway safety hazard. The original factory engine failed catastrophically in 2015 at 116,440 miles and was replaced under NHTSA recall 15v-568. The second engine failed in 2021 at 244,710 miles and was replaced under NHTSA recall 17v-226. The third engine (the second replacement) has now failed prematurely at 334,935 chassis miles, lasting a mere 90,225 miles. An authorized Hyundai dealership diagnosed a total failure of the oil control rings. This mechanical defect allows engine oil to bypass the pistons directly into the combustion chambers. This causes severe, rapid oil consumption, spark plug fouling, engine stalling, and total loss of motive power at highway speeds without prior dashboard warning illumination. The manufacturer is failing to provide safe, durable remedies for its federally mandated safety recalls (see warranty info magnuson-moss warranty act (15 u. S. C. § 2301 et seq. / breach of implied warranty of merchantability). Instead, they are installing subsequent replacement powerplants that suffer from the exact same structural vulnerabilities and component lifecycle failures. This creates a continuous risk of sudden engine seizure and traffic collisions for consumers.

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I am writing to report a direct violation of the theta ii class action settlement terms by Hyundai motor America. This morning , I emailed an executive case manager explicitly explaining that my 2017 Sonata has an active p1326 code, has the 2019 ksds update, and requires a mandatory diagnostic under NHTSA recall 17v226 that cannot be denied due to a salvage title. Instead of replying to my facts, the case manager kathy gave me a hard denial falsely framing my federal recall safety request as a "voluntary goodwill warranty" issue to justify her rejection. Please help me in getting authorization my car with Hyundai dealership in plano TX to run the bearing rod test and get it fixed.

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Fuel line leak, car is parked, fire hazard, a mechanic has been there to inspect.

When my father was driving, the vehicle stalled out with no prior odd activity. He pulled over to the side of the road and attempted to start the vehicle. He saw smoke, opened the hood, saw flames and cleared the area of the vehicle. Due to the large Hyundai/kia engine recall for his year of vehicle, the engine had been replaced 2-3 times and only ever been serviced by the dealership. We do not know if all recall repair work had been done, because there was also a fuel line recall which was "fixed" in 2020 and 2022.

See all problems of the 2013 Hyundai Sonata 🔎.

The low-pressure fuel pump module assembly, located directly beneath the rear passenger seat cushion, experienced a plastic housing failure. A stress fracture on the upper plastic fuel outlet nipple caused raw liquid gasoline to actively weep and pool on top of the module inside the passenger cabin. This component is retained and available for inspection upon request. Risk to safety: raw liquid gasoline pooling inside the interior passenger compartment creates an severe, immediate fire and explosion hazard. Additionally, vehicle occupants were exposed to toxic fuel vapors while driving. Inspection & dealer confirmation: an authorized Hyundai dealership inspected the vehicle and confirmed raw fuel leaking at the top of the fuel pump module assembly. This exact module had previously been removed and disassembled during a 2024 manufacturer recall service to replace the internal fuel filter and tank seal. Stress applied to the plastic fittings during that recall service appears to have caused the plastic top-hat to fracture over time under line pressure. Hyundai corporate was notified of the safety hazard and prior recall history, but refused assistance. Warning symptoms: the failure began with a strong, persistent fuel odor inside the vehicle cabin. No dashboard warning lights, check engine lights, or diagnostic trouble codes (dtcs) triggered prior to or during the failure. Summary: a stress-fractured plastic fuel pump housing allowed raw fuel to pool in the passenger cabin following a prior manufacturer recall repair involving the disassembly of the same component.

