2021 Hyundai Sonata Hybrid: engine overheating

Filed Sep 18, 2026 · Fuel system · AZ

The vehicle was brought to an authorized Hyundai dealer to have Service Campaign TBH and 94B completed. These campaigns were explicitly designed to prevent known mechanical defects (cracked EHRS assemblies and high-voltage battery errors). The software patches failed to protect the vehicle. The physical hardware has now catastrophically failed exactly as predicted by the campaign, resulting in extreme engine overheating and a physically swollen high-voltage battery pack. Hyundai is refusing to cover the cascading physical damage caused by their own failed campaign remedy, leaving me with an active safety and fire hazard. FUEL/PROPULSION SYSTEM" and explicitly state that the vehicle experienced an unchecked thermal event due to an ineffective corporate software update (Campaign TBH / 94B). All documents I have supporting this will not fit in this upload limit.

Filed Mar 9, 2025 · Engine · CA

Overheated engine alarm came on while I was on the freeway on a rainy day. Vehicle was towed to Hyundai dealership in which service technician found that the part preventing water from leaking into the muffler was broken. Hyundai dealership has ordered replacement part but it is on backorder. The broken part that needed replacement has been on backorder for close to a month and there is not an ETA of when the part will be received. Prior to the overheated engine alarm going off, cold air was blowing out of the vents even when the heat option was selected.

Filed Mar 5, 2025 · Engine · OH

Coolant system leaks in to the engine or exhaust system, which is evident in white smoke exhaust and coolant level dropping. In my situation, I required an entire container of coolant to perform a daily commute, and the reservoir was empty by the time I made it to the dealership. Car is rendered undrivable due lack of coolant and engine overheating. My car was in the dealership repair facility for 6 weeks awaiting parts on back order due to nationwide shortage. A technical service bulletin has been issued for this manufacturer defect (23-EM-009H). Cost of repairs was roughly $2,300.

Filed Jan 13, 2025 · Engine · MI

EHRS Coolant Leak- problem started in [XXX] when engine overheated. The weather in Michigan in inclement and being stranded in the intense cold can lead to loss of life. I had it towed to a Hyundai dealership that was unable to find the problem and in attempting to "find a leak" used the incorrect dye, necessitation transferal to another more competent dealership where the problem was diagnosed and was fixed with a replacement part. In December 2023 a TSB 23-EM-009h was issued by Hyundai describing this problem and issuing a part (Center Muffler). I was not informed and the problem recurred. currently this is the third episode and Hyundai after paying 95% of the previous cost, now only agrees to pay 85% and denies reimbursing me for the car rental. Warning lights appeared with all 3 occurrences. Hyundai should have issued a recall to obviate this. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Aug 20, 2024 · Engine · IL

Coolant leak acting like blown head gasket. Coolant was leaking into the exhaust system. Defective EHRS system

Filed Feb 13, 2024 · Engine · IN

Initially had loss of cabin heat. Later, vehicle randomly overheated. Repair shop replaced EGR due to finding confidant buildup of water/coolant mix. Within one week, problem returned. Dealer notified me that while replacing another part they found a TSB for coolant leakage into exhaust that was consistent with my issue. After research, it is clear that this is a widespread failure and should be a recall.

Filed Dec 19, 2023 · Engine · PA

My vehicle's heat stopped working suddenly. A short while later, I received and overheat warning for the engine. I had to stop repeatedly on the shoulder of the highway to allow the car to cool so I could move it to a safe space at the next exit. The dealer has confirmed that the coolant was leaking into the exhaust system and burning up. This resulted in white smoke, inconsistent power, and a stumbling engine when it would switch over from the electric to the gas engine. This problem comes on suddenly and can leave you in a very bad situation since there is no warning to this problem. The dealer reported my car had no coolant left in it which is why it was frequently overheating. I have read about this problem on many online forums and it seems to be very common in this car. Hyundai needs to create a fix.

Filed Dec 4, 2023 · Engine, Transmission · OH

While driving, engine alerted that it was overheating. Pulled over and coolant was very low, so I refilled it and then while driving to my family's garage to use the lift, saw white exhaust smoke. Took it to an independent mechanic, and in the ~10 mile trip there, over a quart of coolant had been burned off. He was able to reproduce the issue. No issues with the engine operation, it runs well and efficient, no check engine light. Mechanic found that a coolant line runs to the middle of the exhaust system and that this seems to be the issue. Other owners seem to have reported this same issue with this same model and roughly the same year, in which the muffler assembly needs replaced due to coolant leaking into the exhaust. Only prior issue was less warm air out of the vents for the previous week or so, but no other issues or warnings.

Filed May 12, 2023 · Engine · 32,547 miles · MI

The contact owns a 2021 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, he received an alert indicating that the engine was overheating and to pull over. No warning lights were illuminated. The contact then veered to the side of the road and waited approximately 15 minutes before restarting the vehicle. The vehicle was then taken to the dealer where the vehicle remained. The vehicle was diagnosed, and it was determined that the engine coolant bypass valve needed to be replaced. The vehicle had not yet been repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 32,547.

Filed Apr 3, 2023 · Engine · IL

The cabin heater started blowing cold air in February. One shop said the car was low on coolant and topped it off. I made an appointment to take the car to a dealer because it's still under warranty (<37k miles). I had to wait 3 weeks. A few days before my appointment, the cabin heater started blowing cold air, again. There is no indicator that the coolant is low. The engine temperature is one of a dozen gauges one can scroll thru, but the "engine overheating" warning started flashing before I thought to check the temperature guage. Smoke came out of the exhaust and, once stopped, from under the hood. There was a risk of an engine fire and/or permanent damage to the engine.

Filed Jan 23, 2023 · Engine · OH

Very loud car alarms sounded, e.g., it sounded like a something like a red alert in an old Star Trek episode. warning light indicated engine overheated, extreme exhaust/smoke bellowed out from rear of car while decelerating on highway exit ramp. My wife and I were inside the car during this event. This event happened on 5 pm EST December 9 at Hamilton Avenue exit on Ohio 126 Cross County Highway (Ronald Reagan Highway) in the Cincinnati metropolitan area. Had to park car within one mile. I had the car towed to the nearest dealer after it had cooled for 1 +hour. I was afraid the engine was going to explode or catch fire as I was decelerating. The dealer suggests the heat exchanger needed replacement. However, after 45 days, Hyundai has not shipped the heat exchanger that I have been made aware. I am concerned this event may be likely to reoccur and with resulting potential injuries to the occupants inside.