Gas Recirculation Valve (egr Valve) problems of the 2017 Hyundai Sonata Hybrid

2/25/2026 vehicle was put in service for a safety warranty recall. 2/26/2026 Hyundai approved the replacement of the engine, but there were costs involved that I was responsible for (approx. $800). 3/9/2026 I was informed by Hyundai the vehicle was complete, and would now last "for another 200,000 miles". I picked up the vehicle and only drove 5+ miles from the dealership when the vehicle’s motor completely shut down, putting me in a very unsafe driving condition, almost causing a serious accident. Vehicle was returned to Hyundai the same day and I was informed they were still figuring out the failure and to be patient. 3/11/2026 Hyundai informed the vehicle would now need a new catalytic converter and O2 sensor, and that it would all be covered under warranty. On 3/12/2026 Hyundai informed me that they would not fully cover the cost of the new parts and I ended up paying another $1300. 3/19/2026 Hyundai notified me that the vehicle service was complete, and the vehicle was ready for pick-up. I picked up the vehicle that day and again only drove 5+ miles when the vehicle repeated the same failure with the motor completely shutting down and again putting me in a very unsafe driving condition and almost causing a serious accident. Vehicle returned to Hyundai the same day. 3/23/2026 was told I would receive update once technician gets to the vehicle. 3/26/2026 informed that the vehicles brake booster actuator needed replaced, and I have to cover the almost $4000 to replace this part and later informed dealerships gm was covering cost. 4/8/2026 vehicle being worked on and completed by the end of that day. 4/9/2026 vehicle failed a 3rd time with same codes and limp mode. Tech line stating to replace egr valve and intake manifold. 4/13/2026 informed that Hyundai refused to pay total amount, but were going to re-submit to not be completely out of pocket. 4/15/2026 vehicle has now been in service for 7 weeks for a safety warranty recall.

Hev warning light came on when I started my car. I heard a sucking air sound at which time I turned off the car. I then restarted and no warning lights were on. Later that day while driving home the warning light came back on. I pulled the codes and it showed p0105 and p0107. Dealer inspected and found the egr pipe(c) separated from flange causing unmetered air leak. Repairs took from 09/26/18-10/02/18.