I purchased fgis car from a used car dealership, for over $6,000. 00 , which is not a ton of money, but plenty enough to not have instant issues. Since my purchase in June 30, 2026, I have already had all of these issues occur. There is white smoke coming from the left tail pipe, it is sluggish when you push on the gas, there is black soot constantly on my rims that is extreamly hard to remove, the high pressure fuel pump jas failed, I can tell because the oil is higher then it was when o had the oil freshly changed, and it smells of gasoline. Inside the oil. The exhaust has stron smell of gasoline. My steering wheel has a loud clinking noise everytime I go over a speed bump on pull into my driveway. Just so many items consistently needing repair or replacement, even though I just had the fuel system cleaned, the oil changed, and filters, and. Oil filter too. I checked to see if any of my issues are covered by a recall warranty, because they all are recalled items for my car year, make, and model, but apparently hyunfai is only covering these dangerous recall items for ul to 10 years. These items shkuld be covered longer, because my carfax states that at least one of these recalled items had already been changed in 2018, and is already broken again!! Hyundai should have covered these extreamly high wear out car parts for a longer period of time, or for the life of the vehicle, if every 5 years your replacing a $1000. 00 part, not including labor, like the (hpfp) I was quoted by auto zone for over that price point!! "ridiculous"! another item is the air bag cover on the driver side windows area, of the body frame it is loose and keeps un-clipping, I am afraid that it is going to possibly just go off and kill me or something!! very disappointed right now, that I cannot get any of these recalled items replaced by the manufacturer!!.

See all problems of the 2011 Hyundai Sonata 🔎.

I own a 2023 Hyundai Sonata sel. Over approximately three years, the vehicle experienced four separate incidents involving sudden loss of engine power and recurring fuel injector/powertrain problems. Three of these incidents occurred while the vehicle was being driven on interstate highways, creating serious safety concerns. The first incident occurred on xxx, on [xxx] [xxx]. My daughter was driving the vehicle at the time when it suddenly lost power while traveling on the interstate. She had to maneuver the vehicle to the shoulder under unsafe traffic conditions. The second incident occurred on xxx, on [xxx] near [xxx]. I was driving the vehicle when it again experienced sudden loss of power while traveling at highway speed. The third incident occurred on xxx, in [xxx]. The vehicle experienced another significant power-loss event and required roadside assistance. The fourth incident occurred on xxx, on [xxx]. The vehicle again experienced a sudden loss of engine power while I was driving on the highway. Despite multiple repair attempts, including repairs related to the fuel injectors, the same or substantially similar power-loss problem continued to recur. Because the vehicle has repeatedly lost engine power while being driven, including multiple incidents at interstate highway speeds, I believe this recurring condition presents a serious safety risk. I am reporting these incidents so NHTSA can evaluate whether this may represent a broader safety-related defect affecting this vehicle model. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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At approximately 130,000 miles, vehicle developed and internal coolant leak caused by a failed exhaust heat recovery system (ehrs) in the center muffler assembly, matching TSB 23-em-009h - a known manufacturing defect documented by Hyundai. Coolant has been slowly leaking internally into the exhaust system. The authorized Hyundai dealership initially failed to diagnose the internal leak and told me there was no leak and wanted to send me home. After pushing back, the internal leak was confirmed. If not caught, this defect could result in engine overheating or complete engine failure without warning. Hyundai motor America has denied goodwill coverage despite this being a documented manufacturing defect.

The vehicle’s fuel tank system failed catastrophically. The vehicle is currently grounded and has been inspected at the Hyundai dealership service center where it was towed. My safety and the safety of everyone on the road was put at extreme risk due to a severe fire and explosion hazard. Additionally, the defect caused the vehicle to suddenly lose power, sputter, and threaten to stall out while driving on a major interstate, creating an immediate risk of a high-speed rear-end collision. When attempting to add fuel, the pressurized tank forcefully spit gasoline back out of the filler neck, creating an active chemical and fire hazard at a public gas station. I was able to drive it home and called via Hyundai roadside assistance to have it towed to an authorized Hyundai dealership service department. On June 15th, 2026, the dealership service technicians officially confirmed the failure, stating that the fuel tank had expanded, the back floor base of the car was melting, and the vehicle was on the verge of exploding.

See all problems of the 2022 Hyundai Sonata 🔎.

