2016 Hyundai Sonata Hybrid
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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These records cover every 2016 Hyundai Sonata Hybrid. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
5 recalls name the 2016 Hyundai Sonata Hybrid. 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.
Risk and remedy
Risk
A turn signal that activates in the opposite direction of what was intended by the driver increases the risk of a crash.
Remedy
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 2017-2018 Sonata, 2016-2018 Sonata Hybrid, 2018-2020 Accent, and 2016-2017 Azera vehicles. The trunk latch may become damaged, preventing the opening of the trunk from the inside. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 401, "Internal…
Risk and remedy
Risk
A person inside the trunk compartment may become trapped, increasing their risk of injury.
Remedy
Dealers will replace the trunk latch base, free of charge. Owner notification letters were mailed December 4, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 208.
Hyundai Motor America (Hyundai) is recalling certain 2015-2016 Veloster, 2012 Santa Fe, 2011-2013 Sonata Hybrid, and 2016 Sonata Hybrid vehicles. The connecting rod bearings inside the engine may wear prematurely, which over time can result in engine damage.
Risk and remedy
Risk
A damaged engine can increase the risk of a fire or it can cause an engine stall, increasing the risk of a crash.
Remedy
Hyundai will notify owners, and dealers will inspect the engine. If bearing damage is found, the engine will be replaced. Dealers will also install a software update containing a new Knock Sensor Detection System (KSDS). Repairs will be performed free of charge. The recall began March 31, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 198.
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…
Risk and remedy
Risk
If the sunroof detaches from the vehicle it could become a road hazard, increasing the risk of a crash.
Remedy
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 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…
Risk and remedy
Risk
An air bag that does not inflate increases the risk of injury.
Remedy
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.
Owner complaints
133 complaints4 involved a crash3 involved a fire1 injuries
What owners report most
Latest complaints
- Electrical system · Engine · Service brakes, hydraulic
The contact owns a 2016 Hyundai Sonata. The contact stated that while driving 70 MPH, the vehicle went into LIMP Mode and decelerated. The check engine warning light and the battery warning light were illuminated. The failure was a recurring failure. The vehicle was towed to the first dealer, and…
The contact owns a 2016 Hyundai Sonata. The contact stated that while driving 70 MPH, the vehicle went into LIMP Mode and decelerated. The check engine warning light and the battery warning light were illuminated. The failure was a recurring failure. The vehicle was towed to the first dealer, and the contact was informed that an oil change was needed. The failure persisted, and the vehicle was taken to another dealer and was diagnosed and DTC: C222908; was retrieved. The manufacturer was contacted by phone and made aware of the failure. The failure mileage was approximately 88,385.
- Electrical system · Power train
Vehicle Impact:While driving, the vehicle suddenly displayed a "Check Hybrid System" warning on the dashboard and suffered a complete, sudden loss of propulsion while on the road. The vehicle dropped power completely and would not restart, creating an immediate, severe safety hazard to myself and…
Vehicle Impact:While driving, the vehicle suddenly displayed a "Check Hybrid System" warning on the dashboard and suffered a complete, sudden loss of propulsion while on the road. The vehicle dropped power completely and would not restart, creating an immediate, severe safety hazard to myself and surrounding traffic.Diagnostic & Component Confirmation:The vehicle was towed to a certified Hyundai dealership (Hyundai of Goshen, Repair Order #6080674). Diagnostic testing confirmed trouble codes P0717 (Input Speed Sensor No Signal) and P0A40 (Drive Motor Position Sensor).The dealership's certified technician explicitly documented that they "followed TSB and found input speed sensor valve body harness is faulty due to heavy corrosion on the sensor connector."Safety Hazard Summary:This is a critical manufacturing and sealing defect where an internal, non-wear component (the transmission valve body wire harness) corrodes prematurely. This corrosion blinds the hybrid control modules to the electric motor's position and output speed. To protect itself, the computer initiates a hard, uncommanded shutdown of the hybrid drivetrain while the vehicle is in motion.Hyundai Motor America was contacted (Case #43225229) but denied any financial or safety assistance because this documented Technical Service Bulletin (TSB) defect has not yet been elevated to a formal safety recall. This sudden powertrain failure presents an unreasonable risk of rear-end collisions and catastrophic highway accidents for 2016 Sonata Hybrid owners.
