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Recall - "Connecting Rod Wear may Result in Engine Stall"

844K views 3K replies 341 participants last post by  flemmons 
#1 ·
I got an email from the DOT that there is an imminent recall for 2011-12 2.0 & 2.4 Sontatas regarding connecting rod bearing failures.

There is a VIN lookup here:

https://vinrcl.safercar.gov/vin/

It says that there is no remedy yet and that we will be getting a letter from Hyundai. The tone of the DOT email was that you should should not delay in getting this fixed because it is a significant safety hazard, so I suppose Hyundai will be getting on this ASAP.
 
#3 ·
No email for me, but my car is affected according to the VIN number. Not sure what to do since there's no fix. :confused:
 
#5 ·
From reading through it, it looks like we'll take our cars to the dealer... they'll listen for a knock.. if no knock we'll just get an extended warranty.. if they hear a knock we'll get a new short block?

I guess I'll be satisfied with a warranty extension, at least now I wont need to trade in my car before the 5/60 is up (2nd owner).
 
#6 ·
http://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/UCM486031/RCLRPT-15V568-9490.PDF

http://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/UCM486679/RCAK-15V568-8864.pdf

Report Receipt Date: SEP 10, 2015
NHTSA Campaign Number: 15V568000
Component(s): ENGINE
Potential Number of Units Affected: 470,000
All Products Associated with this Recall

Vehicle MakeModelModel Year(s)

  • HYUNDAISONATA2011-2012
    Details

    2 Associated Documents


    Manufacturer: Hyundai Motor America

    SUMMARY:

    Hyundai Motor America (Hyundai) is recalling certain model year 2011-2012 Sonata vehicles manufactured December 11, 2009, to April 12, 2012 at Hyundai Motor Manufacturing Alabama and equipped with either a 2.0 liter or 2.4 liter Gasoline Direct injection engine. In the affected vehicles, metallic debris may not have been fully removed during manufacturing of the engine crankshaft. If the debris was not completely removed, oil flow may be restricted through the connecting rod bearings, causing connecting rod damage. A worn connecting rod bearing will produce a metallic, cyclic knocking noise from the engine and possible engine failure. CONSEQUENCE:

    Engine failure would result in a vehicle stall, increasing the risk of a crash. REMEDY:

    Hyundai will notify owners, and dealers will inspect the vehicles and replace the engine assembly, as necessary, free of charge. Additionally, Hyundai Motor America will increase the warranty for the engine sub-assembly (short block) to 10 years/120,000 miles for both original and subsequent owners of 2011 and 2012 Sonatas manufactured at Hyundai Motor Manufacturing Alabama equipped with 2.0 liter and 2.4 liter Gasoline Direct injection engines. An interim notification will be mailed by November 2, 2015. A second notification will be mailed when parts are available. Owners may contact Hyundai customer service at 1-855-671-3059 or by visiting www.HyundaiUSA.com/Campaign132. Hyundai's number for this recall is 132. NOTES:
 
#9 ·
Im curious what action Kia will be taking. Seems like Hyundai bears all responsibility since they made the engines.
 
#10 ·
Looks like my 2012 is affected.

Question, will they be adding another 10 years and 120K to the warranty once the engine is replaced.
 
#13 ·
So they will give an extended warranty (for what that's worth given how uber nit picky they have been so far) but the issue is engine failure that could cause accident or worse. So if they don't hear a rod knock you just get passed on? Doesn't seem like a solution honestly as to whether or not you hear a noise does not indicate engine stability....
 
#35 · (Edited)
Yes. They are stating that if the defect is present it can lead to catastrophic engine damage, which obviously can lead to serious injury or death. It sounds like they are literally "banking" on having sufficient time from the onset of this blockage caused wear to have vehicles successfully inspected, and once past the apparent initial single dealer "test", to put the onus on owners to successfully monitor for any possible future occurrence, and to then safely bring it in again, and in time. We should all hear at least some loud enough level of "knock", but what is loud enough, and what about the average "romantic" driver (Q: "What kind of car do you have?" A: "A blue one").

Hey, this really could put a dB crimp in some folks cruisin' musical enjoyment.

Unless what ever test they are administering is able to detect which engines are in fact 'meaningfully' impure with an _ extremely low false negative rate, this seems like a grossly negligent plan. I say this in the non-expert belief that the fragments could exist for days, months, or years without causing externally detectable symptoms and pass their single point test, until some future point, or points, when sufficient blockage(s) occurs to start to cause enough damage to then either be detected with a "knock test", or if not corrected in time, seize the mill. I hope this is not the case.

Do external tests have the ability to "hear" that well to be able to reasonably insure the safety and sanity of all? While not a perfect analogy, some arterial-sclerosis exams can yield results that seem manageable until a break away(s) occur(s), travels, blocks, and really, really ruins ones day.

It's clear that, at least so far, many 2011 and 2012's are not seizing, and it's a shame that 'the manufacturing process' went askew for Hyundai, but without further information, this still somehow seems way wrong.
 
#16 ·
#18 · (Edited)
Red Sled is affected as well. She was born in may 2010 and my Vin pulls up the campaign from the site.

Good news bc my engine has been burning oil for the last year.

Will pair nicely with the new tranny from 2 years ago.

Thanks Hyundai!
 
#23 ·
I drive my Santa Fe 99% of the time now. Imma get mine!

Red Sled is a garage queen these days...although ironically I did drive it today to try out the new steering gear I installed.
 
#25 ·
Yes there is a slight knick at idle. Reported that to dealer so it should be in the service history.

Question I have in the back of my head....Santa Fe also has the same engine. Wonder if they are affected too?
 
#28 ·
During the manufacturing of the engine, excess metal debris may have been generated during factory machining operations, possibly contaminating the connecting rod oiling passages and restricting oil flow to the connecting rod bearings and increasing the potential of premature bearing wear. A worn connecting rod bearing:
 Will produce a metallic, recurring knocking noise from the engine that increases in frequency as the engine rpm increases.


4-5+ yr old engine, metal debris from machining.. engine run how crank rotations for 50,000+ miles, how many oil changes ??

I worked with kid who was tasked to rebuild a Toyota 7M Turbo Supra motor,, block, crank and misc come back from machine shop,, he did not wash the first part.. put it together,, started it,, didnt run too long before it was knocking.. he did it 2x I think, then they ended up giving customer an engine I think,, (been around 21yr ago)
 
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#29 ·
I still hope Optima, Sorento, and Sportage owners dont get shafted in this. This is a much bigger problem than just the Sonata.
 
#31 ·
#39 ·
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