2016 Hyundai Sonata
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Vehicles › Hyundai › Sonata › 2016
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
These records cover every 2016 Hyundai Sonata. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
6 recalls name the 2016 Hyundai Sonata. Newest first.
Hyundai Motor America (Hyundai) is recalling certain 2015-2017 Sonata, 2016-2017 Sonata Hybrid, and Sonata Plug-In Hybrid vehicles. The Smart Junction Box (SJB) software logic may not properly interpret the signals received from the multifunction switch, which could cause the turn signal to activate in the opposite direction of what the driver intended.
A turn signal that activates in the opposite direction of what was intended by the driver increases the risk of a crash.
Dealers will update the SJB software, free of charge. Owner notification letters were mailed November 19, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 210.
Hyundai Motor America (Hyundai) is recalling certain 2015-2016 Sonata and Genesis vehicles. In the affected vehicles, the warning light to indicate that the parking brake is applied may intermittently not illuminate in the dash due to corrosion in the switch.
If the parking brake indicator is not illuminated when the parking brake is applied, the driver may operate the vehicle with the parking brake partially engaged, increasing the risk of a crash.
Hyundai will notify owners, and dealers will replace the parking brake switch, free of charge. The recall began on August 4, 2017. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 164.
Hyundai Motor America (Hyundai) is recalling certain model year 2015-2016 Sonata Hybrid vehicles manufactured December 8, 2014, to August 18, 2015, and Hyundai Sonata vehicles manufactured May 28, 2014, to March 18, 2016, equipped with the panoramic sunroof option. Due to a bonding issue with the sunroof wind deflector, the sunroof panel on the affected…
If the sunroof detaches from the vehicle it could become a road hazard, increasing the risk of a crash.
Hyundai will notify owners, and dealers will repair the wind deflector anchor plate, free of charge. The recall began December 2016. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 152.
Hyundai Motor Company (Hyundai) is recalling certain model year 2016 Sonata vehicles manufactured March 28, 2016 through April 12, 2016. The affected vehicles have a driver-side frontal air bag that may not adequately protect the driver's neck from injury in the event of a crash. As such, these vehicles fail to comply with the requirements of Federal…
A frontal air bag that does not adequately protect the driver's neck may increase their risk of injury in the event of a crash.
Hyundai will notify owners, and dealers will replace the driver's frontal air bag module, free of charge. The recall began October 14, 2016. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 148.
Hyundai Motor Company (Hyundai) is recalling certain model year 2015-2016 Sonata vehicles manufactured May 29, 2014 to February 11, 2016, 2017 Elantra vehicles manufactured January 12, 2016 to February 22, 2016, and one 2016 Sonata Hybrid vehicle manufactured October 15, 2015. In these vehicles, the driver's frontal air bag may be missing a chemical…
An air bag that does not inflate increases the risk of injury.
Hyundai will notify owners, and dealers will replace the driver's frontal air bag module, free of charge. The recall began on May 5,2016. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 144.
Hyundai Motor America (Hyundai) is recalling certain model year 2015-2016 Sonata vehicles manufactured May 28, 2014, to August 21, 2015. The affected vehicles are equipped with an Antilock Braking System (ABS) warning light intended to warn the driver if there is an ABS malfunction. In the event of an ABS malfunction, the Brake System warning light will…
If the driver is alerted there is a brake system malfunction, but not specifically with the ABS system, the driver may operate the vehicle unaware that the vehicle's brakes may lock up during hard braking, increasing the risk of a crash.
Hyundai will notify owners, and dealers will update the ABS control unit software, free of charge. The recall is expected began on November 30, 2015. Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 134.
I am filing a formal safety complaint regarding severe vehicle instability, structural safety risks, and dealership workmanship negligence following a federal safety recall engine replacement. My vehicle received a new engine block under a federal campaign at a local dealership. Immediately upon picking up the vehicle, the front suspension developed a severe, heavy mechanical knocking and bumping noise over road surfaces under 20 mph, making the vehicle structurally unstable and hazardous to drive. To perform this engine swap, technicians were physically required to drop the front subframe framework and disconnect the lower suspension linkages and steering column components. The dealership is actively trying to deflect safety accountability for an assembly error. They issued a new estimate attempting to charge me over $3,200 to replace the entire front strut and rear shock assembly, claiming it is a 'pre-existing wear-and-tear' issue due to mileage. However, I hold the dealership's official Multi-Point Vehicle Inspection report from when the car was first dropped off for the engine failure three weeks prior. In that mandatory baseline safety report, their own technician thoroughly checked the under-carriage and officially marked my 'Shock Absorbers / Suspension' and 'Steering Gear Box / Linkage and Boots' as PASSED with green checkmarks. This objective paper trail proves the front chassis was tight, silent, and structurally safe before the repair. The safety hazard was introduced solely during the dealership's engine reassembly. The Service Manager explicitly refused to step out of his office to address this safety complaint, and the dealership released a compromised, structurally unsafe vehicle to a consumer. I request a formal federal safety investigation into this branch's safety compliance regarding recall implementation.
