2011 Hyundai Sonata

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles.  During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types.  The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement.  Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia.  The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio.  The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires.  In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines.  The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS.  It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension.  For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied.  Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates.  To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years.  In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires.  Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis.  Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023).  The agency reserves the right to take additional action if warranted by future circumstances.  To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.

During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Hyundai Sonata and Santa Fe vehicles equipped with Theta II and Lambda II engines (approximately 1.3 million vehicles). ODI also reviewed field data of other Hyundai vehicles equipped with Theta II, Gamma, Nu and Lambda engines (approximately 4.8 million). As a result of this PE, Hyundai has issued NHTSA Recalls 20V-746 and 21V-727 to address potential engine failures and fires in certain Hyundai vehicles equipped with various engine types. Additional information on these and other related recall actions is available in the downloadable version of this resume available at NHTSA.gov. In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure rewlated recalls mentioned above and conducted previously. See the EA21-003 Opening Resume available at NHTSA.gov for more information. Also available in the downloadable version of this resume is a list of the reference numbers for the 302 ODI reports, or Vehicle Owner Questionnaires (VOQs), cited above which ODI received through mid-November 2021. Note that the Manufacturer reports cited above are customer complaints received through March 2019.

On September 24, 2026, I brought my vehicle to Kelly Hyundai Service Center for two recall repairs: IBU/BCM Anti-Theft Software Upgrade and Decal Application Anti-Theft Ignition Cylinder Protector and Decal Installation My vehicle was at the dealership all day. At the end of the day, I received a call from the technician advising me that the recall work could not be completed due to an electrical issue. When I returned home, I immediately noticed several problems that did not exist prior to the service appointment. Specifically: The high beams no longer worked. The dashboard illumination was not functioning properly. The automatic door lock system stopped working. The trunk could only be opened with the key. I contacted the service center and was informed that the only way they could determine the cause of these issues was for me to bring the vehicle back and pay a $200 diagnostic fee. I explained that I did not believe I should be charged to diagnose problems that appeared immediately after their attempted recall repair. I requested to speak with the service manager, but I was told he was unavailable. I never received a return call from management. On October 1, 2026, I returned to the service center and spoke with the manager. He recommended that I leave the vehicle for further evaluation. I did so, but later that day I received another call stating that the recall still could not be completed and that I would again need to pay a $200 diagnostic fee. I picked up my vehicle because I did not believe I should be responsible for that expense. The problems began only after the dealership attempted the recall repair and that I should not be required to pay diagnostic charges to identify or correct issues that may have been caused during that process.

NHTSA ID

11773764

Incident

Oct 1, 2026

While driving home and negotiating an ordinary turn onto our residential street, we heard a loud popping sound. We immediately pulled over and discovered that the driver’s-side rear wheel was leaning inward substantially. Upon inspecting the suspension, I discovered that the cylindrical bushing attachment on a rear suspension control arm had fractured, allowing the suspension connection to separate. I subsequently walked back to the location where the noise occurred and recovered the detached metal fragment. The fracture surfaces exhibit distinctly different coloration, suggesting that part of the fracture may have existed for some time before the final separation. Of greater concern, upon inspecting the corresponding suspension component on the passenger side, I discovered a substantial crack along what appears to be the same fracture path as the failed driver’s-side component. Both sides appear to exhibit a common structural weakness. The failure occurred during ordinary driving without a collision or known impact immediately preceding the event. A similar failure at highway speed could cause a serious crash, injury, or death. I understand Hyundai previously conducted rear lower control arm replacement Service Campaign TP3 for certain 2011–2013 Sonata vehicles. I request that NHTSA investigate whether this failure is related to a known defect or represents a broader safety concern. Photographs of the failed driver’s-side component, recovered fragment, and corresponding passenger-side crack are available. The vehicle and recovered fragment are being preserved for further inspection. I request that this incident be reviewed as a potential safety-related structural suspension defect.

NHTSA ID

11773529

Incident

Oct 25, 2026

My 2011 Hyundai Sonata with the 2.4L Theta II GDI engine developed an engine failure at 99,928 miles. On XXX Hyundai’s dealer (McFarland Hyundai, [XXX]) ran Hyundai’s T3G connecting-rod-bearing test, and the engine returned NO PASS. Hyundai’s own test recorded the oil level as full. This engine family is the subject of Hyundai’s connecting-rod-bearing safety campaigns and its extended engine warranty. Hyundai declined the repair (#XXX) as “exceptional maintenance neglect,” although the oil and filter were changed about 730 miles before the failure, with two more documented oil changes in the prior 16 months. Connecting-rod-bearing failure in this engine can cause engine seizure or stalling while driving, which creates a crash risk. The vehicle is at the dealer and has not been repaired. I am reporting this so NHTSA has a record of a Theta II failure in a vehicle covered by these campaigns that was denied repair. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11771950

