162 – Bearing Wear may result in Engine Seizure – 2013-2014 Hyundai Sonata & Santa Fe Sport

NHTSA Campaign Number: 17V226
Manufacturer Hyundai Motor America
Components ENGINE AND ENGINE COOLING
Potential Number of Units Affected 572,000

 

Bearing Wear may result in Engine Seizure

Bearing wear may result in the engine seizing, increasing the risk of a crash.

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2013-2014 Sonata and Santa Fe Sport vehicles.

Machining errors during the engine manufacturing process may cause premature bearing wear within the engine.

 

Remedy

Hyundai will notify owners, and dealers will inspect the engine, replacing the engine short block, as necessary, free of charge.

The recall began June 2017.

Owners may contact Hyundai customer service at 1-800-633-5151.

Hyundai’s number for this recall is 162.

 

Notes

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.

 

Check if your Hyundai has a Recall

 

---

Date: June 08, 2017 

Attn: Dealer Principal/General Manager/Service Manager/Parts Manager

Subject: Recall 162: 2013-2014 Sonata/Santa Fe Sport 2.0 & 2.4L GDI Engine Inspection (REMEDY NOT AVAILABLE)

 

Update

• The engine inspection procedure is currently being finalized and will include a new Engine Noise Inspection Tool (PN: G1XTD CP001).
• All dealers will receive an initial shipment of one (1) tool on Friday, June 9th, 2017.
• Sample tool image:

HMA is making preparations to implement the recall remedy.  Further communication and a Technical Service Bulletin will be provided when available.

 

Affected Vehicles

Hyundai Motor America is conducting a safety recall to inspect, and if necessary, replace the engine assembly in:

• All Model Year 2013 and 2014 Hyundai Sonata vehicles equipped with 2.0 liter and 2.4 liter gasoline direct injection (GDI) engines manufactured at Hyundai Motor Manufacturing Alabama
• Certain Model Year 2013 and 2014 Hyundai Santa Fe Sport vehicles equipped with 2.0 liter and 2.4 liter gasoline direct injection (GDI) engines

 

Description

The engines in these vehicles may contain residual debris from factory machining operations, potentially restricting oil flow to the main bearings and leading to premature bearing wear.  Over time, a bearing may fail and the vehicle could lose power while in motion.  Indications of a worn connecting rod bearing include:

1. Knocking noise from the engine
2. Reduced power and/or hesitation
3. Illumination of the “Check Engine” warning lamp
4. Illumination of engine oil pressure warning lamp

 

Service Action

• The final inspection procedure is currently being developed. In the interim, if customers notice an abnormal knocking noise from their engine, they are encouraged to seek service at their local Hyundai dealer as soon as possible.
• For customers or any used vehicles in dealer inventory that are currently experiencing an issue related to the engine:
• 2013-2014 Sonatas – Dealers should follow the existing Sonata Engine Warranty Extension TXX3 procedure described in Technical Service Bulletin (TSB) #16-01-SSS.
• 2013-2014 Santa Fe Sport – Dealers should follow the standard engine warranty process or contact Warranty Prior Approval (PA) for vehicles that are outside the engine warranty parameters.
• Customers currently experiencing engine issues should not continue to drive their vehicles.
• Customers should be placed in a Service Rental Car (SRC) while engine parts are ordered and repairs are performed.
• Used vehicles in dealer inventory that are currently experiencing an issue related to the engine should not be sold or test driven until repaired.
• For customers not experiencing an issue related to their engine:
• Customers should be advised that Hyundai is currently developing the remedy for the recall and Hyundai will notify all owners beginning in May, 2017. Customers can check Hyundai’s Recall 162 website for updates: hyundaiusa.com/campaign162
• Affected VINs are posted on WebDCS> Service Tab> Uncompleted Campaign VIN Listing –Retailed. Dealers may use owner information provided for the purpose of conducting and performing this recall campaign, and for no other purpose.
• Refer to the below Customer FAQ.

 

Customer Notification

Manufacturers are required to notify consumers of a recall on their vehicle within 60 days of filing a recall notice, even without a final repair procedure. Hyundai plans to notify all owners of the vehicles described above beginning in May, 2017.

 

Thank you for your prompt attention to this important safety matter and continued commitment to taking care of Hyundai customers.

 

Hyundai Motor America

---

Date: June 23, 2017 

Attn: Dealer Principal/General Manager/Service Manager/Parts Manager

Subject:Recall 162: 2013-2014 Sonata/Santa Fe Sport 2.0 & 2.4L GDI Engine Inspection

 

Affected Vehicles:

Hyundai Motor America is conducting a safety recall to inspect, and if necessary, replace the engine assembly in:

• All Model Year 2013 and 2014 Hyundai Sonata vehicles equipped with 2.0 liter and 2.4 liter gasoline direct injection (GDI) engines manufactured at Hyundai Motor Manufacturing Alabama (HMMA).
• Certain Model Year 2013 and 2014 Hyundai Santa Fe Sport vehicles equipped with 2.0 liter and 2.4 liter gasoline direct injection (GDI) engines manufactured at Kia Motor Manufacturing Georgia (KMMG) and HMMA.