- Engine · Lane departure › Blind spot detection
EGR needs to be replaced as this is a major engine issue
- Unknown or other
Vehicle experiences intermittent DTC C222908 (Integrated Brake Actuator internal circuit malfunction). Warning lights (Brake, ABS, ESC, Hybrid System) illuminate intermittently, brake pedal feel changes, and regenerative braking fails. Dealer confirmed stored code but refused repair stating "no…
Vehicle experiences intermittent DTC C222908 (Integrated Brake Actuator internal circuit malfunction). Warning lights (Brake, ABS, ESC, Hybrid System) illuminate intermittently, brake pedal feel changes, and regenerative braking fails. Dealer confirmed stored code but refused repair stating "no current issue". This is a known failure in 2015-2019 Hyundai hybrids that can lead to sudden loss of hydraulic brake assist and increased stopping distance. Safety critical defect.
- Electrical system · Engine · Fuel/propulsion system
The car will randomly lose acceleration and jerk forward. It will make a beeping noise while the hev system warning flashes on the dash. It also says to turn off engine. While the warning is flashing and engine light is on it goes into a limp mode and you have limited acceleration. It has almost…
The car will randomly lose acceleration and jerk forward. It will make a beeping noise while the hev system warning flashes on the dash. It also says to turn off engine. While the warning is flashing and engine light is on it goes into a limp mode and you have limited acceleration. It has almost caused multiple wrecks when I go to acceleration from turning or at lights in traffic because I cant go over 20-30 mph. I have turned the car on and off and the hev system and engine light turns off and the car continues to work normal. It eventually comes back on and does the same loss of power/hev warning. It will be random and does not matter on how fast you are going to trigger the warning lights and loss of power.
- Engine
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at 20 MPH, the message "Shut Down" was displayed, and the vehicle lost motive power. The contact was able to pull over to the side of the road; however, the vehicle failed to restart. The vehicle was towed to the…
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at 20 MPH, the message "Shut Down" was displayed, and the vehicle lost motive power. The contact was able to pull over to the side of the road; however, the vehicle failed to restart. The vehicle was towed to the dealer, where it was diagnosed with engine failure, and the contact was informed that the engine needed to be replaced. The vehicle was not repaired due to the cost. The manufacturer was notified of the failure and declined to cover the repair under warranty. The failure mileage was approximately 140,600.
- Engine
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at an undisclosed speed, the vehicle went into LIMP Mode with several unknown warning lights illuminated. The vehicle was towed to the dealer and was diagnosed with engine failure. The contact was informed that the…
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at an undisclosed speed, the vehicle went into LIMP Mode with several unknown warning lights illuminated. The vehicle was towed to the dealer and was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 70,000.
- Electrical system
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to pull over to the shoulder of the roadway, and the message "Warning - Do not Attempt to Restart" was displayed. No…
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to pull over to the shoulder of the roadway, and the message "Warning - Do not Attempt to Restart" was displayed. No warning lights were illuminated. The vehicle was towed to the dealer, who diagnosed a failure of the engine wiring harness. The vehicle was repaired, but the failure reoccurred. The vehicle was taken back to the dealer and was diagnosed as a failure with the engine wiring harness. The vehicle was not repaired. The vehicle had been back to the dealer several times. Recently, the contact was informed that the wiring harness was soy-based insulated, and rodents were causing damage to the wiring harness due to the smell. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 80,000. The VIN was not available.
- Engine
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated while driving approximately 65 MPH, the check engine warning light was illuminated, and the vehicle stalled. The contact was able to exit the highway; however, the contact was unable to restart the vehicle. The contact had the…
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated while driving approximately 65 MPH, the check engine warning light was illuminated, and the vehicle stalled. The contact was able to exit the highway; however, the contact was unable to restart the vehicle. The contact had the vehicle towed to a dealer to be diagnosed. The vehicle was diagnosed, and it was determined that the engine needed to be replaced. The vehicle was not repaired. The contact stated that prior to the engine failure, the engine had been replaced two years prior. The manufacturer was not informed of the failure. The failure mileage was approximately 180,000.
- Electrical system · Engine · Power train
While on the highway vehicle started shaking violently, flashing engine light then service hybrid system along with every light on the dash! Car still running poorly, stiff steering very hard to slow down to get to safety! By the time I was able to pull over the engine was knocking and a burning…
While on the highway vehicle started shaking violently, flashing engine light then service hybrid system along with every light on the dash! Car still running poorly, stiff steering very hard to slow down to get to safety! By the time I was able to pull over the engine was knocking and a burning smell was coming from the engine compartment. I popped the hood shut the car off , the exhaust manifold and converter(in one together) was so hot it was glowing! I’m thankful I was able to get to safety without it catching fire because it was on its way there! I called for a tow and sent it to the dealer where Hyundai is replacing the engine.