Incident

Aug 10, 2026

The passenger frontal airbag deployed on its own while the vehicle was being driven, with no collision or impact that the driver is aware of. The driver airbag did not deploy. The incident occurred on October 4, 2026, at about 11:14 PM, shortly after the driver refueled at a gas station and was heading toward the highway. The airbag tore open the dashboard panel and cracked the windshield from the inside where the bag struck the glass. The driver brought the vehicle back to the gas station and it was towed. It has not been driven since. Safety risk: The sudden deployment startled the driver and the cracked windshield reduced visibility while the vehicle was moving. Anyone in the passenger seat would have been struck at close range. Recall history: This vehicle received the Recall 174 / NHTSA 18V-137 airbag control unit remedy (ACU main wiring harness installation, part 91700-4R100-QQH) at a Hyundai dealer in September 2025, at about 305,800 miles. The deployment occurred about 13 months and 18,400 miles later, at 324,243 miles. Warning signs: No airbag warning light or other warning appeared before the deployment. The vehicle was serviced at a Hyundai dealer about one month earlier (oil change and multi-point inspection), and no airbag or restraint-system problem was reported. Inspection: The vehicle is at a Hyundai dealer and is available for inspection. We have asked that the airbag control unit, airbag module, and stored crash data be preserved. A case has been opened with Hyundai Motor America. As of this report, the vehicle has not been inspected by the manufacturer, police, or an insurer, and no dealer has confirmed the cause. Cause: UNKNOWN. Our best assessment is an electrical fault in the airbag control unit or its wiring, which received recall work in 2025.

NHTSA ID

11769008

Incident

Oct 4, 2026

I was driving down the road going the speed limit and all of a sudden it felt like I hit a brick wall my car staked out and I was stuck in the middle of the road for about 20 minutes and finally I got it to start and drove home it did it again 2 months later

NHTSA ID

11762026

Incident

Apr 11, 2025

I had taken my Sonata to Mike Miller Hyndia in Peoria,I'll and they agreed to do the recall although they had my vehicle for two weeks. They did not service it and when I picked it up they said I had to drive it till the service engine light come on. I was driving it five days later and heard a loud noise and car started malfunctioning I was stuck in a middle of a intersection and I had to push vehicle off road. I broke my right hand in this process and I have also lost my job I am very concerned why they did not service it after they agreed too and sent me off in it in that condition ..The car is currently parked and unsure what to do with it ..

NHTSA ID

11760651

Incident

Aug 24, 2026

The vehicle suffered an internal connecting rod bearing failure, a known manufacturing defect affecting the Theta II GDI engine. The failure was explicitly diagnosed via the manufacturer - specific OBD-II fault code p1326 Knock Sensor Detector System. This defect causes sudden engine stalling poses an immediate risk of catastrophic engine failure or fire while driving. Hyundai Motor America has denied financial reimbursement for the required engine repair because the work was completed by an independent shop and third-party arbitration deadline (BBB Auto Line) communicated to me. The manufacturer is actively refusing to remedy an acknowledged safety defect.

NHTSA ID

11757692

Incident

Jul 6, 2026

On the freeway at night when headlights and back lights quit working. Got off freeway and were able to temporarily fix it. A few months later while parked in driveway and not in use for a couple of days, lights came on without our knowledge and drained our battery. Neighbor alerted us to the situation.

NHTSA ID

11756748

Incident

Aug 10, 2026

Some Hyundai vehicles may be equipped with a parking distance warning (PDW) sensor(s) that may trigger various DTCs and display warning messages on the instrument cluster, resulting in the PDW sensor(s) failing to detect nearby objects or triggering multiple false alarms. This condition may be a result of external damage to the PDW sensor membrane or sensor cover from rock chips or road debris, a collision, or previous vehicle repairs or modifications.

Some vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin outlines the combustion chamber cleaning procedure for vehicles diagnosed with this condition. All internal combustion engines consume some engine oil during normal operation, depending on driving conditions and mileage, and this procedure should only be performed when deemed necessary based on inspection and diagnosis of the vehicle as outlined in TSB 26-EM-015H, Engine Oil Consumption – Inspection & Repair Guidelines, or the latest revision.

Certain vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin provides the inspection and repair procedures for vehicles exhibiting this condition. All internal combustion engines consume engine oil as part of normal engine operation. Oil consumption rates may vary based on mileage, operating conditions, driving habits, and maintenance history. Hyundai recommends following the prescribed maintenance schedule and periodically checking the engine oil level using the dipstick to maintain proper engine oil level.

The warranty coverage for the clock spring has been extended to 15 years with unlimited mileage from the date of original retail delivery or date of first use. Refer to the warranty and service parts information outlined in this bulletin whenever clock spring replacement is required.

The warranty coverage for the clock spring has been extended to 15 years with unlimited mileage from the date of original retail delivery or date of first use. Refer to the warranty and service parts information outlined in this bulletin whenever clock spring replacement is required.

The warranty coverage for the clock spring has been extended to 15 years with unlimited mileage from the date of original retail delivery or date of first use for original & subsequent owners.