 

At Initial Launch:

• Ensure your dealer has received the Engine Noise Inspection Tool (PN: G1XTD CP001)
  • Applicable to both Recall 162 and Recall 132
  • An initial shipment of one (1) tool was sent to all dealers on June 09, 2017 at no charge
  • A subsequent shipment was sent to some dealers the week of June 19, 2017 based on affected campaign vehicle volume, at no charge
  • Dealers may order additional tools beginning early July, 2017
• Review the Recall 162 Technical Service Bulletin (TSB) #17-01-047 published on June 23, 2017
  • Refer to Hyundaitechinfo.com
• Update your GDS Mobile tablet
  • Samsung Galaxy Note 2014 Edition 10.1 or S2 models with latest software as of June 24, 2017
  • Software must be updated daily or the inspection application will not function
• Certified Pre-Owned (CPO) vehicles previously de-certified due to open Recall 162 are eligible to be re-certified
  • A vehicle may be re-entered into CPO inventory status once all applicable recalls are completed, as long as it meets all other CPO eligibility guidelines

Please review this document in its entirety for information on the service, parts, and customer handling process.

 

Hyundai Motor America

---

Customer FAQ

 

Q1:  What is the problem?

A1:  The engines in these vehicles may contain residual debris from factory machining operations, potentially restricting oil flow to the main bearings and leading to premature bearing wear.  Over time, a bearing may fail and the vehicle could lose power while in motion.  Indications of a worn connecting rod bearing include:

1) A knocking noise from the engine that increases in frequency as the engine rpm increases 2) Reduced power and/or hesitation

• Illumination of the check engine light in the instrument cluster
• Illumination of engine oil pressure warning lamp

If the vehicle continues to be driven with a worn connecting rod bearing, the bearing can fail, and the vehicle could stall.

 

Q2:  When will owners be notified?

A2:  Owners will be mailed notification letters beginning in May, 2017.

 

Q3:  Can the recall service be performed now (prior to receiving notice)?

A3: The final inspection procedure is currently being developed.  In the interim, if customers notice an abnormal knocking noise from their engine, they are encouraged to seek service at their local Hyundai dealer as soon as possible.

 

Q4:  If a customer had this repair previously completed, how can they be reimbursed?

A4:  Customers can contact the Hyundai Customer Care Center at 1-855-671-3059 for additional information regarding their vehicle and the prior engine replacement for which they are seeking reimbursement.

 

	Key Contact Information
Dealer Support	Contact Information	Description
Techline	1‐800‐325‐6604	Vehicle Technical Support for Hyundai Dealer Technicians
Warranty HELPREP Line	1‐877‐446‐2922	Warranty Claim questions for Hyundai Dealers
Warranty Prior Approval (PA) Center	1‐844-371-3808	Warranty Prior Approval (PA) Center for Hyundai Dealers
Xtime Technical Support	Support@xtime.com 1‐866‐984‐6355	Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes
Customer Support	Contact Information	Description
Hyundai Customer Care Center (Recall / Campaign Questions)	1‐855‐671‐3059	Customer questions or concerns related to recall or service campaigns
Hyundai Recall / Campaign Website	www.hyundaiusa.com/campaign162	Updated information related to the specific recall or service campaign
Hyundai Customer Care Center (General Questions)	1‐800‐633‐5151	Customers general questions, non–campaign related
Hyundai Roadside Assistance	1-800-243-7766	Hyundai Roadside Assistance

 

	Key Reference Information
Name	Source
Campaign Central	Consolidated repository of recall and service campaign info.  Located on the service tab homepage in www.HyundaiDealer.com
Car Care Scheduling (Xtime) – Tutorials	www.HyundaiDealer.com > Service > Dealer Resources > Documents Library > Car Care Scheduling
Car Care Scheduling (Xtime) – Recall Appointment Notification	1.     Log into Xtime 2.     Under the menu at the top left, select ‘CONFIGURE’ 3.     Under the dealership tab, click “EMAIL COMMUNICATION” 4.     Slide the toggle to “ADVANCED” 5.     Populate as many e-mails as desired in the “PARTS DESK EMAIL FIELD”
Parts – Campaign Parts Management (CPM) Procedure	As applicable; www.HyundaiDealer.com > Parts > Documents Library > Campaign Parts Management
Service Rental Car (SRC) Program	www.HyundaiDealer.com > Service tab
Technical Service Bulletin (TSB)	www.HyundaiDealer.com > Service tab > Hyundai Tech Info
Uncompleted Campaign VIN Listing	A listing of vehicles is located on WEBDCS> SERVICE tab> select UNCOMPLETED CAMPAIGN VIN LISTING – Dealer Stock and Retailed.
Recall Campaign Website	www.hyundaiusa.com/recall www.hyundaiusa.com/campaign162
NHTSA Website	www.safercar.gov

 

---

Table of Contents

 

Recall Overview ………………………………………………………. 3

Readiness Checklist ………………………………………………… 3

TSB ………………………………….. see Hyundaitechinfo.com

Inspection Process ………………………………………………….. 4

Parts …………………………………………………………………………. 7

Dipstick & Oil Filter ………………………………………………. 7

Oil ……………………………………………………………………….. 7

Engine Sub-Assembly and Service Kit(s) ………………… 8

Tools Required ……………………………………………………….. 10

Online Scheduling …………………………………………………… 11

Customer FAQ …………………………………………………………. 14

Contact / Reference Information …………………………… 15

---

.