The contact owns a 2016 Hyundai Sonata. The contact stated that while getting an oil change, the contact was informed that the oil pan was empty. The contact could not recall seeing leaks or making changes to the oil change routine. An independent mechanic informed the contact of an engine recall regarding excessive oil consumption. The contact was referred to the dealer. The contact had the oil inspected twice more and was informed of low oil levels on each occasion, but there were no leaks or burning oil odors. The vehicle was taken to the dealer, where it was confirmed that no open recall was associated with the VIN. The dealer replaced several sensors; however, the contact was unable to specify which sensors were replaced. The dealer stated that the vehicle needed to be driven until the next oil service, at which point the oil would be changed and the engine sealed. The contact was referred to the NHTSA hotline to file a safety complaint. The manufacturer was notified of the issue, and a case was escalated. The failure mileage was approximately 70,000.
The contact owns a 2016 Hyundai Sonata. While the contact's daughter was driving 55 MPH, the engine seized. The contact stated that the failure had occurred while the contact's two minor grandchildren were inside the vehicle during the failure. The vehicle was towed to an independent mechanic. The vehicle was later towed to the dealer where it was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The manufacturer was contacted, and a case was filed. The contact was informed about the eligibility for the extended warranty under Campaign 953. The contact was informed that the repair was not covered under the extended warranty because the Campaign 953 was not completed. The failure mileage was approximately 60,436.
While driving on the freeway, the check engine light started flashing and the gas pedal became useless. This put the driver and the passenger of the car in massive danger as they could no longer accelerate on the freeway. Luckily, they were able to get off the freeway without causing an accident. Upon reading the code at an auto shop, they discovered that it was P1326 or a knock sensor issue. This malfunction caused the car to go into limp mode and put the passengers in serious danger. Several calls to the Hyundai Service Center were made yesterday (Saturday, October 3rd). However, not one was ever answered. They hope to be able to get the car to the dealership's service center as soon as possible, but the earliest appointment online is multiple weeks away. This same car was recently at the dealership service center for an internal engine oil consumption problem and thoroughly inspected. The car is up to date on all software and recalls. Even though a valve cover replacement fixed the oil consumption issue, the owners are now having even worse issues. This is the only car for a married couple who are both working and going to college full-time. This issue has been a severe complication to their scheduling, and they were put in harm's way on the freeway.
Backup vision system failed. Couldn't see vision because screen was blank. Radio didn't work either. Went to dealership with the problem they said it was not covered by the warranty. Paid to have it fixed.
I am concerned that the engine may seize or stall without warning while driving, creating a risk of crash, injury, or death. The Theta II engine defect is known to cause engine seizure, stalling, and fire. Hyundai has denied warranty coverage based on mileage and second-owner status — both of which are explicitly prohibited as denial grounds under the Settlement — leaving me driving an unsafe vehicle.
The vehicle experienced a Theta II engine failure at under 57,830 miles while driving on northbound [XXX] near the [XXX] Parkway U-turn in [XXX]. The engine made a loud noise and lost power. I was able to coast to the far right side of the U-turn under the bridge. I called HERO (Austin's emergency roadside assistance). They responded, determined it was not a battery issue, and pushed the vehicle to the Southern Leisure Spa parking lot on the southbound side of the road. The vehicle was then towed. The vehicle is equipped with the KSDS (Knock Sensor Detection System) software update, installed as part of Hyundai's remedy for this known defect. Despite KSDS being installed, the engine failed due to connecting rod bearing wear, consistent with the documented Theta II defect. A Hyundai dealership confirmed KSDS was installed but denied the warranty claim, citing maintenance records. The vehicle is available for inspection upon request. The Theta II engine defect has been the subject of prior NHTSA investigations and Hyundai recalls. This complaint is filed to document another failure of the same defect in a vehicle with the manufacturer's remedy installed. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
The car died while going 70 on a highway with no warning signs. The car completely shut off and will not turn over or move at all.