- Visibility › Sun/moon roof assembly
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at an undisclosed speed, the driver's side sunroof detached. The contact stated that the sunroof was caught up on the netting in front of the sunroof. The contact stated that the tracks were fractured. There were…
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at an undisclosed speed, the driver's side sunroof detached. The contact stated that the sunroof was caught up on the netting in front of the sunroof. The contact stated that the tracks were fractured. There were no warning lights illuminated. The local dealer was contacted but the vehicle was not diagnosed or repaired. The manufacturer was contacted, and the contact was informed that the repair was not covered under NHTSA Campaign Number: 16V726000 (Visibility). The approximate failure mileage was 103,000.
- Engine · Hybrid propulsion system
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated while driving approximately 60 MPH, the check engine warning light illuminated, and the message "Check Hybrid System, Turn Off the Engine" was displayed, and the vehicle was shaking while decelerating. The vehicle was towed to the…
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated while driving approximately 60 MPH, the check engine warning light illuminated, and the message "Check Hybrid System, Turn Off the Engine" was displayed, and the vehicle was shaking while decelerating. The vehicle was towed to the dealer where it was diagnosed with the Technical Service Bulletin: 198. The Technical Service Bulletin was completed; however, the failure recurred. The vehicle was towed to the same dealer where it was diagnosed with a drained battery and catalytic converter failure. The vehicle was repaired; however, the failure recurred. The vehicle was towed to the same dealer. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 147,000.
- Engine and engine cooling
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated while operating the vehicle, the dashboard warning lights had suddenly activated and the vehicle went into LIMP Mode causing the vehicle to decelerate. The vehicle was taken to the local dealer on several occasions and the NOx…
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated while operating the vehicle, the dashboard warning lights had suddenly activated and the vehicle went into LIMP Mode causing the vehicle to decelerate. The vehicle was taken to the local dealer on several occasions and the NOx sensor, intake manifold and EGR were replaced but the failure persisted. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 104,000.
- Unknown or other
The wind guard for the panoramic sunroof of my 2016 Hyundai Sonata Hybrid broke & flew almost all the way off while driving down [XXX] in the Cleveland area. I was able to grab the end before it broke off completely and flew into traffic behind me. There was no warning prior to detachment. Hyundai…
The wind guard for the panoramic sunroof of my 2016 Hyundai Sonata Hybrid broke & flew almost all the way off while driving down [XXX] in the Cleveland area. I was able to grab the end before it broke off completely and flew into traffic behind me. There was no warning prior to detachment. Hyundai insists this part failure is not part of a prior recall for this exact same product failure on this make & model and therefore will not cover. Their suggested solution is glue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
- Electrical system · Engine · Power train
While driving the car completely cut off i could not use my brakes my horn or steering wheel
- Electrical system · Engine · Power train
My check Hybrid system light comes on and then my car stops allowing me to drive , the gas stops working ! This happened 3 times on the highway very dangerous
- Engine
I was driving on the freeway and the car went from 70 mph to 60 then 50 then 40 slowing on the freeway each second. This has happened multiple times, each time taken in Hyundai and “repaired” only to happen a couple months later.
- Electrical system · Forward collision avoidance › Adaptive cruise control · Vehicle speed control
Hev warning turn off engine sign while driving on the interstate my car lost power and the car behind me had to suddenly move over this IS very unsafe while driving down the interstate
- Electrical system · Engine · Unknown or other
HEV WARNING TURN OFF ENGINE CAR STARTED SHAKING while driving on the interstate gas pedal went to the floor car started making a loud noise from the engine I put car in park and it would not move for 45 minutes at a stop sign
- Electrical system · Engine
As I was driving on the highway at 65MPH, a sudden warning appeared on the dashboard that read, "CHECK HYBRID SYSTEM/TURN OFF ENGINE". Immediately after that, I noticed that my vehicle started behaving erratically, making it difficult to control. I stepped on the gas pedal expecting the car to…
As I was driving on the highway at 65MPH, a sudden warning appeared on the dashboard that read, "CHECK HYBRID SYSTEM/TURN OFF ENGINE". Immediately after that, I noticed that my vehicle started behaving erratically, making it difficult to control. I stepped on the gas pedal expecting the car to pick up speed and move forward. Despite the pressure I applied, the car failed to accelerate, leaving me stuck in my current position. After nearly causing a severe accident on a busy interstate, I was able to safely pull my car over to the side of the road. After conducting extensive research, I discovered that the issue I am facing with my hybrid vehicle is actually quite common among Hyundai Sonata Hybrids. It's surprising to note that despite this problem's prevalence, no recall or common solution has been provided to address it. I am highly concerned that Hyundai has not taken any action to address this issue. I request an immediate resolution as I could have been severely injured or lost my life today!
