I am filing a formal safety complaint regarding severe vehicle instability, structural safety risks, and dealership workmanship negligence following a federal safety recall engine replacement. My vehicle received a new engine block under a federal campaign at a local dealership. Immediately upon picking up the vehicle, the front suspension developed a severe, heavy mechanical knocking and bumping noise over road surfaces under 20 mph, making the vehicle structurally unstable and hazardous to drive. To perform this engine swap, technicians were physically required to drop the front subframe framework and disconnect the lower suspension linkages and steering column components. The dealership is actively trying to deflect safety accountability for an assembly error. They issued a new estimate attempting to charge me over $3,200 to replace the entire front strut and rear shock assembly, claiming it is a 'pre-existing wear-and-tear' issue due to mileage. However, I hold the dealership's official Multi-Point Vehicle Inspection report from when the car was first dropped off for the engine failure three weeks prior. In that mandatory baseline safety report, their own technician thoroughly checked the under-carriage and officially marked my 'Shock Absorbers / Suspension' and 'Steering Gear Box / Linkage and Boots' as PASSED with green checkmarks. This objective paper trail proves the front chassis was tight, silent, and structurally safe before the repair. The safety hazard was introduced solely during the dealership's engine reassembly. The Service Manager explicitly refused to step out of his office to address this safety complaint, and the dealership released a compromised, structurally unsafe vehicle to a consumer. I request a formal federal safety investigation into this branch's safety compliance regarding recall implementation.
2016 Hyundai Sonata engine problems
463 complaints (63% of all complaints for this car). Typical mileage when it fails: 80,000. 1 crash reported.
- owner complaints
- 463
- of this car's complaints
- 63%
- typical mileage
- 80,000
- crashes
- 1
- recalls
- 0
Which part fails
- Engine: oil/lubrication5
- Engine: oil/lubrication: sump/tank1
- Engine: oil/lubrication: seals/gaskets1
At what mileage
Complaints by mileage at the time of the problem.
Hyundai Sonata engine problems in other years
Specific symptoms reported on the 2016 Hyundai Sonata engine
Phrases found in the owners' own descriptions, so one complaint can mention several symptoms.
Engine failure 147Check engine light 142Oil consumption 135Knocking 94Stalling 89Loss of power 53Misfire 28Won't start 10Overheating 7
Related recalls
No recalls on record for this model year.
Related investigations
Loss of Motive Power
the federal safety agency 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 under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitionersâ 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. ODIâs evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to the federal safety agency 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. Â 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 the federal safety agency's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, the federal safety agency does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing the federal safety agencyâs reasons for denial of the petition will be published. The reference numbers for the complaints to the federal safety agency 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
DP22003
Engine Fires
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
EA21003
What 2016 Hyundai Sonata owners say
Most recent owner complaints, unedited.
The contact owns a 2016 Hyundai Sonata. The contact stated that while getting an oil change, the contact was informed that the oil pan was empty. The contact could not recall seeing leaks or making changes to the oil change routine. An independent mechanic informed the contact of an engine recall regarding excessive oil consumption. The contact was referred to the dealer. The contact had the oil inspected twice more and was informed of low oil levels on each occasion, but there were no leaks or burning oil odors. The vehicle was taken to the dealer, where it was confirmed that no open recall was associated with the VIN. The dealer replaced several sensors; however, the contact was unable to specify which sensors were replaced. The dealer stated that the vehicle needed to be driven until the next oil service, at which point the oil would be changed and the engine sealed. The contact was referred to the federal safety agency hotline to file a safety complaint. The manufacturer was notified of the issue, and a case was escalated. The failure mileage was approximately 70,000.
The contact owns a 2016 Hyundai Sonata. While the contact's daughter was driving 55 MPH, the engine seized. The contact stated that the failure had occurred while the contact's two minor grandchildren were inside the vehicle during the failure. The vehicle was towed to an independent mechanic. The vehicle was later towed to the dealer where it was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The manufacturer was contacted, and a case was filed. The contact was informed about the eligibility for the extended warranty under Campaign 953. The contact was informed that the repair was not covered under the extended warranty because the Campaign 953 was not completed. The failure mileage was approximately 60,436.
While driving on the freeway, the check engine light started flashing and the gas pedal became useless. This put the driver and the passenger of the car in massive danger as they could no longer accelerate on the freeway. Luckily, they were able to get off the freeway without causing an accident. Upon reading the code at an auto shop, they discovered that it was P1326 or a knock sensor issue. This malfunction caused the car to go into limp mode and put the passengers in serious danger. Several calls to the Hyundai Service Center were made yesterday (Saturday, October 3rd). However, not one was ever answered. They hope to be able to get the car to the dealership's service center as soon as possible, but the earliest appointment online is multiple weeks away. This same car was recently at the dealership service center for an internal engine oil consumption problem and thoroughly inspected. The car is up to date on all software and recalls. Even though a valve cover replacement fixed the oil consumption issue, the owners are now having even worse issues. This is the only car for a married couple who are both working and going to college full-time. This issue has been a severe complication to their scheduling, and they were put in harm's way on the freeway.
I am concerned that the engine may seize or stall without warning while driving, creating a risk of crash, injury, or death. The Theta II engine defect is known to cause engine seizure, stalling, and fire. Hyundai has denied warranty coverage based on mileage and second-owner status — both of which are explicitly prohibited as denial grounds under the Settlement — leaving me driving an unsafe vehicle.
