2019-2020 Hyundai Elantra, 2019-2021 Kona & Veloster NU 2.0L Atkinson Engine Inspection (Recall 203)

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April 28, 2021 NHTSA CAMPAIGN NUMBER: 21V301000

Improperly Heat-Treated Piston Oil Rings

A damaged engine may stall, increasing the risk of a crash. In addition, oil may leak onto hot exhaust components, increasing the risk of a fire.

 

NHTSA Campaign Number: 21V301

Manufacturer Hyundai Motor America

Components ENGINE

Potential Number of Units Affected 125,840

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2019-2020 Elantra, 2019-2021 Kona and Veloster vehicles equipped with 2.0L Nu MPI engines. The piston oil rings may not have been properly heat-treated, which could result in engine damage.

 

Remedy

Dealers will inspect and, if necessary, replace the engine, free of charge. In addition, Hyundai will deploy Piston Ring Noise Sensing System (PNSS) software. Owner notification letters were mailed August 24, 2021. Owners may contact Hyundai customer service at 1-855-371-9460.

 

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

 


Q&A

 

Q&A: Recall 203 – Nu Engine Piston Oil Ring

 

Q1: What is the issue?

A1: The engines in the subject vehicles may have been assembled using piston oil rings that were produced with inconsistent nitride heat treating by the piston oil ring supplier resulting in excessive oil ring hardness. Excessive hardness can cause chipping of the piston oil ring’s outer periphery, which could lead to abnormal scuffing of the engine’s cylinder bore. A damaged cylinder bore could create accelerated oil consumption, which may then cause abnormal knocking noise from the engine and/or illumination of the oil pressure warning light.

 

Q2: What are the affected vehicles?

A2: The subject vehicles include:

  • 55,838 model year 2019-2020 Hyundai Elantra vehicles equipped with 2.0-litre “Nu” MPI engines and produced from November 1, 2018 through July 6, 2020 by Hyundai Motor Company in South Korea for sale in the U.S. market.
  • 95,223 model year 2019-2021 Hyundai Kona vehicles equipped with 2.0-litre “Nu” MPI engines and produced from November 3, 2018 through September 1, 2020 by Hyundai Motor Company in South Korea for sale in the U.S. market.
  • 7,432 model year 2019-2021 Hyundai Veloster vehicles equipped with 2.0-litre “Nu” MPI engines and produced from November 2, 2018 through May 27, 2020 by Hyundai Motor Company in South Korea for sale in the U.S. market.

 

Q3: What is the safety concern?

A3: Continual operation of the vehicle in this condition could result in a seized connecting rod bearing, which could cause damage to the engine block and eventually stall the vehicle. In limited instances, a connecting rod could puncture the engine block and cause engine oil to leak, which, in the presence of hot surfaces, could increase the risk of a fire.

 

Q4: Have there been any accidents or injuries?

A4: As of the date of this filing, Hyundai is not aware of any confirmed crashes or injuries attributable to the recall condition. Five (5) vehicle fires with an undetermined root cause have been confirmed in the U.S. market.

 

Q5: What will be done during the recall service at the dealer?

A5: Hyundai Motor America plans to notify owners of affected vehicles to return their vehicles to their Hyundai dealers for an engine inspection test to determine the presence of damage on the cylinder bore and piston skirt. If abnormalities relating to damage is found, the engine will be replaced with a new one.

As an added level of protection, all affected vehicles will receive an enhanced engine control software update containing a new Piston Noise Sensing System (“PNSS”) program. The PNSS continuously monitors engine vibrations for unusual patterns potentially indicating an abnormal condition with the engine, such as a damaged cylinder bore and/or piston skirt, which could lead to an engine failure. The PNSS is currently under development and will be applied when available.

The remedy procedure will be performed at no charge. Hyundai will provide reimbursement to owners for repairs according to the plan submitted to NHTSA on May 16, 2018.

 

Q6: When will owners be notified?

A6: Owners will be mailed notification letters beginning in late June 2021.

 


*** Dealer Stock and Retail Vehicles ***

As required by federal law, dealer must not deliver new vehicle for sale or for lease to customers until all open recalls have been performed.  Dealers must also perform all open recalls on used  vehicles, demo, and rental vehicles prior to placing them into customer use and whenever an affected vehicle is in the shop for maintenance or repair.

When a vehicle arrives at the Service Department, access Hyundai Motor America’s “Warranty Vehicle Information (VIS)” screen via WEBDCS to identify open Campaigns.

 

Description:  On certain vehicles listed below, the engine may have been assembled using piston oil rings that were out of specification.  This can cause abnormal scuffing of the engine cylinder bores due to chipped piston oil rings which can also result in accelerated engine oil consumption.