Recall Overview

 

The engines in certain 2013-2014 model year Sonata (YF) and Santa Fe Sport (AN) vehicles equipped with 2.4L and 2.0T GDI engines may contain residual debris from factory machining operations, potentially restricting oil flow to the main bearings and leading to premature bearing wear. Over time, a bearing may fail and the vehicle could lose power while in motion. Indications of a worn connecting rod bearing include:

1. Knocking noise from the engine
2. Reduced power and/or hesitation
3. Illumination of the “Check Engine” warning lamp
4. Illumination of engine oil pressure warning lamp

 

The service process consists of an inspection and dipstick, oil and oil filter replacement.  If the vehicle does not pass the inspection, the dealer will replace the engine.  See the “Inspection Process” section for additional information.

 

Service/campaign tools are required. See the “Tools Required” section for additional information.

 

Hyundai Motor America will notify all owners of the affected vehicles to visit their local Hyundai dealers for inspection.  Final Customer Notification letters of the recall are scheduled to begin mailing beginning in early July 2017 (interim letters were mailed in April/May).

 

.

Readiness Checklist

 

• Review the Recall 162 Technical Service Bulletin (TSB) #17-01-047
  • Refer to Hyundaitechinfo.com
• Update your GDS Mobile tablet
  • Samsung Galaxy Note 2014 Edition 10.1 and S2 models with latest software
  • Software must be updated daily or the inspection application will not function
• Ensure your dealer has the Engine Noise Inspection Tool
  • Applicable to both Recall 162 and Recall 132
• Ensure your dealer has the other tools required as listed in the “Tools Required” section of this document:
• Have Service Rental Car (SRC) vehicles available and a process in place
  • Note: If the customer needs an engine replacement, be prepared to place them in a SRC.  Once ready to submit the warranty claim for the rental, ensure the repair claim is in the system and the number of days are justified with a timeline
• Prepare for the volume of customers requiring an inspection and dipstick, oil, and oil filter replacement  The VIN list for eligible customers in your market area is available on WebDCS > Service tab > Uncompleted Campaign VIN List
• Conduct a resource assessment to support the recall; people, time, facility, parts, and adjust accordingly. Remember that you still need to accommodate your regular customers as well as customers from other recent recalls/campaigns
• Shop Capacity – Instructions to set up appointment scheduling through Xtime has been sent to your service managers. See “Online Scheduling” section for additional details

 

.

Inspection Process

 

The Technical Service Bulletin (TSB) #17-01-047 for this recall was published on June 23 2017.  Refer to Hyundaitechinfo.com for the latest TSB.

 

Follow the inspection procedure outlined in the bulletin to perform the engine noise inspection, and if necessary, to replace the engine.  The following is an overview outlining the service and parts process.  Refer to the additional sections referenced within this document for details.

Inspection and dipstick, oil and oil filter replacement:

• Will take 0.7 hours
• Utilizes the GDS mobile tablet – Samsung Galaxy Note 2014 Edition 10.1 and S2 models with latest software as of June 24, 2017
• Utilizes the Engine Noise Inspection Tool
• Data will be uploaded to HMA electronically for use in confirming test results and part order by VIN See “Pass” or “No Pass” below:

 

Pass

√ Upload test results

√ Install rod assembly-oil level (dipstick), oil filter and oil (conventional Quaker State 5w30) √ Verify oil level

√ See Parts section for additional details

 

(See “No Pass” on next page)

No Pass
√  Place the customer in a Hyundai Service Rental Car (SRC) √  Do not order the engine until approved by Warranty Prior Approval (PA) √  Do not inform the customer that they will need a new engine until approved by Warranty Prior Approval (PA) √ Immediately upload test results o Tests will not upload if mobile tablet is not connected to a Wi-Fi network; please ensure tests are uploaded to avoid any delay in PA review √ PA request will be auto created and saved in WebDCS PA Request screen. Dealer will be required to edit PA request if needed and submit to PA for review o In certain instances where multiple tests are performed, duplicate requests may be auto created. Please ‘Delete’ the duplicate or any unneeded requests to remove it from PA list √ PA will review the audio file within 1 business day to ensure validity of the test
PA Review: Replace Engine	PA Review: Re-Test
√ If there are no anomalies in the audio files, PA will approve the PA request and advise dealer to move forward with engine replacement	√ If there are anomalies in the audio files, PA will request for the test to be redone along with recommendations to ensure results are more conclusive
√ Part numbers o Engine sub-assembly part o Service kit(s) o VIN required √ Refill oil – synthetic (Quaker State 5w30) ü See Parts section for additional details	√ Dealer will perform re-test √ Dealer will upload re-test results and update related PA request √ PA will review the re-test
	PA Re-Test Review: Pass	PA Re-Test Review: No Pass
	√ PA agent will update and close out the PA request √ Follow initial “Pass” scenario above	√ If result is a No Pass and anomalies in the audio files are still present, PA agent may have dealer perform test again with other recommendations or perform normal engine diagnosis worksheet √ If result is a No Pass and there are no anomalies in the audio file, PA agent will approve PA request and advise dealer to move forward to “Replace Engine” scenario
	√ Note: If result is a Pass but the customer continues to complain about abnormal engine noise, PA agent will advise dealer to perform normal engine diagnostic procedures

 

Additional Inspection Process Notes:

If the Engine is NOT Running:

• The test cannot be performed
• Submit PA request
  • Attach RO and completed engine diagnostic worksheet
  • Video may be required of a walk-around and an attempt to start the vehicle o Tear down and/or photos of the oil pan contents may be required
• Contact PA at 1-844-371-3808 for any questions

 

If Additional Part Replacement Is Needed:

• If additional parts are needed to repair the vehicle and are covered under warranty, submit a claim. PA is not required.
• If ancillary parts are required to be replaced as part of the inspection or repair, or if the parts needed to repair the vehicle are no longer covered under warranty, contact PA for approval PRIOR to performing the repair

 

Comebacks AFTER Recall Completion:

• Regardless of mileage, contact PA for all vehicles that have previously passed an inspection using the GDS or have had the engine replaced under the recall, and are now experiencing engine related issues
• PA will provide next steps

 

.

