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

The contact owned a 2016 Hyundai Sonata Hybrid. The contact stated that while driving approximately 25 MPH, the steering wheel became firm while navigating a turn, and the vehicle crashed into a tree. There were no warning lights illuminated. The contact was unconscious and woke up to being treated by an EMT. The contact sustained injuries to his chest and fractured ribs. Medical attention was provided at the hospital. The air bags deployed as needed. A Police report was filed. The vehicle was towed to a tow lot. The vehicle was deemed a total loss. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 13,000.

NHTSA ODI 11509548

The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while his wife was driving at a slow speed out of the driveway, she heard a knocking sound coming from under the hood. The check engine warning light was illuminated. The vehicle was towed to the dealer where it was diagnosed that the engine needed to be replaced. The vehicle was repaired; however, the failure recurred. The contact stated that after the vehicle was retrieved from the dealer, the check engine warning light illuminated after 300 miles. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 163,000.

NHTSA ODI 11508408

The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated that while his son was driving at an undisclosed speed, the vehicle lost motive power. The vehicle was towed to the dealer, where it was diagnosed with low oil and engine failure. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 20V746000 (Engine). The manufacturer was made aware of the failure. The failure mileage was 67,036. The contact noted that the failure speed was approximately 40 mph. It wasn't long after purchasing the vehicle that the engine seized while driving. The contact stated that the manufacturer will not honor the warranty due to the incident occurring from "an outside influence". Said influence is unknown to the contact.

NHTSA ODI 11502815

While driving the hybrid system warning light comes on and says to check hybrid system, vehicle goes into limp mode will not accelerate over 25 mph and codes need to be cleared before vehicle van be driven. This has caused me to almost have several accidents. The vehicle slows down and gives no warning prior to this occurring. It has started happening more frequently vehicle currently has 85k miles.

NHTSA ODI 11500417

While driving on the highway at speed, I received a red Check Hybrid System error, and immediately lost all acceleration, putting myself and all occupants at risk on a busy interstate highway, as we tried to find a safe way to quickly change lanes and coast to a stop in a safe location. The cause is under diagnosis by a Hyundai Service Center. This was a sudden failure and there had been no previous warning alerting us to substandard system condition.

NHTSA ODI 11494395

The contact owns a 2016 Hyundai Sonata Plug-In Hybrid. The contact stated while driving 70 MPH or faster in Hybrid Mode, the vehicle stalled. The HEV error warning light was displayed on the instrument panel. The check engine warning light was also illuminated. The contact turned off the vehicle and disengaged the HEV Mode for the vehicle to restart and function as intended. The failure occurred three times. The vehicle had been taken to the dealer however, the mechanics were unable to determine the cause of the failure. The vehicle was not repaired. The manufacturer was made aware of the failure and opened a case. The approximate failure mileage was 66,000.

NHTSA ODI 11490124

The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated while driving approximately 65 MPH, several unknown warning lights illuminated and the vehicle decelerated independently. The contact was able to park on the side of the road before the vehicle stalled. The vehicle was not drivable. The contact towed the vehicle to a local dealer, where it was diagnosed with needing the knock sensor to be replaced. The vehicle was repaired. The manufacturer had not been informed of the failure. The failure mileage was 34,252.

NHTSA ODI 11482465

My 2016 plug in hybrid Sonata repeatedly inidcates that there is "high system temperature switching to hybrid mode." This first happened on my first long trip in the car in 10/21 and has happened repeatedly since. This happens at all temperatures, including moderate temperatures (mid 70s). It seems to happen randomly, such as when battery has several miles of charge left in it, when it is fully discharged, and repeatedly when the car is already running in hybrid mode, which a driver could interpret means that the engine is about to shut down, as I did on a long trip. I have taken it to two separate dealers, and the only thing they did was replace the fuel pump, which did not solve the problem. In addition, the battery life has reduced greatly, despite the fact that I always fully discharge and recharge the batter. As you can see from the attached Hyundai forum comments, this appears to be a prevalent problem for this make and model car and no relief from the manufacturer appears to be on the horizon.

