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Recalls

5.4K views 18 replies 10 participants last post by  DarrenBach  
#1 · (Edited)
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.

    I know the hybrid is made in South Korea and not Alabama, but something to keep an eye on since it does use the 2.4.
 
#4 ·
I do realize the engines are different, (ours being Atkinson) and manufactured in different plants, but have to wonder if the early production ones utilized the same technology in clearing out the oil passages in the manufacturing process.
I am curious what caused a couple of these hybrid owners' engines to seize though, and if others have seized and they were just written off as neglect on the owner's part:
http://www-odi.nhtsa.dot.gov/owners/SearchResults?prodType=V&searchType=PROD&targetCategory=A&searchCriteria.model=SONATA+HYBRID&stats=1886001%2C0%2C0%2C14%2C3%2CSONATA+HYBRID&makeStats=&jsonBaseURL=%2Fdownloads%2Ffolders%2F&searchCriteria.model_yr=2011&searchCriteria.make=HYUNDAI&searchCriteria.prod_ids=1886001
One of the complaints exactly describes his hybrid's engine seizing due to improper lubrication, and Hyundai's lack of repair under warranty.
I wish the site would list the subsequent results that the complainant had with Hyundai if any at all.
 
#5 ·
One of the complaints exactly describes his hybrid's engine seizing due to improper lubrication, and Hyundai's lack of repair under warranty.

I wish the site would list the subsequent results that the complainant had with Hyundai if any at all.
We have a Hybrid seized up.. top end covered in mud... how would that be a Hyundai lack of lubrication.. the lack here is the oil turned to crap and did poor job of lubricating engine.. that owner fault, not Hyundai..
 
#6 ·
Of course if the owner didn't change the oil and it is proven that lack of maintenance was the cause of the seized engine then shame on that owner. But, what I am referring to is if the vehicle was maintained correctly and the engine seized because of the recall issue and it seized before this recall was announced, would Hyundai have just blamed the owner's maintenance practices and just not covered the repair and left the owner high and dry? The person who wrote that complaint doesn't mention if he/she had the required maintenance performed and no follow up is documented on that site.
 
#7 ·
#9 ·
A thread where the poster appeared to have trouble distinguishing the difference between an engine oil pump and a transmission oil pump. An engine oil pump failure would not have brought him into the shop for transmission (hybrid system failure) problems. A "hybrid system failure" alarm could be generated either by the electrical or mechanical side of the drivetrain.

What the poster did not disclose was his oil change frequency. Without that information, I don't take much stock in that entire thread's worth.
 
#10 ·
Finally a recall for this problem, too many years in the making unfortunately.
December 1, 2020 NHTSA CAMPAIGN NUMBER: 20V746000
Engine Damage May Cause Stall or Fire
A damaged engine can increase the risk of a fire or it can cause an engine stall, increasing the risk of a crash.

NHTSA Campaign Number: 20V746000
Manufacturer Hyundai Motor America
Components ENGINE
Potential Number of Units Affected 128,948
Summary
Hyundai Motor America (Hyundai) is recalling certain 2015-2016 Veloster, 2012 Santa Fe, 2011-2013 Sonata Hybrid, and 2016 Sonata Hybrid vehicles. The connecting rod bearings inside the engine may wear prematurely, which over time can result in engine damage.
Remedy
Hyundai will notify owners, and dealers will inspect the engine. If bearing damage is found, the engine will be replaced. Dealers will also install a software update containing a new Knock Sensor Detection System (KSDS). Repairs will be performed free of charge. The recall is expected to begin January 22, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 198.
 
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#13 ·
Remedy
Hyundai will notify owners, and dealers will inspect the engine. If bearing damage is found, the engine will be replaced. Dealers will also install a software update containing a new Knock Sensor Detection System (KSDS). Repairs will be performed free of charge. The recall is expected to begin January 22, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 198.
 
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#14 ·
Just got my 2nd letter today and it says to make an appointment which will take about an hour to check for bearing damage. If damage is found, then they will replace the engine, which will take about 10 hours.