Component & Inspection: Vehicle engine suffered connecting rod bearing failure and entered restricted P1326 "Limp Home Mode" (max 2,000 RPM). The vehicle is grounded and available for inspection at Bud Clary Hyundai in [XXX].Safety Risk: Sudden, unexpected loss of power occurred while driving, placing me and other drivers at immediate risk on public roads due to the vehicle's inability to maintain normal traffic speed or safely accelerate.Dealer & Corporate Confirmation: Active P1326 engine code is confirmed. Car has been held for 14 days. The franchise is violating federal settlement rules by explicitly refusing to execute the mandatory, free mechanical Bearing Clearance Test (BCT) unless I pay out-of-pocket fees.Inspection & Corporate Compliance Failure: Car was brought to the dealer on XXX. The service manager admitted in writing that they are withholding safety diagnostics to protect shop labor hours due to an automated computer flag regarding a clerical title brand discrepancy. Hyundai Corporate is actively enabling this violation; my case manager refuses to issue a manual compliance override for the safety test and is violating federal settlement terms by withholding my contractually mandated alternative transportation.Warning Lamps & Symptoms: Flashing Check Engine Light and limp home mode triggered instantly and unexpectedly on XXX. There were zero warning symptoms, messages, or abnormal noises prior to that date INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
My Sonata 2016 suddenly lit up the Check Engine icon, which was blinking. It is available for inspection request, as it's in the shop right now. Added 2 qts of oil just to be safe. Was hoping the light would go away in the morning. It didn't. The car was sputtering and jerking while I was attempting to get where I was going, so I drove a little slower so it wouldn't stall out, which would have caused someone behind me to crash into me if it stopped suddenly. My mechanic said it was engine failure, possibly due to oil burning. Hyundai Dealer told me there is no recall for this issue, but my mechanic said there had been. I was never notified of such, and when I called them, they said that there was no recall, and she acted like she had never heard of the problem. I find that amazing, since on your website, there are some 717 claims of the same problem.
My 2016 Hyundai Sonata (VIN: [XXX]) has a serious safety issue involving excessive engine oil consumption. The vehicle loses oil rapidly between changes and requires frequent top‑offs to avoid engine damage. This creates a risk of sudden engine failure while driving. The dealership, South Charlotte Hyundai (10518 Cadillac Street, Pineville, NC 28134), refused to perform Hyundai’s official oil‑consumption test. Instead, they told me to pay $750 for a combustion cleaning and stated it would not fix the underlying problem. They would not document the refusal or provide any testing. I contacted Hyundai Corporate multiple times: • May 21, 2026 – Executive Office complaint submitted • June 3, 2026 – Follow‑up sent • June 29, 2026 – Regional escalation sent My Hyundai case number is XXX. As of XXX Hyundai has not responded to any of my Executive Office or Regional escalations. Only Customer Care replied with a template denial and no investigation. I have been waiting over two months with no action from Hyundai Corporate. I am reporting this because the manufacturer has not addressed a safety‑related defect, the dealership refused required testing, and the vehicle continues to consume oil abnormally. I am requesting NHTSA’s assistance in documenting this defect and Hyundai’s lack of response. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Cylinder 3 misfire code and rough idle/driving car tries to stall out, engine is consuming a quart of oil every 500 miles and has 30psi compression in cylinder 3. Car only has 129k miles
My 2016 Hyundai Sonata 2.4L suffered an in-transit engine failure and entered emergency limp mode with an active P1326 rod bearing defect code, which is a recognized fire and safety hazard under NHTSA mandates. Service Campaign 953 was successfully completed on August 12, 2019, qualifying the vehicle for a lifetime settlement engine replacement. Walser Hyundai Brooklyn Park (RO #257457) has issued an administrative denial based solely on a prior-salvage title flag from a cosmetic theft recovery. The manufacturer is actively stalling a court-ordered federal safety recall remedy based on an administrative title brand, despite the engine compartment being structurally original and undamaged. Hyundai Corporate Case #42869828 is open but unresolved.
The contact owns a 2016 Hyundai Sonata. The contact stated that while driving approximately 60 MPH, the vehicle suddenly shut off with the message "HEV System Failure" displayed. The driver safely pulled over to the side of the road and restarted the vehicle. A towing truck arrived on the scene and reset the diagnostic codes before towing the vehicle. The vehicle was towed to the local dealer. The dealer retrieved several diagnostic trouble codes; however, the dealer was unable to determine the cause of the failure. The vehicle was test-driven but the failure was not duplicated. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was approximately 149,000.
After the emissions 9c2 recall car hesitant when changing an Hyundai has knowledgement of the problem but don’t have a fix
I was driving at night and my passenger headlights went out. About 2 years prior the same thing happened but it was the driver side headlight that went out. It was $1100 to get the driver side replaced and now here i am having to pay the same amount to replace the passenger side headlights. It was not a simple replacing the bulb. Something inside went broke causing the dealership to have to install a whole new headlight set.
