The defect
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.
The risk
Engine failure would result in a vehicle stall, increasing the risk of a crash.
The 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. Interim notifications were mailed to owners starting on October 8, 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.
NHTSA's own wording · initiated by MFR
Vehicles covered
| Model | Model years |
|---|---|
| Hyundai Sonata | 2011, 2012 |
Components: ENGINE
Model years in this recall
NHTSA complaints and the number of recall campaigns for each model year this recall covers.
| Model | Year | Complaints | Recalls |
|---|---|---|---|
| Hyundai Sonata | 2011 | 3,378 | 14 |
| Hyundai Sonata | 2012 | 1,558 | 8 |
Other engine recalls in 2015
4 of the 863 recall campaigns reported to NHTSA in 2015 concerned the engine; Hyundai Motor America filed 205 campaigns in all.
| 15V720000 2 Nov 2015 | McNeilus Truck & Manufacturing, Inc. |
| 15V195000 1 Apr 2015 | Mitsubishi Fuso Truck of America, Inc. |
| 15V095000 19 Feb 2015 | Bombardier Recreational Products Inc. |
NHTSA recalls (public domain) · all recalls of 2015