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Recall 15V568000

Engine Knocking Noise And Failure

Recall Details

The engine during manufacturing may have retained metallic debris from the crankshaft. Presence of this metallic debris could cause engine noise and failure. Dealers will inspect and replace affected engines as necessary, and extend the warranty of the engine short block to 10 years / 120,000 miles free of charge to resolve the concern.

Our Quick Take

The engine may develop a knocking noise and could fail due to a manufacturing process allowing excessive metallic debris to remain after the crankshaft of the engine was manufactured and installed. This could result in the engine stopping and stalling, resulting in potential of a crash.

What Should You Do?

Recalls on your Hyundai must be performed by a Hyundai dealership. Hyundai will begin notifying known owners of affected vehicles in November 2015. If you do not receive a notification, but wish to check to see if your vehicle is included, please contact one of your local Hyundai dealers below. They will also check for any other uncompleted recalls on your vehicle. For best results, be prepared to provide your Vehicle Identification Number (VIN) to the service department consultant you speak with.

Affected Cars

Engine, September 10, 2015

Original Recall from the NHTSA

Manufacturer's Report Date
September 10, 2015
NHTSA Action Number
N/A
Potential Number of Units Affected
470,000
NHTSA CAMPAIGN ID Number
15V568000
Component
ENGINE
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.
Notify
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.
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Recall data provided by the National Highway Traffic Safety Administration