- Unknown or other
I was driving to work and suddenly my car gives me signal hybrid system alert turn off the engine and completely shut down on me as I was in the freeway. Thankful I made to safe area. I had it tow to the dealership and they are mentioning to me that they are not sure if is Power train module but…
I was driving to work and suddenly my car gives me signal hybrid system alert turn off the engine and completely shut down on me as I was in the freeway. Thankful I made to safe area. I had it tow to the dealership and they are mentioning to me that they are not sure if is Power train module but they want charge me $1391. They say is not guaranteed that’s going to fix the issue the service advisor mentioned he could be the transmission or the engine. I’m just so overwhelmed because me taking there I thought they have everything figure it out. Communication with them is really hard to get through them they always giving me the round arounds. Please help
- Visibility · Visibility › Sun/moon roof assembly
The contact owns a 2016 Hyundai Sonata. The contact stated that while driving approximately 55 MPH, the sunroof exploded without impact. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified about the failure. The contact stated that the failure was related to NHTSA Campaign Number: 16V726000 (Visibility). The failure mileage was approximately 130,000.
- Unknown or other · Visibility › Sun/moon roof assembly
Panoramic sunroof wind deflector bonding failed. The detached wind deflector can come off while driving and interferes with the sunroof closing. It’s possible that the wind deflector and the glass sunroof could detach entirely while driving and cause an accident. I have used the sunroof feature…
Panoramic sunroof wind deflector bonding failed. The detached wind deflector can come off while driving and interferes with the sunroof closing. It’s possible that the wind deflector and the glass sunroof could detach entirely while driving and cause an accident. I have used the sunroof feature less than 5 times since purchasing the vehicle in May 2019. There is a recall on this part for the Sonata Hybrids for the dates of 12/8/14 to 8/18/15. On 4/7/23 Long Hyundai of Chattanooga confirmed the problem and charged me $185.73 to look at the problem. They will order a new part and install it which will cost me $398.94. I declined because I think that this is a manufactured flaw that should be repaired by Hyundai at no cost to me. I have spoken at length with Hyundai customer service representatives and was informed that they would not repair it because it is not included in the recall. They recommended that I contact Better Business Bureau. BBB Auto Line informed me that NHTSA handles recall issues.
- Electrical system · Exterior lighting · Service brakes, air
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at approximately 60 MPH, the brake pedal was depressed and failed to respond. The "Stop Car, Check Brakes" message was displayed. The ABS and traction control warning lights were illuminated. The contact pulled…
The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while driving at approximately 60 MPH, the brake pedal was depressed and failed to respond. The "Stop Car, Check Brakes" message was displayed. The ABS and traction control warning lights were illuminated. The contact pulled over and turned off the vehicle, and stated that after restarting the vehicle, the warning lights were no longer illuminated. The vehicle was taken to a local dealer where it was diagnosed and serviced under NHTSA Campaign Number: 20V746000 (Engine) and 21V749000 (Exterior Lighting, Electrical System). The vehicle was repaired; however, the failure reoccurred intermittently. The vehicle was then taken to Homestead Hyundai (111 S Homestead Blvd, Homestead, FL 33030) where it was diagnosed that the power brake booster and rear wheel speed sensors needed to be replaced. The power brake booster was replaced; however, the failure reoccurred. The vehicle was then taken back to the dealer, and the wheel speed sensors were replaced. The manufacturer was not made aware of the failure. The approximate failure mileage was 130,000.
- Electrical system · Engine · Exterior lighting
HEV turn off engine light pops up WHILE driving. I could’ve been on the highway or the middle of no where and have to turn off my car, just to turn it back on and it seems fine? This has happened a total of 5 times since owning this vehicle, and I’ve gotten all code on the car fixed about a month ago.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Pedestrian alert sounds
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for…
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.
- Loss of Motive Power
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…
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.
- Engine Fires
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…
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.