NHTSA ODI 11478763

My vehicle first went into limp mode and stalled while driving December 2021. Vehicle was taken to Dealership in Alpharetta, GA. I was advised the knock sensor needed an update. The update was completed but the vehicle continued to go in limp mode and stall again March 2022 after driving less than 1000 miles since previous repair. The vehicle was taken to dealership in Wake Forest, NC. This time there was no update for the knock sensor so I was advised they would need to replace knock sensor but it was on backorder until end of May 2022. The knock senor was replaced picked up vehicle and engine light came on by the time I had drove 50 miles and vehicle started to go in limp mode and stall again and car started shaking an bad vibration. Drove the car next morning and it put me down again going into limp mode, stalling, whole dash board lit up every warning light on and dinging, car shaking and made loud noise had to have towed back to dealership. This time dealership claim it came from misfire on cylinder 3 but that doesn't explain all the issues. I was called to pick up car again June 2022 car had bad vibration, knocking, still going into limp and stall mode, hybrid system warning light came on again, gear sticking not changing like it's supposed to had towed back to dealership. This time dealership replaced other 3 cylinders picked up car July 2022. Did a test drive advised car is still stalling, gear still sticking, vibration still , air not cooling and hybrid indicator needle bouncing back and forth from power to 80 never stabilized. Dealership claims can't find anything wrong. I have almost been hit 10 times since December 2021 because of vehicle going into limp mode while driving this is very dangerous to be going 55 to 70 and vehicle drops speed back to 10 all of a sudden in traffic

NHTSA ODI 11478504

The car requires a quart of oil every 1 to two weeks. Brought it to multiple dealerships and was never given a reason why. Car was making knocking noises anytime driven at 45 or below and sometimes higher. We believe it had to be about the recall Hyundai has advised us about multiple times. We brought it to them on Friday July 22nd. They updated the Hybrid system and we left. Driving the car to work July 27th and the car went into “limp” mode and stated that there was a issue with the hybrid engine and to shut the car off immediately. I was able to pull the car off the road and turn it off. The engine light constantly blinked when the error happened. When I shut the car off and turned it back on, it the same hybrid error shows up on the screen again. We had to have it towed to the same dealership we went to the previous day. They have to diagnose the issue but it might take weeks because they have one hybrid tech.

NHTSA ODI 11476347

There is a recall outstanding that for some reason isn't associated with my car's VIN so the manufacture Hyundai is refusing to pay or make repairs. They even suggested that I buy a part that should fix the problem, after paying $246.75 for the part; the problem remained. The recall number is 16-01-067 for 2016 SONATA (LF) and SONATA HYBRID (LF-HEV); my car is a 2016 Sonata Hybrid. SUBJECT: PANORAMIC SUNROOF WIND DEFLECTOR PLATE REPAIR (RECALL 152) Description: Certain 2015 and 2016 model year Hyundai Sonatas and 2016 Sonata Hybrids come equipped with an optional panoramic sunroof. The sunroof assembly incorporates a wind deflector to help reduce wind noise in the passenger compartment when the sunroof is open. If the wind deflector becomes partially detached from its mounting bracket while the sunroof is open, the deflector can interfere with the closing of the moveable sunroof panel. In some cases this interference can result in the sunroof panel detaching from its mounting tabs. If the sunroof panel detaches while the vehicle is in motion, the panel could become an obstacle to other drivers, increasing the risk of a crash. The wind deflector on my car detached a year ago and after several requests to fix the detached deflector the dealership hasn't and refuses to recognize the recall. Is there a way to help get my car's VIN appropriated associated to this recall so if can be fixed?

NHTSA ODI 11476114

The contact owns a 2016 Hyundai Sonata Hybrid. The contact received notification of NHTSA Campaign Number: 21V749000 (Exterior Lighting, Electrical System) however, the part to do the recall repair was not yet available. The contact stated that the vehicle was unable to start. The vehicle was towed to the dealer; however, the vehicle was not diagnosed nor repaired and remained at the dealer. The manufacturer was made aware of the failure and a case was opened. The failure mileage was approximately 110,000. Parts distribution disconnect.

NHTSA ODI 11472959

The contact owns a 2016 Hyundai Sonata Plug-In Hybrid. The contact stated while the vehicle was approaching a stop sign, the vehicle stalled. The contact stated there was no warning light illuminated. The vehicle was not drivable. The contact stated he manually pushed the vehicle to the side of the roadway. The contact went back with his trailer and trailered the vehicle to the local dealer where it was diagnosed with needing the Hybrid control unit to be replaced. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 120,000.

NHTSA ODI 11472475

I have a 2016 Hybrid Sonata [XXX], the dash started flashing and said...... HEV trouble! STOP the engine now! Now I have a orange engine light. I brought the car to the dealer. They will look at it and contact me. This car cost me plenty, last year they made me pay for a new engine, it would eat up a quart of oil every two weeks. That is 2 quarts a month. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ODI 11470513

The contact owns a 2016 Hyundai Sonata Hybrid. The contact stated while driving approximately 55 MPH, the vehicle was shaking. The hybrid battery, PHEV system, and check engine warning lights were illuminated. The vehicle stalled. The vehicle was towed however, the independent mechanic was unable to determine the cause of the failure. The vehicle was then towed to the local dealer, who diagnosed a failure with the engine and catalytic converter. The engine was replaced. The failure reoccurred. The manufacturer was notified of the failure. The approximate failure mileage was 120,000.