Parts

 

Dipstick & Oil Filter

• Dipstick, oil, and oil filter are required replacement when vehicle passes the Recall 162 inspection
• Dealer submits order in WebDCS using noted part number from the TSB 

Oil

• Inspection: Quaker State 5w30 conventional motor oil
• Engine Replacement: Quaker State 5w30 synthetic motor oil

  

***Dealers are encouraged to maintain adequate stock of both motor oil SKU’s based on their  requirement needs and lead-time from order to delivery, which is typically 5 days. ***

 

How to Reorder:

Dealers Enrolled in Hyundai Lubricants Program	Dealers NOT in Hyundai Lubricants Program
√ Order through e-serve or	√ Order form located on HyundaiDealer.com>Service Homepage>Campaign Central>Recall162 folder
√ Contact Shell Customer Service at 1-877-350-7030	√ E-mail to: customercare-us@shell.com  OR √ Customer Service telephone  1-877-350-7030
√ Quaker State Advance Durability 5w30 Conventional motor oil (24 quart container) SKU: 550023662 Full synthetic motor oil (6 quarts) SKU: 550036717   ***Orders placed before 4:00 CST are processed the same day with delivery within five (5) days***

 

Engine

Engine Orders

• Warranty Prior Approval (PA) is required to place order
  • VIN will be required
  • “No Pass” data upload needs to be completed
  • Engine replacements will be subject to claim reviews including review of audio files and parts account debit
  • Dealers should hold the old engines for 20 days from the warranty payment date
• Dealer submits an E-Order in WebDCS using the VIN and the noted part numbers from the TSB #17-01-047

Note: Order will be automatically converted to a SPL order

• List of ETAs will be posted when parts are available on HyundaiDealer.com > Service Homepage> Campaign Central> Recall 162 folder
• Urgent cases must be escalated to the Hyundai Parts Hotline at 1-800-545-4515
• Orders related to Recall 162 cannot be upgraded to XVOR

 

Shipping of Parts

• Engine and the service kit(s) will be shipped via ground in separate packages. The Dealer will be able to identify the parts by the “QQH” at the end of the part number
• The method of shipping will be DDS or LTL
• Shipping and handling fees will be waived for this Recall. Check the warranty box when placing the order so that any handling fees are deferred for 30 days.  Handling fees will not be applied if the warranty claim arrives within 30 days of the ship date
• The Packing List and Packing Labels for all packages will display the last 7 digits of the VIN
• On the Packing List, the last 7 digits of the VIN will appear in the Dealer Bin Location field

 

 

Sample Packing List

 

Sample Label

 

 

***Dealers can email any questions related to parts ordering and/or shipment to

HyundaiPartsHotline@MobisUSA.com and receive a response within 24 hours. ***

 

.

Tools Required

 

• GDS Mobile Samsung Galaxy Note 2014 Edition 10.1 or S2 models with latest software as of June 24, 2017
  • Required to perform Recall 162 and Recall 132 inspection procedure
  • Perform latest GDS Mobile update daily to access the GDS inspection application

• Hyundai G1XTDCP001 Engine Noise Inspection Tool
  • Required to perform Recall 162 and Recall 132 inspection procedure
  • An initial shipment of one (1) tool was sent to all dealers on June 09, 2017
  • A subsequent shipment was sent to some dealers the week of June 19, 2017 based on affected campaign vehicle volume, at no charge
  • Additional orders will be available through the parts ordering process in WebDCS o Sample picture below:

• Hyundai 09314-3Q100 Torque Wrench Socket
• Hyundai 09353-2B000 Injector Combustion Seal Ring Installer
  • Required to perform the engine sub-assembly replacement
  • Sample pictures below:

 

 

.

Online Scheduling

 

How to Set Capacity and Lead Times for a Recall Service

1. Navigate to the ‘Configure’ page after logging into the Xtime Business Portal.

 

2. Click on the ‘Resources’ tab, click on ‘Campaigns’, and select ‘All Time’ to view all available recalls.
3. As new recalls are launched with remedy available, they will be automatically added to the Xtime catalog, and configured with a default value of “NL” (No Limit) for each day of the week.

 

4. The Service Manager can sort, search, and set the Lead Time, and Daily Capacity Limits for individual campaigns.

 

5. Appointment takers will have visibility to the designated lead time when booking appointments, so if a recall-related repair is added to an appointment the service date is advanced by the lead time.

 

6. Consumers will also have visibility to the required lead time when booking appointments.

 

7. In addition to managing individual recalls, the Parts and Service Manager should input their email addresses so they can be notified when a recall appointment has been made, to confirm parts and time are available.

 

 

.

Customer FAQ’s

 

Q:  What is the problem?

A:  The engines in these vehicles may contain residual debris from factory machining operations, potentially restricting oil flow to the main bearings and leading to premature bearing wear.  Over time, a bearing may fail and the vehicle could lose power while in motion.  Indications of a worn connecting rod bearing include:

1. A knocking noise from the engine that increases in frequency as the engine rpm increases
2. Reduced power and/or hesitation
3. Illumination of the check engine light in the instrument cluster
4. Illumination of engine oil pressure warning lamp

If the vehicle continues to be driven with a worn connecting rod bearing, the bearing can fail, and the vehicle could stall.