- Electrical overstress
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…
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.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 11008009This bulletin provides instructions to update the 4th generation AVN head unit software to ensure the SIM Over The Air function for the Bluelink service is operating properly.
- 11006829Hyundai is conducting a campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.
- 11002760This bulletin provides instructions to update the 4th generation AVN head unit software to ensure the SIM Over The Air function for the Bluelink service is operating properly.
- 10253275This TSB provides a procedure to diagnose and replace, if necessary, an automatic transmission with Incorrect Ratio DTC (transmission clutch slip in gear above limit) listed on Page 2.
- 10251285This bulletin contains information about the proper removal of the windshield wiper blade protective cover on all models. If the protective cover is not removed correctly, there is a possibility of the rubber insert and rail spring becoming partially separated on the inner side of the wiper blade, which could lead to poor wiping performance and/or possible scratching of the windshield glass. Follow the procedure in this bulletin to properly remove the windshield wiper blade protective cover on all new wiper blades.
- 10247189This bulletin provides important checkpoint guidelines when performing engine oil and filter change services.
- 10240082A class action lawsuit against Hyundai Motor America (HMA) alleges that certain Hyundai vehicles (Class Vehicles) were manufactured, marketed, sold, and/or leased with an engine defect that can result in sudden engine seizure, stalling, engine failure, and in some circumstances, engine fire, and that some owners and lessees of Class Vehicles have been improperly denied repairs under warranty. Neither HMA nor Hyundai Motor Company have been found liable for any of the claims alleged in the lawsuit. The parties have instead reached a voluntary settlement (the Settlement) to avoid lengthy litigation and to provide owners of Class Vehicles certain benefits.
- 10235566Hyundai applies a Paint Protection Film (PPF) on new vehicles before delivery to dealerships. It provides a barrier between the paint and contaminants, such as rail dust, acid rain, and industrial fallout. In rare cases, the paint can become clouded under the PPF. These spots are the result of moisture trapped between the PPF and the paint.
- 10235524The warranty coverage for certain 2015-2017MY Sonata (LFa) and Sonata Hybrid/Plug-in (LF HEV/PHEV) vehicles exhibiting reduced power steering assist and/or motor driven power steering (MDPS) warning lamp has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first. Refer to the TSB 23-ST-003H (or latest version) for warranty, service parts information, and diagnostic information outlined in the bulletin.
- 10235349The warranty coverage for certain 2015-2017MY Sonata (LFa) and Sonata HEV/PHEV (LF HEV/PHEV) vehicles exhibiting reduced power steering assist and/or motor driven power steering (MDPS) warning lamp has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first. Refer to the warranty, service parts information, and diagnostic information outlined in this bulletin.
- 10230904This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes or during normal driving operation.
- 10227320Certain vehicles may experience the Check Engine warning lamp illuminated with DTC P1326 and/or engine may exhibit abnormal noise, or no crank/no start condition related to connecting rod bearing wear or damage. This Dealer Best Practice outlines the service process to inspect the vehicle and replace the engine or update the engine ECU software based on the inspection results, as well as related warranty coverage for the conditions outlined above.
- 10227317Certain vehicles listed below may experience the Check Engine warning lamp illuminated with DTC P1326 and/or an engine concern/noise related to connecting rod bearing wear or damage. Follow the procedure to inspect the vehicle and replace the engine and/or update the engine ECU software (if new ROM is available) based on the inspection results.
- 10227316The warranty coverage for engine repair or replacement regarding engine damage or malfunction from connecting rod bearing wear has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first, and is valid for original and subsequent owners. Commercial entities and individuals engaged in the buying, selling, leasing, or renting of motor vehicles, as well as salvaged vehicles, are ineligible for the extended warranty.
- 10227313Op code/part number (reference guide for service campaign T6G)
- 10217258Effective June 2, 2008, Federal Motor Vehicle Safety Standard 110 (FMVSS 110) established a threshold for correcting load carrying capacity information indicated on tire placards when vehicle weight has been increased before retail sale. This limit is the lesser of 1.5% of GVWR or 100 pounds. If the total added weight exceeds the lesser of the limit, a label must be added to the driver-side B-pillar within 25mm (1 inch) of the original tire placard.
- 10217251Follow the guidelines outlined in this bulletin to inspect and clean or replace certain components of the engine intake system accordingly during engine short block or sub-assembly replacement.
- 10211675The Powertrain warranty coverage for certain engine repairs and/or replacement where the engine damage or malfunction is related to connecting rod bearing wear, has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first, and is valid for original and subsequent owners.
