What 157 owners told NHTSA about the 2016 Hyundai Sonata Plug-in

EGR needs to be replaced as this is a major engine issue

NHTSA ODI 11751204

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.

NHTSA ODI 11700973

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.

NHTSA ODI 11692279

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.

NHTSA ODI 11680336

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.

NHTSA ODI 11659350

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.

NHTSA ODI 11658460

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.

NHTSA ODI 11644593

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.

NHTSA ODI 11615081

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.

NHTSA ODI 11603439

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.

NHTSA ODI 11584421

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.

NHTSA ODI 11579661

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)

NHTSA ODI 11578335

While driving the car completely cut off i could not use my brakes my horn or steering wheel

NHTSA ODI 11572766

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

NHTSA ODI 11566685

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.

NHTSA ODI 11554489

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

NHTSA ODI 11551356

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

NHTSA ODI 11551358

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!

NHTSA ODI 11549710

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

NHTSA ODI 11533741

The contact owns a 2016 Hyundai Sonata Plug-In Hybrid. The contact stated that on three separate occasions while driving approximately 65 MPH, the “Check Hybrid System - Turn Off Engine” message was displayed. The check engine warning light illuminated. The contact then stated that the vehicle decelerated and went into LIMP Mode. The vehicle was towed to the dealer however, the failure could not be duplicated. The contact stated that the failure recurred. The vehicle was taken back to the dealer but the failure could not be duplicated; however, the contact stated that he provided diagnostic test data to the technician that displayed error codes however, the failure could not duplicated. The vehicle was not repaired. The manufacturer was notified of the failure and the contact was provided a case number. The failure mileage was approximately 65,000.

NHTSA ODI 11529173

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.

NHTSA ODI 11527134

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.

NHTSA ODI 11519770

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.

NHTSA ODI 11518028

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.

NHTSA ODI 11514654

While driving the car getting error message on dashboard "Check Hybrid System Turn Off Engine", The Gas engine turn off and switch to continue on electric till able to pull on the side of the road. Turn Off engine, wait a min. Start car again and working fine. This issue appears randomly many times in the last two years while driving. Car was at dealer shop multiple times with no repair, was told we don't see active error message or they can't re-create the error. however scan show P261F error. Open Ticket with Hyundai #21018148 while car at the dealers for weeks at the time. each time told check engine got back on but not the message they are looking for.

NHTSA ODI 11514685