 

Q:  What is done during the recall service at the dealer? 

A:  Hyundai dealers will inspect the engine and replace the dipstick, oil and oil filter.  If necessary, they will replace the engine.  This will be performed at no cost to owners.

 

Q:  How long will it take for the inspection? 

A:  The inspection procedure should take no longer than one hour.  If it is necessary to replace the engine, the repair time will depend on parts availability and the dealer’s workload.  Dealers can arrange for a loaner vehicle as needed.

 

Q:  What if I need my vehicle towed to the dealership? 

A:  Most vehicles are still covered under the 5 year Roadside Assistance program. Customers can contact Roadside Assistance to have their vehicle towed at 1-800-243-7766.

 

Q:  What if I have already paid for repairs related to this recall? 

A:  Customers can go online to www.HyundaiUSA.com/campaign162 to submit a reimbursement claim. Specific details including copies of the required documents (repair order, proof of payment, proof of ownership, etc.) will be required. Please keep in mind your recall must still be completed by the dealer.

 

Q:  When will owners be notified? 

A:  Final Customer Notification letters of the recall are scheduled to begin mailing beginning in early July 2017 (interim letters were mailed in April/May).

 

Q:  What if I previously had my engine inspected under the recall, and now my engine is experiencing the symptoms listed in the recall? 

A:  Although prior inspections may not have found issues with your vehicle, if you experience engine knocking, unusual engine noise, or illumination of the oil lamp, please contact your Hyundai dealer to schedule an appointment to have an engine inspection performed.

 

.

Contact / Reference Information

 

	Key Contact Information
Dealer Support	Contact Information	Description
Parts	HyundaiPartsHotline@MobisUSA.com 1-800-545-4515	Parts ordering hotline
Techline	1‐800‐325‐6604	Vehicle Technical Support for Hyundai Dealer Techs
Warranty HELPREP Line	1‐877‐446‐2922	Warranty Claim questions for Hyundai Dealers
Warranty Prior Approval (PA) Center	1‐844-371-3808	Warranty Prior Approval (PA) Center for Hyundai Dealers
Xtime Technical Support	Support@xtime.com 1‐866‐984‐6355	Assistance with Car Care Scheduling
Customer Support	Contact Information	Description
Hyundai Customer Care Center (Recall / Campaign Questions)	1‐855‐671‐3059	Customer questions or concerns related to recall or service campaigns
Hyundai Recall / Campaign Website	www.hyundaiusa.com/campaign162	Specific recall or service campaign information
Hyundai Customer Care Center (General Questions)	1‐800‐633‐5151	Customers general questions, non‐campaign related
Hyundai Roadside Assistance	1-800-243-7766	Hyundai Roadside Assistance

 

	Key Reference Information
Name	Source
Campaign Central	Consolidated repository of recall and service campaign info.  Located on the service tab homepage in www.HyundaiDealer.com
Car Care Scheduling (Xtime) – Tutorials	www.HyundaiDealer.com > Service > Dealer Resources > Documents Library > Car Care Scheduling
Car Care Scheduling (Xtime) – Recall Appointment Notification	1.     Log into Xtime 2.     Under the menu at the top left, select ‘CONFIGURE’ 3.     Under the dealership tab, click “EMAIL COMMUNICATION” 4.     Slide the toggle to “ADVANCED” 5.     Populate as many e-mails as desired in the “PARTS DESK EMAIL FIELD”
Parts – Campaign Parts Management (CPM) Procedure	As applicable; www.HyundaiDealer.com > Parts > Documents Library > Campaign Parts Management
Service Rental Car (SRC) Program	www.HyundaiDealer.com > Service tab
Technical Service Bulletin (TSB)	www.HyundaiDealer.com > Service tab > Hyundai Tech Info
Uncompleted Campaign VIN Listing	WEBDCS> SERVICE tab> select UNCOMPLETED CAMPAIGN VIN LIST
Recall Campaign Website	www.hyundaiusa.com/recall www.hyundaiusa.com/campaign162
NHTSA Website	www.safercar.gov

 

---

Technical Service Bulletin	GROUP RECALL	NUMBER 17-01-047
	DATE	MODEL(S)
	JUNE 2017	2013-2014MY SONATA (YF) SANTA FE SPORT (AN)
SUBJECT: SONATA / SANTA FE SPORT GDI ENGINE INSPECTION / REPLACEMENT (RECALL CAMPAIGN 162)

 

*IMPORTANT

*** Retail Vehicles Only ***  Dealers must perform this Recall Campaign whenever an affected vehicle is in the shop for any  maintenance or repair.    When a vehicle arrives at the Service Department, access Hyundai Motor America’s “Warranty  Vehicle Information” screen via WEBDCS to identify open Campaigns.

 

Description: Certain 2013-2014 model year Sonata (YF) and Santa Fe Sport (AN) vehicles equipped with 2.4L and 2.0T GDI engines require an inspection to confirm normal operation.  The inspection procedure will help indicate if the engine is operating normally or if an excessive connecting rod bearing wear condition in the engine crankcase may be present.  If the vehicle continues to be driven with a worn connecting rod bearing, the bearing can fail and the vehicle could stall.

 

Perform the Inspection Procedure on Page 5 to inspect the engine for noise. The noise inspection will result in a PASS, NO PASS, or RETEST.