Recall remedy failure and manufacturer coercion my certified pre-owned 2022 Hyundai Sonata limited has been held completely out of service at an authorized Hyundai facility since June 2, 2026, due to severe fuel tank expansion under active NHTSA safety recall 25v-796 (Hyundai campaign 286). The dealership confirmed that the defective expanding plastic fuel tank ballooned with enough force to structurally warp and buckle the unibody center floor pan and frame rails. Rather than providing a safe, timely remedy under federal recall guidelines, Hyundai corporate and the dealership are attempting to coerce me into an unfair, non-statutory "voluntary trade-in" that simply pays off my remaining loan balance ($22,000) while completely wiping out the $9,000 in cash equity ($3,000 down payment and $6,000 in monthly payments) I have invested into the car. Upon rejecting this predatory trade-in offer, the manufacturer immediately threatened an additional 6 to 8-week delay to attempt a massive structural frame and unibody pull, which would bring the total out-of-service time to over 90 to 110 cumulative days. Furthermore, the dealership is actively withholding the internal diagnostic write-ups and structural alignment prints from me. I am requesting that the NHTSA investigate this recall remedy failure. Hyundai is using extreme delays (90+ days) and structural frame threats to force consumers to abandon their financial equity rather than issuing lawful, purchase-price repurchases for vehicles deemed structurally unsafe due to a manufacturing defect. I can't provide any documents as they have refused being able to provide me with any. Was told I would be emailed a copy from the dealership several times and they never end up sending over any information.

The safety recall (Hyundai recall 227, NHTSA recall 22v-312) repair on my 2013 Hyundai Sonata (previously completed by a Hyundai dealership prior to my purchase in April 2026) has suffered a critical mechanical failure. In may 2026, within 30 days of driving the vehicle, the recalled safety component completely failed while the vehicle was in operation on a public roadway. This sudden failure created an immediate safety hazard, resulting in complete fuel loss, forcing me to immediately pull over and have the vehicle towed to a repair facility (meineke). An independent mechanical inspection confirmed that the exact component covered under the manufacturer's original safety recall had failed again. Because a critical, manufacturer-designated safety recall remedy failed to permanently correct the underlying defect within 30 days of use, this vehicle remains an active safety hazard.

1. ) following Hyundai's 9c2 campaign update for the ecu that was completed back on may 27th, 2026, my 2015 Sonata went into limp mode [solid check engine light present] while I was accelerating up an on-ramp on the 2nd drive cycle since the update was performed. I was already far away from the dealership so I was forced to limp it to my local shop that I regularly use to have it checked out. It was confirmed that the code on the vehicle was p200a for intake manifold runners. Since the update was for smog regulation, the code was cleared in order to see if it would come back. Since then, it has not, however the vehicle continues to have one persistent problem. The rpms will dramatically dip and then surge back upwards while the car is coasting (no gas and no brake applied). 70% of the time, you can feel the car violently jerk as it appears to try and correct itself. 2. ) I've brought this car to multiple dealerships, have a case open with corporate and have also found that this is a systemic issue with this specific update in these cars. All and all, nothing has been done. I'm repeatedly turned away over and over again because their techs are only permitted to look into it once they have hard evidence of a fault. In this case, that would be a dashboard light. I'm told that I may only return if the check engine light comes back, which as I mentioned previously, posed a huge safety risk to myself the first time it appeared. If I can only go 55mph down the highway, I am at risk of being rear-ended or struck in some way. 3. ) the problem has not been reproduced by the dealer as they will not test drive it to see the dip and spike. However, the code was still pending for awhile in the vehicle before it cleared it on its own, so that was acknowledged by at least one place. 4. ) vehicle has not been inspected by anyone but a dealership and local mechanic. 5. ) no other signs prior to the vehicle limping out on me other than some acceleration concerns on may 27th, 2026.

I am submitting this complaint regarding a serious safety issue involving my Hyundai Sonata. While driving under normal conditions, my vehicle suddenly entered a low-power ("limp") mode without warning. The vehicle would not accelerate beyond approximately 30–35 mph, creating a potentially hazardous situation in traffic. At the same time, the check engine light began blinking. The sudden loss of power significantly reduced my ability to maintain traffic speed and safely maneuver the vehicle. This condition could have increased the risk of a rear-end collision or other accident. I brought the vehicle to an authorized Hyundai dealership (fred beans Honda of abington ph# 215-392-9020) for diagnosis. The dealership confirmed that the vehicle stored diagnostic trouble code (dtc) p1326, related to the knock sensor detection system (ksds). According to the dealership, the vehicle entered limp mode as a result of this fault. The abrupt reduction in vehicle power and speed occurred without sufficient warning and created a safety concern. I am reporting this incident so that NHTSA can investigate whether this condition represents a broader safety defect affecting Hyundai Sonata vehicles equipped with the ksds system. Vehicle information: make: Hyundai model: Sonata model year: 2014 I request that NHTSA review this issue and evaluate whether additional action is warranted regarding vehicles experiencing dtc p1326 and associated limp-mode operation.

