2020 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.

Car was taken to dealership for inspection. Upon inspection, it was determined that the fuel tank had expanded and pushed towards the heat shield, and expanded upward pushing up the back seats of vehicle. It was determined to not safe to drive. Manufacturer contacted me and offered a buyback. Upon their offer of a buyback, it was determined that I would owe the manufacturer approximately $2,000. I have requested that they fix it, and they have refused to give me the paperwork I requested about the car's condition and fixability. I am in the process of negotiating and am filing this complaint for the record.

NHTSA ID

11753819

Incident

Apr 21, 2026

Fan motor fuse box quit working and ac/heat no longer operational. First time was around October 21, 2025.

NHTSA ID

11751988

Incident

Jul 16, 2026

My vehicle while driving, it is jerking and shaking. When I come to a stop, the cars rpms go up and down while the car is shaking. When I pressed the gas pedal to accelerate the car will not accelerate as normal and the car jerks as I’m driving it. The RPMs rev up and down without any pressure placed on the gas pedal. The check engine light came on.The miles per hour only allows me to put one digit. I wanted to clarify that the problem is occurring anywhere between 0 mph to 65 mph when these the car jerks and shakes and the RPMs go up and down without me pressure on the gas pedal.

NHTSA ID

11749650

Incident

Jul 10, 2026

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the low oil warning light illuminated. The contact added oil to the engine. The dealer was made aware of the failure. The vehicle was taken to the dealer several times, and several oil consumption tests were performed. The contact was informed that the oil consumption test results did not indicate excessive oil consumption. The failure reoccurred. The vehicle was taken to the dealer, and the contact was informed that the oil level was a half quart low. The contact was informed that no repair options were available. The manufacturer was not made aware of the failure. The failure mileage was approximately 80,000.

NHTSA ID

11749550

Incident

Mar 10, 2026

Mileage

80,000 mi

The seat belt latches do not latch or will spontaneously unlatch. This has been a problem for about 4 years. I have checked for recalls and not seen any for my car. I will check with the dealer but have tried vacuuming the latches without effect. I have never experienced anything like this in any previous vehicle. The warning buzzer lets me know when the seatbelt unlatches, but I seriously doubt the belt would hold in case of an accident.

NHTSA ID

11749402

Incident

Jul 1, 2022

No air coming from cabin, upon further inspection found melted multifuse with melting terminal pin area in fuse box. No prior signs of warning, leaving vehicle without operable air condition for high temperatures.

NHTSA ID

11746626

Incident

Jun 24, 2026

The contact owns a 2020 Hyundai Sonata. The contact stated that while driving at an undisclosed speed with the family inside the vehicle, a strong gasoline odor was inside the cabin of the vehicle. The contact stated that the fuel gauge was lowering quickly. Upon exiting the vehicle, the contact became aware of gasoline gushing heavily out of the vehicle onto the ground. Two months prior to the failure, the vehicle was taken to an authorized dealer due to an abnormal sound coming from the rear of the vehicle. The contact received notification of NHTSA Campaign Number: 25V796000 (Fuel System, Gasoline); however, the recall repair was not performed because the part for the recall repair was not yet available. The vehicle was towed to a dealer where it was determined that the gas valve was not properly fixed. The abnormal sound in the rear of the vehicle was due to the fuel expansion, which caused the tank to rupture and melt. The melting caused the fuel pump to expand and melt, causing structural damage to the body of the vehicle. The structural expansion caused the rear passenger seats to raise up. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 89,000.

NHTSA ID

11745596

Incident

Jun 17, 2026

Mileage

89,000 mi

My 2020 Hyundai Sonata 2.5L is experiencing excessive engine oil consumption. At approximately 88,063 miles, Great Lakes Hyundai documented that the engine oil level was 1.30 quarts below full after an oil-consumption check. The dealer topped off the oil, submitted photos and a prior-authorization/goodwill request to Hyundai, and Hyundai declined assistance. The dealer recommended combustion chamber cleaning with an estimate of $979.76. I am concerned that this excessive oil consumption could lead to sudden engine damage, loss of power, stalling, or engine failure if the oil level drops between checks. The vehicle is only a 2020 model year, and this level of oil consumption appears abnormal. I am also concerned about possible emissions/catalytic converter damage from oil burning.

NHTSA ID

11743992

Incident

May 18, 2026

The National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driver‑side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN), that have been identified in U.S. vehicles following prior crashes, theft, or non‑certified airbag replacements. These inflators are not approved for use, may rupture during deployment, and have caused serious injuries and fatalities. Please see attached announcement, provided by NHTSA, for more details.

The National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous driver’s-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN). These inflators were not supplied, approved, or authorized by the vehicle manufacturers and have primarily been found in vehicles that previously experienced a crash and underwent airbag replacement using non-genuine parts. These dangerous inflators have ruptured during deployment, posing a serious risk of injury or death due to metal fragments entering the vehicle cabin. To date, Hyundai is aware of three people who have died while driving a Hyundai vehicle with one of these substandard replacement airbag inflators that deployed in what likely would have been a survivable crash. NHTSA has issued a public advisory urging vehicle owners and service professionals to have vehicles inspected if there is reason to believe that a non-genuine replacement airbag may have been installed. Vehicles with salvage or rebuilt titles, prior airbag deployments, or unknown repair histories may present a higher risk. NHTSA strongly cautions against self-inspection by vehicle owners and recommends inspection by trained technicians.

Some 2019MY and newer vehicles equipped with a front view camera may illuminate certain warning lights and trigger DTC C272246 fault code for the front camera. In the following cases, the front camera auto-calibration range may be exceeded while driving: • If the front camera is not properly installed and is completely or partially detached. • In case of excessive changes affecting the vehicle's balance (e.g., loading excessively heavy cargo in a specific location of the vehicle, or significant under-inflation of the tires). • Specific road conditions affecting the vehicle's balance (e.g., excessive road crown) This TSB provides instructions on how to service the vehicle when the front camera related warning light(s) are triggered due to system out of calibration (DTC_C272246).

Some Sonata (DN8, DN8A) vehicles may have DTCs P218100, P2181F0, and/or P2181F1 (Cooling System Performance) set in the Engine Control Module, resulting in an illuminated Check Engine warning lamp. Follow the procedure in this TSB to replace the Integrated Thermal Management (ITM) module and update both the Engine Control Module (ECM) and Transmission Control Module (TCM) if applicable. Follow the flowchart in this TSB to update the appropriate modules.

This 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.

This bulletin provides information related to the changes introduced in the 2025 1st Navigation Map and Software Update. The changes may vary depending on vehicle type, model, and navigation system as described in this TSB.