NHTSA Complaint #11512791 — 2020 HYUNDAI SONATA HYBRID

ENGINE issue reported to NHTSA

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Complaint Details

ODI Number 11512791
Vehicle 2020 HYUNDAI SONATA HYBRID
Component ENGINE
Date of Incident
Date Filed
Mileage N/A miles
Crash No
Fire No
Injuries 0
Deaths 0
Vehicle Towed No
State IL

Consumer Description

I have had the same issue 3 separate times related to the coolant system. The first time happened January 2021. I was driving on the highway and I noticed that when the car switched from electric to fuel a large plume of white smoke came out of the exhaust and then the engine overheating message started. I checked the coolant tank and it was completely empty. I managed to get some coolant in the car and get to my destination. I checked the coolant tank again and all the coolant that had been put in was gone. I immediately had the car towed to the dealer. They found the issue was a leak near the muffler and eventually replaced that and other gaskets. In May 2022, I noticed again that when I switched from battery to fuel on acceleration that there was a plume of smoke coming out of the exhaust and my coolant was very low. Brought to the dealer and they confirmed again there was a leak but this time with the EGR cooler and associated parts. In December 2022, I had just gotten an oil change from the dealer and they gave me a clean check up. The next evening I was on the highway again and I received the engine overheating message. I was able to get to the dealer the next morning after refilling the coolant twice. I provided them with the previous paperwork from the other two fixes. They confirmed again that the leak was happening with the muffler so they replaced more parts. In all I have for over 3 months fixing the same issue. I posted on Reddit to see if others have had the same issue and slowly more and more people with the same model year or the year after are reporting the same problems as seen https://www.reddit.com/r/Hyundai/comments/uhx7lf/coolant_leak_through_exhaust_on_2020_sonata_hybrid/?utm_source=share&utm_medium=web2x&context=3 Every time it's happened it's been covered under warranty but my concern is that it happens outside of the warranty and I will be on the hook for an expensive repair or forced to a new vehicle.

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