 

Follow the corresponding Service Procedure based on the noise inspection results:

Inspection Result	Service Procedure
PASS	Page 8
NO PASS	Page 9
RETEST	Page 9

 

Applicable Vehicles: 

2013-2014MY Sonata (YF) vehicles produced at HMMA with 2.4L and 2.0T GDI engines (VIN begins with 5NP…)

2013-2014MY Santa Fe Sport (YF) vehicles produced at KMMG with 2.4L and 2.0T GDI engines (VIN begins with 5XY…)

 

NOTICE

The inspection process will require the use of a Tablet-based GDS Mobile system (Samsung  10.1 or S2) with the latest GDS Mobile update. PC-based GDS is not supported.   Verify the latest GDS Mobile update is installed each day by connecting the GDS Mobile to  the internet via WiFi and launching the GDS application. Update the GDS Mobile software if  needed.   The verification process must be performed each day the GDS Mobile is used to complete  this Campaign. The Special Inspection application will not function until it’s verified.

 

GDS Mobile Information:                                                                                

Update Version	Comment
Perform GDS Mobile update daily	See above Notice

 

SST Information:                                    

Engine Noise Inspection Tools were shipped to each dealer. Additional tools can be ordered through the PDC.

 

Description	Tool Part #	Image	Comment
Engine Noise  Inspection Tool	G1XTD-CP001		For noise inspection
Torque Wrench Socket	09314-3Q100		Only needed if engine replacement required.   Refer to TSB 10-FL-019 for the detailed usage instructions
Injector Combustion Seal Ring Installer	09353-2B000

 

NOTICE

DO NOT disassemble or modify any components of the engine inspection tool. If any part of the  tool is damaged, a new one should be ordered. Individual components of the tool cannot be ordered.

 

Parts Information:

Inspection Results / Procedure	Model	ENG	MY	Part Name	Part Number	QTY
PASS (Inspection with Oil Level Rod, Oil, and Oil Filter Replacement)	Sonata / Santa Fe Sport	ALL	ALL	Rod Assembly-Oil Level	26611-2G050QQH	1
	Sonata / Santa Fe Sport	ALL	ALL	Oil Filter	26300-35503	1
NO PASS (Inspection and 2.4L / 2.0T Engine Replacement)	Sonata	2.4L	13MY	Engine AssemblySub	21101-2GK50QQH	1
			14MY		21101-2GK70QQH
		2.0T	13MY		21101-2GK60QQH
			14MY		21101-2GK80QQH
	Santa Fe Sport	2.4L	13MY		21101-2GK01QQH
			14MY		21101-2GK02QQH
		2.0T	13MY		21101-2GK03QQH
			14MY		21101-2GK04QQH
	Sonata / Santa Fe Sport	2.4L	13-14 MY	Service Kit 1	21111-2GK50QQH 21111-2GK60QQH	1
		2.0T
	Sonata	2.4L/ 2.0T	13-14 MY	Service Kit 2	21111-2GK70QQH	1
	Santa Fe Sport	2.4L
	Santa Fe Sport	2.0T		Service Kit 3	21111-2GK80QQH

 

 

NOTE:

1. Select the appropriate campaign parts for the corresponding inspection results and the applicable vehicle and engine type.
2. For each vehicle that requires an engine replacement, a total of (2) service kits should be ordered depending on the vehicle and engine type. Do not order (3) service kits for a single VIN.
   • Service Kit 1 + Service Kit 2 OR
   • Service Kit 1 + Service Kit 3

 

Warranty Information:

Model	Op. Code	Operation	Op Time	Causal Part	Nature Code	Cause Code
Sonata / Santa Fe Sport (2.4L, 2.0T)	71CA21I0	Inspection with Oil, Oil Filter, and Oil Level Rod Replacement	0.7 M/H	See notes below	Q75	ZZ1
Sonata 2.4L (non-Turbo)	71CA21R0	Inspection, 2.4L Engine Long Block, Service Kits	8.5 M/H
Sonata 2.0T (Turbo)	71CA21R1	Inspection, 2.0T Engine Long Block, Service Kits	8.8 M/H
Santa Fe Sport 2.4L (FWD, nonTurbo)	71CA21R2	Inspection, 2.4L Engine Long Block, Service Kits	8.5 M/H
Santa Fe Sport 2.0T (FWD, Turbo)	71CA21R3	Inspection, 2.0T Engine Long Block, Service Kits	8.7 M/H
Santa Fe Sport 2.4L (AWD, non- Turbo)	71CA21R4	Inspection, 2.4L Engine Long Block, Service Kits	8.9 M/H
Santa Fe Sport 2.0T (AWD, Turbo)	71CA21R5	Inspection, 2.0T Engine Long Block, Service Kits	9.1 M/H

 

NOTE: Submit Claim on Campaign Claim Entry Screen.

• If any part(s) are found in need of replacement while performing Recall Campaign 162 and the affected part(s) are still under warranty, please submit a separate claim using the same Repair Order used for the Recall Campaign 162. If the affected part(s) are out of warranty, request a Prior Authorization # for goodwill consideration prior to completing the Campaign.
• For Causal Part #, use the parts catalog with the vehicle’s VIN to find the appropriate part number for the ENGINE-ASSY-SUB (engine long block).

 

Inspection Procedure:

1. The Inspection Procedure will consist of preparing the vehicle and then performing an inspection using the “Special Inspection” function of the GDS Mobile application.