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I went shopping notice needed gasoline filled the tank 3/4 the next day I smell gasoline on my2013 Sonata hybrid VIN [xxx] inside the car and I did not notice any light alerts etc. , just the smell of gasoline inside the car. I ask for a ride I was scare to drive to the dealer on Monday 5/6/26 around 12:30 pm I called the dealer I was gonna dropped the car they told me diagnostic would take 3 days , I was afraid to cut on fire since my gas left a big stain and was wet gasoline in the parking lot at work. , I called Hyundai USA mentioned the problem I notice there is a recall for gas pump leaking and causes gas tank to crack recall for 17v-226 for fuel pump leaking 0n Hyundai Sonatas hybrid 2011-2016 my car is in the Hyundai dealership [xxx] [xxx] they called me telling me my gas tank is cracked cost of repair labor 2800. 00 and 280. 00 diagnostic charge and is ready for pick in 30 min no recalls I must pay for this service information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Was driving and stopped at a stoplight. When I went to drive it started sputtering and if I wouldn’t have driven into a gas station, it would’ve given out in the middle of the road. It wouldn’t let me switch to drive or reverse , only neutral or park. It threw a code p0301, cylinder 1 misfire. Had to get it towed. Now I have to get my spark plugs and fuel injectors replaced.

This is a well-known and widely reported issue: 2013 Hyundai Sonata hybrid car, which has recently experienced the following dashboard alert: "hybrid system warning! safely stop and do not drive. " when the car is pulled over and shut down and sits for roughly 10 minutes, it starts up just fine and runs again for an undetermined amount of time, and then the alert will go off unexpectedly. This has happened twice, once the car was driven about 4 miles, and the alert came on, and the second time the alert came on as the car was started for the first time of the day. The car repair shop indicates that there are no codes saved when this happens. This is apparently a documented issue, where the codes are not saved, and difficult to diagnose by repair shops and dealers. It could lead to the vehicle completely shutting down while driving at highway speeds within traffic, which could cause a serious accident involving multiple vehicles and people. Why is this not recalled by the dealer and fixed? this has been reviewed by the dealer and by an independent repair shop. Is the NHTSA waiting for the death count to require the manufacturer to address the issue?.

Hyundai motors America has failed to comply with its statutory obligations in conducting the recall campaign 25v796, and is instead engaging in behavior substantially similar to that which has been previously censured by NHTSA. My Sonata suffered irreparable damage related to this campaign as confirmed by hma. 49 u. S. C. § 30120(a)(1)(a) allows hma to choose one of three remedies: repair, replacement, or refund. However, they 1) say it cannot be safely repaired, 2) will not replace it, and 3) are not offering a repurchase as required by statute, I. E. "by refunding the purchase price, less a reasonable allowance for depreciation. " instead, Hyundai's case manager aditya informed me on 5/29/2026 at 12:57 pm that they will make a repurchase offer "based on the kelly blue book value. " I protested and cited the statute, but he maintained that Hyundai has their process and subsequently gave an unconscionably low offer that was not based on any reasonable measure of depreciation. I insisted on a reasonable, defensible calculation. I proposed 1) using the state formula for calculating reasonable depreciation as applied in both texas and California (hma and my home states), or 2) using actual market values (of which I have tangible data) to determine the actual market loss in value. Hyundai has rejected both of these reasonable proposals in favor of an arbitrary formula that would leave me with thousands of dollars in lost value. On June 9, 2026, when I pressed executive case manager jenifer for an explanation of their proposed depreciation formula, she only stated that "it’s a standard calculation across the board" and that it applies "regardless of state" and they "will not change it. " the NHTSA discussed this behavior in its final order and determination against fiat in federal register vol. 45 no. 7, and endorsed a "reasonable" model similar to my proposal #2 above. It found fiat non-compliant for its behavior which had a nearly similar impact.