Went from 65 and dropped down to 40 going up grades on the freeway. Started shaking, check engine light went on and electric battery disappeared from dash. Got to top of grade, went back to normal. Problem repeated on next grades. Car had just left dealership lot an hour prior where it was safety inspected and they said all was fine. Took back to dealership for inspection and they said that there were no codes showing for what happened and all was well with the vehicle, when obviously it was not.
The following mandatory software update was performed on my vehicle: ECU SOFTWARE UPDATE FOR THETA II EMISSIONS IMPROVEMENT (SERVICE CAMPAIGN 9C2). After this update my vehicle drivetrain is quite erratic. In particular when the engine is cold it appears to jerk even when in Parking gear position. When cold the drivetrain experiences erratic gear shifts. This provides little confidence when driving and could result in safety issues when merging into traffic. Once the engine has reached its normal operating temperature it still makes occasional gear shift that are jerky and probably not good for the transmission. This vehicle had a very smooth transmission prior to the ECU software update, now I am hesitant when I need to merge into traffic, since I am not sure it will select the correct gear when accelerating. I have reported this to the dealership and Hyundai corporate service center and both indicate that when the engine is cold that the drivetrain can act strange, but once it is up to temperature it should be smooth. I have looked on the web and noticed multiple Hyundai owners with similar engines reporting the same issue after this software update. Hyundai may have satisfied the EPA requirements with this software, but they may have a created a safety issue for the vehicle operator and their passengers.
Car just stated making g noise went into lp.mode now saying k ock sensor
After completion of Hyundai Service Campaign 9C2, my 2016 Hyundai Sonata SE is very difficult to drive at low RPMs. Cold start its sluggish and jerks and driving uphill feels like transmission slipping but is not. An additional update to the ECM needs to be conducted ASAP.
My 2016 Hyundai Sonata is experiencing severe oil consumption due to a known Hyundai engine defect. The engine burns oil rapidly and loses more than a quart between oil changes. This creates a safety hazard because the engine can stall, seize, or fail while driving. The Hyundai dealership did NOT perform the official Hyundai oil-consumption test. They only checked the dipstick, noted the oil was low, and submitted a request for a paid combustion cleaning. Hyundai declined to pay for the cleaning, and the dealership is refusing to perform the required oil-consumption test unless I pay $750.00. Hyundai Corporate also refused to authorize the test, stating the vehicle is out of warranty, even though this is a known engine defect affecting many Hyundai vehicles. Without the official test, Hyundai will not review the engine defect or consider a goodwill engine replacement. This is a safety issue because the engine can fail without warning. The dealership and Hyundai are refusing to perform the required diagnostic test unless I pay $750, and refusing to review the defect without that test.
Dear Hyundai Customer Care, I am writing to report a safety concern with my 2016 Hyundai Sonata. The dashboard has developed significant cracking near the passenger-side airbag, which raises concerns about proper airbag deployment in the event of an accident. This level of deterioration seems premature and not consistent with normal wear and tear. I would like to know if there are any recalls, service bulletins, or assistance programs related to this issue, and what steps I should take for this issue as it is a safety concern for myself and passengers. I appreciate your prompt attention to this matter. This has had an ongoing issue for awhile.
This vehicle has a major engine flaw; Hyundai USA KNOWS about it, and STILL will not issue a recall for EXCESSIVE OIL CONSUMPTION. First episode: October 2023 at 86,371 miles. Dealership replaced leaking valve cover gasket and changed woefully-soiled spark plugs. Still under manufacturer warranty, but I paid the balance. Second episode: FOUR MONTHS LATER (Feb. 2024; 89,078 miles), another limp mode and Check Engine lamp. The spark plugs are soiled again with oil, so the dealership changes the spark plugs again, instead of addressing the underlying issue - Excessive oil consumption. Still under warranty, yet I pay the bill...AGAIN. Episode Three: October 04, 2024. Hyundai Sonata goes into limp mode again with CHECK ENGINE LIGHT illuminating – cylinder 1 was misfiring. All spark plugs fouled again; all spark plugs replaced. Valve cover gasket was leaking, so that was replaced as well. Yup, I paid for the repairs out-of-pocket. Episode Four: May 02, 2025. Vehicle goes into limp mode again, with CHECK ENGINE LIGHT turning on. Another spark plug fouled up, so it was replaced. Ignition coil replaced as well. Episode Five: June 19, 2025. Limp mode and Check Engine Lamp illuminates yet again, so Hyundai of North Charleston (SC) initiates an oil consumption test. "...[3.5 quarts of] oil consumption is excessive...", yet Hyundai denies everything. Hyundai is actually admitting to an underlying issue but offers ZERO assistance.