NHTSA ODI 11466083

Recently Service Campaign 966 (NHTSA ID Number: 10210205 Manufacturer Communication Number: 22-01-028H) was applied to my vehicle for improved knock sensor detection system (KSDS) logic. Six days following the software update, my vehicle stalled when DTC P1326 came active during my wife's commute home. We had the vehicle towed to the dealership where a knock sensor was identified to be replaced. 10 days after getting the vehicle back, knocking was heard from the engine compartment and DTC 1326 came active again, causing the vehicle to immediately stall. It did not go into engine protection mode as service campaign 966 indicated it would. My concern is that Hyundai changed the sensitivity of knock detection to prevent warranty claims on engines that may be affected by increased bearing wear; and in preventing replacing engines, they have caused engines (mine included) to stall. This engine stalling is a safety issue and they have left customers with no option to use their vehicle safely if the engine passes their bearing clearance test, which is required for an engine replacement under warranty.

NHTSA ODI 11465009

Recall [XXX] : Engine Inspection / Replacement ([XXX]) In the month of Oct 21, my Hyundai sonata hybrid, had severe engine issues and stalled. Upon inspection by dealer, it was determined, it needs engine replacement as there was a recall for these engines. After 3 months of waiting, in January 2022, I received my car back supposedly with the new engine. today [XXX] my car has stalled again with a similar engine issues and I have towed my car to the same dealer (DORAL HYUNDAI : Miami Florida) for inspection. fortunately i was not injured or ended up in an accident. the car just stalled suddenly with red lights on for every parameter along with engine light. luckily i was on the onramp and not in between the freeway. still was a dangerous situation as cars barely managed to save from hitting me when the car suddenly slowed down and stopped I feel, Hyundai didn't perform their replacement part effectively or efficiently. Probably replaced the car with a similar faulty engine. I request you to please investigate this matter my name is [XXX] and my email id is [XXX] and [XXX]. my cell phone number is [XXX]. thanks, [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ODI 11464133

Hybrid system shut down while driving on I5 freeway at 60mph speed. Lost power completly finding myself in a very dangerous situation barely making it to the shoulder without being hit by other cars. This happened twice after 2 recalls performed on the car. Knock sensor replacement and software update. First recall was attempted by Hyundai of Kirkland WA. HEV system failure and multiple lights turned on while driving on the freeway the following day. Car was towed to Lee Johnson in Everett WA and I was told the recall was not performed correctly. After repair, same thing happened the following day. HEV failure and multiple lights turned on finding myself once again in very dangerous situation on the same busy freeway. Manufacturer is not taking this seriously. I see they have lots of vehicles with the same problem. Please investigate this failure before somebody dies. Next will file a police report. Car still at the dealership with no news on what might cause this. Has been at the dealer for over a week.

NHTSA ODI 11462544

The NHTSA has numerous complaints from owners of the 2016 Hyundai Sonata and 2016 Hyundai Sonata Hybrid with failures associated with the following: abnormal (knocking) noise from engine, reduced motive power and/or hesitation, illumination of the “Check Engine” warning lamp, illumination of engine oil pressure warning lamp, and a burning smell, oil leaking, and smoke. After research, I found the recall 21V301000, which lists “Part 573 Safety Recall Report 21V-301”, and I have attached it. I believe the piston oil rings are potentially a source of engine failure for the 2016 Hyundai Sonata and 2016 Hyundai Sonata Hybrid (since they are from the same manufacturer) and not the process and defect that Hyundai previously listed (that they stated was corrected), yet referenced in their recall. Hyundai and Kia both have defects with their ignition coils that have the shared part number: 27300-2E601, which also appears as: 27300 2E601. We have a 2016 Hyundai Sonata Hybrid Limited that is on its 3rd set of ignition coils, and some Hyundai Elantra and Kia Forte owners have reported the use of a 4th set of ignition coils. I have researched this part number by contacting multiple Hyundai Certified Parts Departments. A Hyundai Parts Department verified that the Hyundai Technical Service Bulletin (TSB) 16-01-003-1 states that it “replaces” part number 27300-2E601 with part number 27300-2E601QQH, but they are the same exact part down to the 27300-2E601 appearing on both parts. One of the Hyundai parts people that I spoke to said that Hyundai put white circle stickers on the top of the ignition coils to differentiate between the older and newer part numbers, but the parts are identical. He said that Hyundai contacted their supplier of the ignition coils and negotiated a lower price due to a high failure rate. This means a significant price difference per ignition coil for the dealers, but keeps a defective part in the concerned vehicles.