 

• Obtain the latest GDS Mobile update daily. The GDS Mobile must be connected to the internet via WiFi daily to confirm the latest software update is installed or the application will not function.
• Connect the GDS VCI to vehicle DLC.
• VCI should be updated with latest version and paired with GDS Mobile.  Open the GDS Mobile App.
• Swipe up on the “More” tab at the bottom of the screen.
• Select the “Special Inspection” function.

2. Prior to inspection, the engine should be in a satisfactory running condition.
   • Engine oil level should be in the normal range (shown at right).
     • Use Quaker State 5W-30 conventional type engine oil to adjust the oil level if necessary.
   • Engine should idle normally.

 

If the engine is running poorly, follow any related diagnosis and repair prior to performing this inspection procedure.

 

3. Prepare the vehicle as follows before beginning the inspection:
   • All accessories off, including the audio system.
   • A/C must be off.
   • Engine coolant temperature above minimum temperature 85°C (185°F).
     • If the engine is cold, then warm the engine before testing.
   • Open the driver’s front window.

 

4. Prepare the vehicle and Engine Noise Inspection Tool as follows:
   1. Remove the oil level rod assy (engine oil dipstick).
   2. Check for interference between the dipstick tube and the intake manifold.

 

Adjust the dipstick tube to create clearance between the tube and manifold if necessary.

 

• Insert the adapter (A) into the oil level gauge tube (dipstick tube).
• Attach the clip (B) to the hood latch.
• Connect the stereo jack (C) to the GDS Mobile headphone jack.
• Feed the inspection tool through the open driver’s front window.

 

5. Follow the selection menus and on-screen prompts of the “Special Inspection” function to complete the Inspection Procedure.
   • Do not tap, pinch or kink the Engine Noise Inspection Tool during the test.

NOTICE

For quality assurance purposes, an audio file of the engine noise and the inspection results will be sent to HMA.

 

6. After the Inspection Procedure is complete, the application will display PASS, NO PASS, or RETEST.
   • This information will be sent to HMA when the GDS Mobile Tablet is connected to a WiFi network.

 

For PASS, NO PASS, or RETEST proceed to the appropriate Service Procedure in the following pages that correspond to the Inspection Results.

 

Inspection Result	Service Procedure
PASS	Page 8
NO PASS	Page 9
RETEST	Page 9

 

NOTICE

The GDS can store a maximum of 5 tests while the device is offline (disconnected from Wi-Fi). In order to perform further tests, connect the GDS to Wi-Fi and select the “Send All Pending” button to send the pending test results to HMA.

 

---

 

.

Service Procedure (Inspection Results = PASS)

1. If the inspection results in a PASS, then an engine replacement is NOT required.

 

2. Replace the engine oil (4.8 quarts) and oil filter.
3. Replace the current Oil Level Rod Assembly with the new campaign part.
   • Remove and discard the existing Oil Level Rod Assembly (engine oil dipstick).
   • Install new ORANGE handle Oil Level Rod Assembly (P/N 26611-2G050QQH)

Note: Replace the dipstick only if the current dipstick’s handle is yellow.

 

4. Start the engine and allow it to run for 10 seconds. Then adjust the engine oil level to near the “F” mark as shown in the picture.
   • Use Quaker State 5W-30 conventional type engine oil to complete this step.
   • Do not overfill.
5. The Service Procedure for Inspection Results = PASS is now complete.

---

 

.

Service Procedure (Inspection Results = RETEST or NO PASS)

1. If the inspection results in RETEST or NO PASS, perform the following steps to remove any sources of interfering noise and then retest the vehicle.

 

• a) Is there any abnormal noise that’s intermittent or does not follow engine RPM?
  • If so, check for the source of the noise from other components such as the exhaust system, engine mounting points, lines and harnesses. Adjust as necessary.
• b) Is there any abnormal noise that could be from engine-driven accessories?
  • If necessary, remove the serpentine belt to isolate all belt-driven accessories to the engine assembly. Limit engine run time during any inspection.  Adjust as necessary.

 

NOTICE

After  completing steps a) and b) above to remove any sources of interfering noise, perform the Inspection Procedure again. If re -inspection results in a PASS:  o Perform Service Procedure for Inspection Results = PASS on Page 7. If re -inspection results in a RETEST: Perform Service Procedure for Inspection Results = RETEST or NO PASS again. If re -inspection results in a NO PASS: Follow the procedures in step c) below to request a Prior Authorization #.

 

• c) If the re-inspection still results in a NO PASS after retesting the vehicle:
  • Do not inform the customer that they will need a new engine until approved by Warranty Prior Approval (PA).
  • Do not order the engine until approved by Warranty Prior Approval (PA).
  • Immediately upload the test results for PA review.
  • If the tablet is not connected to a Wi-Fi network at the time of the test, the result will not be automatically uploaded. Please ensure test results are uploaded as inspections are performed to avoid any delay in PA review.
  • Go to the WebDCS PA Request screen. The PA request will be auto-created and saved. Edit the PA request if needed and submit to PA for review.
  • PA will review the audio file within 1 business day to ensure validity of the test.
  • If there are no anomalies in the audio files, the PA agent will approve the PA request and advise the dealer to proceed with the engine replacement.
  • If there are anomalies in the audio files, the PA agent will request for the test to be performed again and for the test results to be uploaded for review.

 

2. Follow the published Service Information from the applicable Shop Manual to remove the Sub Engine Assembly from the vehicle.

