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

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 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 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

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

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

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

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

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

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 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

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

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