See all problems of the 2020 Hyundai Sonata 🔎.

Nhtsa recall number22v312000 I am writing to formally file a complaint regarding my 2013 Hyundai Sonata (VIN: [xxx] ), which is subject to a manufacturer recall #189 due to a fuel line defect posing a fire risk and potential severe injury. Today, I visited wallace Hyundai in fort pierce, florida, and the service manager mr. Louis larussa and associate employed what I can only describe as a warranty circumvention tactic. They repeatedly delayed my recall repair by claiming I must first complete other optional recalls, unrelated to the fuel issue. They stated that they would not be paid by the manufacturer unless all recalls were done together. This is not only unprofessional but also a disregard for the serious safety hazard posed by this fuel line defect,they prioritize dealership financial interests over customer safety and contradicts the purpose of a safety recall. Furthermore, I was told I would need to leave my car for days or even weeks because parts supposedly must be ordered. As this is a nationwide recall, I expect a swift, ready-to-implement solution. I demand immediate action from Hyundai to honor the recall and ensure my safety is prioritized. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Car was taken to dealership for inspection. Upon inspection, it was determined that the fuel tank had expanded and pushed towards the heat shield, and expanded upward pushing up the back seats of vehicle. It was determined to not safe to drive. Manufacturer contacted me and offered a buyback. Upon their offer of a buyback, it was determined that I would owe the manufacturer approximately $2,000. I have requested that they fix it, and they have refused to give me the paperwork I requested about the car's condition and fixability. I am in the process of negotiating and am filing this complaint for the record.

Car engine caught fire. Allstate notified pictures provided below.

I have the 2015 Hyundai Sonata with the 2. 5 gdi engine that eventually will seize due to internal damaged caused by manufacture design flaws. My Hyundai threw a p0010 code which causes my car to idle high and causing low vacuum affecting my brakes. I had a diagnostic test done at a Hyundai dealership that told me it was a cvvt cam sprocket issue and that it was the beginning of the end of the engine, they quoted me 3700. 00 but the engine was to far gone and this repair would only accelerate the engine to seize. They said since the engine isn't seize Hyundai will not cover the cost to repair or exchange the engine, I contacted the Hyundai customer service who stated since the repair that is needed wasn't the root cause of the problems associated with the engine swap warranty they were not going to help me even though I explained to them that the cars high accelerating and the braking system been jeopardized and been told the engine is beyond repairs I feel Hyundai should reconsider their decision and help a loyal customer. I have purchased 12 brand new hyundaj since 2001. The customer representative was extremely un professional even suggesting I scrap my car, also I contacted my Hyundai service technician who said Hyundai customer service never contacted them about my car, when they said they spoke with the technician. Also I received an extended warranty on the 2. 4 gdi engine from Hyundai who many Hyundai customers are or have dealt with. I also purchased an extended warranty which I believe should have been extended as well thank you.

On April 14, 2026, my 2019 Hyundai Sonata was parked at a retail store parking lot. Returning from the store, I attempted to start the car, and it did not start. I attempted to start it again, and I saw smoke coming out from under the hood. I immediately exited the vehicle and opened the hood. I saw open flames coming out of the engine area, about 4” high. I called 911 and waited about 10 minutes for the fire department to arrive. During this time, the flames engulfed the entire engine compartment and extended vertically above the hood height. The hood eventually melted and fell back onto the engine area. The fire department came and put out the fire. The car is totaled. There were no injuries, thank god!.