The vehicle experienced a Theta II engine failure at under 57,830 miles while driving on northbound [XXX] near the [XXX] Parkway U-turn in [XXX]. The engine made a loud noise and lost power. I was able to coast to the far right side of the U-turn under the bridge. I called HERO (Austin's emergency roadside assistance). They responded, determined it was not a battery issue, and pushed the vehicle to the Southern Leisure Spa parking lot on the southbound side of the road. The vehicle was then towed. The vehicle is equipped with the KSDS (Knock Sensor Detection System) software update, installed as part of Hyundai's remedy for this known defect. Despite KSDS being installed, the engine failed due to connecting rod bearing wear, consistent with the documented Theta II defect. A Hyundai dealership confirmed KSDS was installed but denied the warranty claim, citing maintenance records. The vehicle is available for inspection upon request. The Theta II engine defect has been the subject of prior the federal safety agency investigations and Hyundai recalls. This complaint is filed to document another failure of the same defect in a vehicle with the manufacturer's remedy installed. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
The car died while going 70 on a highway with no warning signs. The car completely shut off and will not turn over or move at all.
Component & Inspection: Vehicle engine suffered connecting rod bearing failure and entered restricted P1326 "Limp Home Mode" (max 2,000 RPM). The vehicle is grounded and available for inspection at Bud Clary Hyundai in [XXX].Safety Risk: Sudden, unexpected loss of power occurred while driving, placing me and other drivers at immediate risk on public roads due to the vehicle's inability to maintain normal traffic speed or safely accelerate.Dealer & Corporate Confirmation: Active P1326 engine code is confirmed. Car has been held for 14 days. The franchise is violating federal settlement rules by explicitly refusing to execute the mandatory, free mechanical Bearing Clearance Test (BCT) unless I pay out-of-pocket fees.Inspection & Corporate Compliance Failure: Car was brought to the dealer on XXX. The service manager admitted in writing that they are withholding safety diagnostics to protect shop labor hours due to an automated computer flag regarding a clerical title brand discrepancy. Hyundai Corporate is actively enabling this violation; my case manager refuses to issue a manual compliance override for the safety test and is violating federal settlement terms by withholding my contractually mandated alternative transportation.Warning Lamps & Symptoms: Flashing Check Engine Light and limp home mode triggered instantly and unexpectedly on XXX. There were zero warning symptoms, messages, or abnormal noises prior to that date INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
My Sonata 2016 suddenly lit up the Check Engine icon, which was blinking. It is available for inspection request, as it's in the shop right now. Added 2 qts of oil just to be safe. Was hoping the light would go away in the morning. It didn't. The car was sputtering and jerking while I was attempting to get where I was going, so I drove a little slower so it wouldn't stall out, which would have caused someone behind me to crash into me if it stopped suddenly. My mechanic said it was engine failure, possibly due to oil burning. Hyundai Dealer told me there is no recall for this issue, but my mechanic said there had been. I was never notified of such, and when I called them, they said that there was no recall, and she acted like she had never heard of the problem. I find that amazing, since on your website, there are some 717 claims of the same problem.
My 2016 Hyundai Sonata (VIN: [XXX]) has a serious safety issue involving excessive engine oil consumption. The vehicle loses oil rapidly between changes and requires frequent top‑offs to avoid engine damage. This creates a risk of sudden engine failure while driving. The dealership, South Charlotte Hyundai (10518 Cadillac Street, Pineville, NC 28134), refused to perform Hyundai’s official oil‑consumption test. Instead, they told me to pay $750 for a combustion cleaning and stated it would not fix the underlying problem. They would not document the refusal or provide any testing. I contacted Hyundai Corporate multiple times: • May 21, 2026 – Executive Office complaint submitted • June 3, 2026 – Follow‑up sent • June 29, 2026 – Regional escalation sent My Hyundai case number is XXX. As of XXX Hyundai has not responded to any of my Executive Office or Regional escalations. Only Customer Care replied with a template denial and no investigation. I have been waiting over two months with no action from Hyundai Corporate. I am reporting this because the manufacturer has not addressed a safety‑related defect, the dealership refused required testing, and the vehicle continues to consume oil abnormally. I am requesting the federal safety agency’s assistance in documenting this defect and Hyundai’s lack of response. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Questions about the 2016 Hyundai Sonata engine
Does the 2016 Hyundai Sonata have engine problems?
Owners have filed 463 complaints about the engine of the 2016 Hyundai Sonata, 63% of all its complaints, more than any other problem.
At what mileage do 2016 Hyundai Sonata engine problems start?
The typical (median) mileage in owner complaints is 80,000 miles.
Was there a recall on the 2016 Hyundai Sonata engine?
There is no recall for this problem on this model year.
What year does the Hyundai Sonata have bad engine?
The Hyundai Sonata model years with the most engine complaints are 2011 (1,012 complaints), 2013 (776 complaints) and 2015 (650 complaints).
Other 2016 Hyundai Sonata problems
Electrical 89Transmission 59Brakes 47Lights 38Fuel system 35Steering 34Body 31Acceleration 30Airbags 21Driver assistance 17Visibility 11Seat belts 9Suspension 5Locks 4Seats 4Tires 3Wheels 2
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