NHTSA ODI 11461452

In January of 2022, my vehicle experienced a complete power loss while driving to work, leaving the car coasting down the road. A Check Hybrid System warning came up on the dashboard, along with several other warning lights, including Check Engine. Luckily, I was able to pull over without an accident occurring. Once stopped, the vehicle did restart and got me to and back from work. A diagnosis effort made at a local Hyundai dealership was unsuccessful as they could not replicate the problem and found no error codes in the auto's CPU system. I continued to drive the vehicle, hoping it was a one time deal, but since then, the identical situation has occurred three more times. I was extremely lucky that I had been in a position to safely pull off to the side of the road. The car has not been driven since March 19, 2022. After researching this scenario online, it appears to be the exact situation reflected in the Hyundai Recall campaign 175 from 2018, where the dealership remove the original VPD module and replace it with a Battery Management System (BMS) that contains an Overvoltage Protection Device (OPD). The recall is said to have been done on my vehicle, but the exact situation has reoccurred. Every time time the car lost power, it was preceded by a shuttering feel in the car, an alarm would go off and the propulsion system would just shut down and the Check Hybrid light would come on. Hyundai's only response has been to drive the car until it fails again (can you believe that?) and bring it in again for diagnosis. Even if that were to be done, the technicians and others on the road, would then be put at risk, as well, if they drove the vehicle in an attempt to get it to fail. I am the second owner of this car and the recall was supposedly done prior to my purchase. I now wonder if the dealer knew of the problem and that is why it was $2K below KBB. I cannot safely drive the car and can't sell it without loss once this safety issue is revealed. Thank you.

NHTSA ODI 11461197

On 04/09/2022 around 6:30 PM EDT, while driving on the Florida Turnpike at the posted 70 mph in Orlando FL, the 2015 Sonata Hybrid suddenly shut down in the center of 4-lanes with heavy traffic. The engine would not run and only sputtered and jerked when I gave it any gas. The display screen lit up with multiple failure symbols including the Hybrid System failure, lane detection failure, and several others. I exited the Turnpike and had a local auto store scan the vehicle finding the following DTC’s: 1. P1326: Excessive connecting rod bearing wear 2. U0293: Lost Communication with Hybrid Powertrain Control Module 3. U1004: Not certain The vehicle was checked and found to be full of oil. The vehicle was serviced at the Hyundai Dealer on 02/25/2022 where they specifically updated the “Excessive connecting rod bearing wear” knock sensor software along with a turn signal issue. Having the engine go into a default mode at 70 mph in heavy traffic was a near disaster. A simple warning would have been adequate to all me to safely navigate to the roadside.

NHTSA ODI 11460360

When entering freeway and needing to get up to speed real quick, the car will accelerate to approximately 50mph and then engine totally cuts out like the gas stopped flowing to it. I then have to let off on the gas considerably or it will not accelerate until I let off on the gas about 1/2 way. I then must "Slowly" accelerate so that it won't cut the engine again. This will happen anywhere if I take off from 0 mph and try to accelerate with peddle eventually going to floor, the car will cut the engine and will feel like its dying until I let off on the gas peddle all the way and then slowly accelerate the vehicle up to speed.

NHTSA ODI 11460292

IF I drive long distances for 30 minutes or more and then stop in somewhere and shut the vehicle off. Once I try and start it, it will give the Yellow CIL Check engine light and the HEV error, bring car to dealer. You have to wait approx 15-25 minutes and then it will start up again. I also seem to notice that it happens even faster when I put the transmission speed control into High Performance. The battery seems to overcharge and go well past the halfway mark almost to 80% and then once I power off and back on vehicle, I get the HEV error message and must wait 15-25 minutes before it will start.

NHTSA ODI 11460291

Contact was driving on city streets, received Hybrid System Warning, turn off engine alert. Car slowed to dangerous speed in heavy traffic, would only drive under electric system. Car pulled over when safe, restarted, same issue recurred. Car brought to local repair shop, where trouble code #P261F recorded- "Coolant Pump A Control Circuit Stuck On." Mechanic discussed with dealer who said it should be under warranty. Towed to Keyes Mission Hills Hyundai in Mission Hills, CA. Fault diagnosed as electric water pump. Per Mission Hills, not covered under 10 year warranty, only 5 year warranty. Car 5 years, 7 month old,19,000 miles, out of warranty. Owner notified dealer about recall campaign 16-01-020 for this specific component. Awaiting consideration for goodwill repair from Hyundai as per the TSB for the campaign.

NHTSA ODI 11459035

This is a plug-in hybrid. Charging light on the dash blinks red indicating there is an issue (per manual). Also blinks while driving. Should be green. Still charges. Taken to two Hyundai dealerships. Computer produces no codes. Dealership does not know how to proceed. Safety concern is it’s unknown if battery is dangerous to charge? Is it dangerous to drive? How does a car indicate a problem but then give no codes.

NHTSA ODI 11454948