 

Shop Manual Section Location: 

Engine Mechanical > Engine And Transaxle Assembly > Engine And Transaxle Assembly > Repair Procedures

 

NOTICE

Record the audio station presets (XM, AM, FM, etc) prior to disconnecting the battery.

 

3. The shipped contents of the service replacement “QQH” Sub Engine Assemblies differ from traditional service replacement engines and must be specially prepared prior to installation.

 

NOTICE

Some components from the existing engine must be transferred to the new engine. Be careful to preserve the vehicle’s original parts. Install all of the newly supplied contents of the applicable Service Kits.

 

4. For 2.4L with ULEV / FED emissions only All 2.4L engines with part numbers in the Parts Information section are produced with the exhaust manifold studs configured for SULEV / CAL emissions package.

2.4L vehicles with a ULEV / FED emissions package require 2 exhaust studs to be relocated on the new engine and 1 exhaust stud transferred over from the old engine.

• Use a commercially available stud removal tool or use the double-nut technique to complete this step.

 

5. Remove and reinstall the engine Knock Sensor from the old engine to the new engine.

(Knock Sensor Fastener)

Tightening torque: 21Nm (15.5lb-ft)

 

6. Follow the published procedure outlined in TSB 10-FL-019 to remove and reinstall the following GDI high pressure fuel system components from the existing engine to the new engine:
   1. GDI High Pressure Pump
   2. Fuel Injectors (4)
   3. Fuel Delivery (Rail) Pipe

The corresponding Service Kit 2/3 will supply the required new parts per TSB 10-FL-019 to complete the transfer of the above existing parts.

CAUTION

Follow TSB 10-FL-019 carefully and replace the following newly supplied parts from the Service Kit 2/3: Mounting flange O-ring (for High Pressure Pump) O-rings, Backup Rings, Washer Seals, Combustion Seal Rings, and clips (for Fuel Injectors) Fuel Pipe (between High Pressure Pump and Delivery Pipe)  In addition, Service Kit 2/3 includes (1) Exhaust Pipe Gasket.  Install this new gasket when attaching the front and center muffler assemblies together during the engine installation.

 

7. Reconnect and reinstall the engine front harness as shown.
   • Be sure to properly route the opposite end of the harness end down towards the front of the engine.

 

8. Install newly supplied Oil Level Guide and Oil Level Rod Assemblies to the new engine.

• Be sure to install the NEW Oil Level Guide (dipstick tube) to the NEW engine.
• Install the NEW Oil Level Rod Assembly (dipstick) to the NEW engine.

 

NOTICE

The engine is shipped without oil  and engine oil must be added at a later step.

 

9. Follow the published Service Information from the applicable Shop Manual to reinstall the Sub Engine Assembly from the vehicle.

Shop Manual Section Location: Engine Mechanical > Engine And Transaxle Assembly > Engine And Transaxle Assembly > Repair Procedures

NOTICE

Be sure to replace the following newly  supplied parts from the applicable  engine Service Kit: Oil Level Rod & Oil Level Guide Assy. Intake Manifold Gaskets (4) Exhaust Manifold Gasket Fuel Tube Assembly (2.0T Only) Turbo Oil Feed Hose & Pipe (2.0T Only) Turbo Oil Drain Gasket (2) (2.0T Only) Oil Drain Gasket (2.0T Only) Gasket (2)

 

NOTICE

If the torque converter has moved from the fully inserted position, carefully push inward and rotate the torque converter until the converter is recessed approximately 9/16 – 5/8” (14 -16 mm) into the transaxle case when reinstalling the automatic transaxle.

 

10. Connect the (2) oil coolant hoses between the oil cooler and the water temperature control assembly.
    • Fill the cooling system with 50/50 ~ 70/30 (Water/Anti-Freeze) coolant mixture.
11. Use Quaker State 5W-30 full synthetic type engine oil to fill the engine crankcase.
    • Add 5.8 quarts for the initial dry fill of the engine.
    • With the fuel system disabled temporarily, crank the engine for several seconds to prime the lubrication system prior to starting the engine.
12. Start the engine to warm it up and begin the cooling system air bleeding process.
    • During this time, check for any leaks.
    • After the engine has warmed up to normal operating temperature, turn the engine off, wait a few minutes, and then  adjust the engine oil level to near the “F” mark as shown in the picture.

 

13. When all fluids have been fully filled and all work quality checks are completed:
    • Set the customer’s audio station presets.
    • Relearn the Steering Angle Sensor using the GDS.
    • Reset the engine adaptive values using the GDS.
    • Perform a short road test to relearn the initial adaptive values.  Verify normal vehicle drivability.

 

14. The Service Procedure for Inspection Results = NO PASS is now complete.

NOTICE

DO NOT damage the short block casting / starter motor mounting tab as described in TSB #17-01-046 for Campaign 132 applicable vehicles. Engine blocks for vehicles affected by this TSB # 17-01-047 (Campaign 162) should not be damaged.

 

---

https://static.nhtsa.gov/odi/rcl/2017/RCRIT-17V226-1988.pdf

 

---

https://static.nhtsa.gov/odi/rcl/2017/RIONL-17V226-0728.pdf

 

---

https://static.nhtsa.gov/odi/rcl/2017/RCMN-17V226-8749.pdf

 

---

https://static.nhtsa.gov/odi/rcl/2017/RCMN-17V226-4739.pdf

 

---

https://static.nhtsa.gov/odi/rcl/2017/RCAK-17V226-3810.pdf

 

---

https://static.nhtsa.gov/odi/rcl/2017/RCMN-17V226-5668.pdf

 

---