Supplemental information to existing NHTSA complaint involving a 2017 Hyundai Sonata plug-in hybrid (VIN: [xxx] ) while traveling at approximately 70 mph on a heavily traveled highway, the vehicle suddenly and completely lost propulsion without warning. The vehicle rapidly decelerated in traffic, creating a significant safety hazard for my family and surrounding motorists and requiring emergency maneuvering to reach the shoulder. The vehicle was towed to an authorized Hyundai dealership, where diagnostic testing identified multiple high-voltage battery system fault codes: • p0b68 • p0b6d • p0b72 the dealership diagnosed a high-voltage battery system failure requiring battery replacement. The vehicle is currently non-drivable. During my research, I found multiple owner reports involving Hyundai Sonata hybrid and plug-in hybrid vehicles experiencing loss of power, hybrid system failures, limp mode conditions, and propulsion-related incidents. I also learned that Hyundai previously issued recall 18v166000 involving 2016–2018 Sonata plug-in hybrid vehicles due to battery management system and voltage protection device concerns that could result in loss of power while driving. Dealer says does appply for my car. Although my vehicle’s fault codes may differ from those addressed in the recall, both involve battery-related failures capable of affecting propulsion and creating a highway safety risk. My concern extends beyond my individual vehicle. A high-voltage battery or battery management system failure that can cause a complete loss of propulsion at highway speed without warning presents a potentially serious safety risk. I respectfully request that NHTSA evaluate whether similar incidents involving Hyundai Sonata hybrid and plug-in hybrid vehicles indicate a broader safety concern warranting further review. I can provide dealership diagnostic reports, repair estimates, towing records, photos, and videos upon request. Thank you for your consideration, [xxx] information redacted pursuant to the freedom of informati.

My 2019 Hyundai Sonata has been experiencing excessive oil consumption since I purchased it. The vehicle requires oil to be added approximately every two weeks, which indicates a serious internal engine issue. Recently, the check engine light turned on, and I took the vehicle to a dealership for inspection. I was told that the engine is “operating normally,” despite the ongoing oil consumption problem. I was also informed that the engine would only be replaced under warranty if it fails completely, such as through connecting rod bearing damage. This means I am expected to continue driving a vehicle that may suddenly fail without warning. I drive daily with my children, and I am concerned about the risk of sudden engine failure, loss of power, or engine seizure while driving, which could lead to a serious accident. I believe this is a known issue with these engines, and it represents a significant safety hazard that should be addressed before a catastrophic failure occurs.

Engine blown out malfunction took two dealer Hyundai folsom lake stated rings are bad sludge buildup in engine and stayed at Hyundai motor America denied engine replacement due to knowledge under theta two engine extended warranty settlement of 150,000 mi 15 years I'm still within warranty but are still being denied had numerous of issues with vehicle oil consumption knock knock sensor replace and other maintenance done since purchase vehicle brand new in 2018.

Engine was replaced couple of months ago due to a recall and today 3/30/2026 I'm pulling up to my driveway getting home from work in my car starts smoking it catches on fire.

I have a car covered by the theta ii settlement. Engine, fuel system. Metal shavings found in oil and oil is diluted with fuel and oil if overfilled 1 inch above full mark on dipstick upon pickup from dealership. The vehicle is available for inspection at my residence; however, it is currently grounded as a known safety hazard. The vehicle is exhibiting symptoms of imminent engine failure (audible knocking, p0011 code, and oil dilution). Despite being shown evidence of this(photo and video of oil overfill and watery viscosity) , the manufacturer instructed me to continue operating the vehicle, placing myself, and other drivers at risk of a high-speed collision or vehicle fire. The symptoms (p0011 code and engine noise) were confirmed by an independent mechanic on March 25th 2026. However, during the official bearing clearance test (bct), the dealership intentionally overfilled the engine oil by 3 quarts (documented via photograph) to muffle mechanical noise and artificially pass the diagnostic and issued a pass on all inspections despite the oil hazard. Hyundai corporate case manager nikulmar dhabi has admitted on record that the dealer was out of compliance by "being outside the standard notification time" yet they refuse to provide a safety-compliant remedy. Warning symptoms & appearance: symptoms first appeared months ago when I repeatedly got a p0011 code, however on March 24th 2026 I received an engine light with a p0011 and the car going into limp mode while I drove. Warning signs included a persistent check engine light (p0011) and audible metallic knocking. Upon checking the oil myself after the dealer "inspected" it, I discovered the oil was 3 quarts over the "full" line, which is a deceptive practice used to mask rod bearing failure.

See all problems of the 2016 Hyundai Sonata 🔎.