- 10211667Hyundai is conducting a campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.
- 10211666Certain vehicles listed below may experience the Check Engine warning lamp illuminated with DTC P1326 and/or an engine concern/noise related to connecting rod bearing wear or damage. Follow the procedure to inspect the vehicle and replace the engine and/or update the engine ECU software (if new ROM is available) based on the inspection results.
- 10211664Hyundai is conducting a service campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.
- 10211662Certain vehicles that have completed Service Campaign 966 may experience the Check Engine warning lamp illuminated with DTC P1326 and/or an engine concern/noise related to connecting rod bearing wear or damage. Follow the procedure to inspect the vehicle and replace the engine and/or update the engine ECU software (if new ROM is available) based on the inspection results.
- 10210206Certain vehicles listed below may experience the Check Engine warning lamp illuminated with DTC P1326 and/or an engine concern/noise related to connecting rod bearing wear or damage. Follow the procedure to inspect the vehicle and replace the engine and/or update the engine ECU software (if new ROM is available) based on the inspection results.
- 10210205Hyundai is conducting a campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.
- 10207815The warranty coverage for certain 2015-2017MY Sonata (LFa) and Sonata HEV/PHEV (LF HEV/PHEV) vehicles exhibiting reduced power steering assist and/or motor driven power steering (MDPS) warning lamp has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first. Refer to the warranty, service parts information, and diagnostic information outlined in this bulletin.
- 10207803Hyundai is conducting a campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.
- 10207802The warranty coverage for certain 2015-2017MY Sonata (LFa) and Sonata Hybrid/Plug-in (LF HEV/PHEV) vehicles exhibiting reduced power steering assist and/or motor driven power steering (MDPS) warning lamp has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first.
- 10206367When asked to provide the Modem Information, the Universal Subscriber Identity Module (USIM) may not be available. This TSB# 21-01-080H describes the 3-part software to correct this condition and activate Blue Link Services.
- 10206366Hyundai is conducting a service campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.
- 10206363When asked to provide the Modem Information, the Universal Subscriber Identity Module (USIM) information is not available. This bulletin describes the 3-part Software to correct this condition and activate Blue Link Services.
- 10203282Hyundai is conducting a service campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.
- 10203280Hyundai is conducting a campaign to enhance the knock sensor software to detect abnormal engine bearing noise before potentially severe engine damage occurs. If abnormal engine bearing noise is detected, the Malfunction Indicator Lamp (MIL) will blink continuously, and the vehicle will be placed in Engine Protection Mode allowing the customer to drive to the nearest Hyundai dealer for diagnosis and repair. In addition, DTC P132600 will be recorded in the ECM. The vehicle can continue to be operated for a limited time in Engine Protection Mode, but it will accelerate slower and have a reduced maximum speed. Engine RPMs will be limited to approximately 1800-2000 RPM.
- 10203277The Powertrain warranty coverage for certain engine repairs and/or replacement where the engine damage or malfunction is related to connecting rod bearing wear, has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first, and is valid for original and subsequent owners.
- 10199106This bulletin describes the procedure to diagnose and repair the Engine Electric Water Pump (EEWP) on certain Sonata Hybrid (LF HEV) and Sonata Plug-In Hybrid (LF PHEV) vehicles with DTC P2600, causing an HEV and/or MIL warning lamp illumination.
- 10196571The trunk latch base can be ordered separately from the trunk latch assembly. This bulletin describes the procedure to replace the trunk latch base.
- 10190049The Powertrain warranty coverage for certain engine repairs and/or replacement where the engine damage, defect, or failure is related to connecting rod bearing wear, has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first, and is valid for original and subsequent owners.
- 10190047Consult the Hyundai Warranty Policy & Procedures and the below tables to determine New or Reman engine usage. Please note that a Reman engine may not be available for certain vehicle models/model years listed in this TSB.
- 10190045Certain vehicles listed below may experience the Check Engine warning lamp illuminated with DTC P1326. Follow the procedure to inspect the vehicle and replace the engine and/or update the engine ECU software (if new ROM is available) based on the inspection results.
- 10190044This bulletin provides the service procedure for engine connecting rod bearing clearance testing. Perform the procedure outlined in this bulletin to fulfill the Bearing Clearance Test inspection requirements to determine next required steps.
- 10190038This bulletin provides best practice recommendations when performing brake service procedures.
Every Hyundai Sonata Hybrid model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.