While driving my car with no warning light or any type of sound just cut off engine while driving. I was on busy highway going slightly uphill and was almost rear ended causing car behind me to swerve to avoid hitting me swerving to other lane and almost colliding into another car. I was able to get to middle divider almost but back end of my car sticking out in #2 lane. I was stuck in car for about 10 minutes then got across Street to sidewalk. There was no warning, no smoke etc prior to engine cutting off. Everything still works lights, a/c, radio etc . Engine tries to turn over but then slowly dies out like a battery issue however I have a 2 year old battery and when I charge it or try to jump start it it doesn't start also everything else powers on. I have had it stall 2 times before on L.A. freeway in which I somehow was able to cross over 4 lanes coasting to side of freeway. And at that time was sideswipped by another vehicle to front of car and car kept going and I really didn't have time to think about that while just trying to maneuver safely to side of freeway. The 1 and 2nd time it stalled it did restart after about 10 min. But this 3rd time it hasn't started again. The most recent incident was4/15/26. Another issue is the massive amounts of oil it consumes. I put in 2 quarts a week . But there is never oil leaking on driveway or anywhere its parked so where is oil going. I've had it checked several times and they said that these cars burn through oil and I also told Hyundai dealer about both issue and nothing was ever done. My s Check engine came on and I took in to shop and picked it up after paying alot of money and light was off but about a week later on. Took it back and pick up and lights off running good another couple thousand again. And on and off just randomly and auto mechanic shop said I would need to take to hyundai dealer to see whats happening. Called and told them never heard back. I have more pic of repairs but couldn't load more
Our Car is 2016 with 97000 miles with engine failure. Previous driving noticed the Engine will slow down suddenly at times. Preston Hyundai Dealer says bad engine cylinder $6000 is a fire hazzard and needs new engine. I see Hyundai sold 199000 2016 Sonatas and replaced 129000 bad engines. They gave a 120000 mile warranty to the 2016 cars. Hyundai said my car in not on the recall list so they will not pay for an engine. The dealer said the engine rods look okay. An engine should last longer than 97000 miles! Please help! [XXX] [XXX] [XXX] My INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing. There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles. During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types. The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement. Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia. The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio. The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires. In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines. The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS. It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension. For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied. Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates. To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years. In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires. Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis. Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023). The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect. During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW. The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications. The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU. In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment. FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle. Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW. These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes. An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time. In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU. This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners. Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW. The risk associated with the ASIC is equally shared among all OEMS involved in the investigation. The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage. There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation. The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU. If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC. Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC. All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled. In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024. With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.
The Office of Defects Investigation opened this investigation on September 3, 2016 based on four reports alleging the rear brakes locked or applied while driving without brake pedal application. One of the reports alleged a fire in the right rear wheel area.The vehicles subject to the investigation are equipped with an optional Electronic Parking Brake (EPB). In this system, an electric motor applies the parking brake by moving the rear brake pads (pads) against the brake rotors (rotors) when activated by the EPB control switch. The EPB is released by the control switch or by selecting a drive gear with the transmission shifter when the ignition is on.If the EPB has not been used within 1000 kilometers (621 miles) the system is designed to perform an Automatic Adjustment Function (AAF) of the pads to check for proper clearance. This function is a pad adjustment only and is preformed with the vehicle in park with the ignition off. It does not set the parking brake or turn the brake indicator light on. Hyundai has identified an error within the EPB control logic that can cause the pads to remain in contact with the rotors at various levels of force after the AAF is completed. This condition could cause the rear brakes to drag at the next drive cycle and may generate some levels of heat and smoke. The EPB control logic error affects model year 2016 vehicles produced from the start of production through March 16, 2016.Vehicles produced from March 17, 2016 incorporate an updated EPB control logic to prevent brake pad drag. On May 11, 2016 Hyundai notified its dealer network of Service Campaign TFF to update the EPB control logic in the affected vehicle population. Dealers will reflash the EPB software to prevent brake pad drag.There are no reports of accidents or injuries as a result of this issue. The incident that alleged fire could not be confirmed as there were no repairs to the vehicle other than replacement of the rear brake rotors and pads.ODI is closing this investigation based on the manufacturer's Service Campaign of the affected vehicles and in consideration that the the effect of brake drag in this instance does not appear to present an unreasonable risk to motor vehicle safety. The ODI reports cited above can be viewed at www-odi.nhtsa/complaints under the following identification (ODI)numbers: 10820359, 10854476, 10875764, 10892736, and 10928478
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
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