Follow the procedures in this bulletin to inspect the vehicle and to determine the applicable repair procedure based on the inspection results.

 

APPLICABLE VEHICLES:

  • Certain 2019-20MY Elantra (AD)* vehicles with 2.0L Nu engines produced through 7/6/2020
  • Certain 2019-21MY Kona (OS) vehicles with 2.0L Nu engines produced through 9/1/2020
  • Certain 2019-21MY Veloster (JS) vehicles with 2.0L Nu engines produced through 5/27/2020

 

NOTE: *Elantra (AD) vehicles have VINs starting with “KMH”.

SST Information:

TOOL NAME FIGURE / TOOL NUMBER NOTE
Engine Vibration Inspection Tool G1XTD-CP200-QQH
  • This tool will be initially supplied by HMA through MPA.  Each dealer will receive one at the start of this recall.
  • A Galaxy tablet device equipped with a headphone / microphone port is required.  Certain models without this port (such as the Samsung Galaxy Tab S6) are not compatible to use with this tool.  Do not use a USB Type C-to-3.5mm Headphone Jack Adapter.

 

NOTICE 

  • During the initial vehicle inspection, engine oil level that is abnormally low (near or below “L”    for relatively low miles since last oil change or top off) due to a possible accelerated engine oil consumption condition will need further diagnosis.
    • Refer to HTSS “Fix it Right” under symptom “Campaign” 
  • If possible, the engine coolant temperature should be closer to normal operating temperature of 85ºC / 185ºF (or higher) to help expedite the actual engine inspection procedure.

 

Inspection Procedure:

1. Prepare the engine vibration inspection tool and GDS-M.

  • Inspect the vehicle in an area where the ambient noise and vibration levels are minimal.
  • Using the last GDS-M software update, the VCI must be updated with the latest firmware also.

 

2. Connect the knock sensor connector (A) of the engine vibration inspection tool to the engine knock sensor (D).

 

3. Connect the ground clamp (B) to the battery ‘-’ terminal.

  • Position the vibration inspection tool harness to avoid interference and vibration from the engine components which may affect the inspection result.
  • Route the wiring harness around the engine compartment as shown below.

 

4. Connect the signal jack (C) to the GDS-M stereo input port.

 

NOTICE

A Galaxy tablet device equipped with a headphone / microphone port is required. Certain models without this port (such as the S6 tablet) are not compatible for this inspection. Do not use a USB-C jack adapter.

 

5. Connect the VCI to the vehicle’s DLC port and check the Bluetooth pairing condition between the VCI and GDS-M.

  • Before pairing: White lamp light
  • After pairing: Green lamp light

 

6. Turn the vehicle ignition ‘ON’ and prepare the GDS for the inspection procedure.

  • Enter the vehicle info into the GDS (E).
  • Swipe up on the “More” tab at the bottom of the GDS home screen (F).
  • Select the “Special Inspection” function (G).

 

NOTE:  If the vehicle is not supported by the inspection program (either wrong model, model year, or engine), then this inspection will not be made possible.

 

7. Enter the mileage and RO number of the vehicle

 

8. Select the “Nu Atkinson Engine Vibration Inspection” and press the ‘Next’ button to proceed.

 

[Refer to link below for guided video information.]

Hyundai Service Learning –Campaign 203 Service Procedure

YouTube video

 

9. To obtain accurate inspection results, verify and acknowledge the check items that must be carried out before the inspection test.

  • Check all the precondition items on the list. (The actual monitoring of the Engine Coolant Temperature will be performed at the following screen.)
  • After all the precondition items have been acknowledged with checkboxes, press the ‘Next’ button to proceed.

 

NOTICE

During the initial vehicle inspection, engine oil level that is abnormally low (near or below “L” for relatively low miles since last oil change or top off) due to a possible accelerated engine oil consumption condition will need further diagnosis.

  • Refer to HTSS “Fix it Right” under symptom “Campaign”

 

10. The inspection program automatically checks engine sensor data and enables the “Next” button when all conditions are satisfied.

NOTE: A “NOT GOOD” status is displayed if the conditions are not satisfied. Press the “Refresh Data” button to obtain new sensor data after warming the engine and turning off the A/C.

  • If all conditions are satisfied, press the “Next” button to proceed.

 

11. After reviewing the vibration inspection process explanation and precautions, press the “Next” button to proceed.

 

12. In this screen, the program will perform an internal diagnosis after the “Start” button is pressed while the engine is at idle speed and  the KS signal is acquired for five seconds.

  • A brief warm up of the engine (by slightly raising the engine speed several times) may be required if the coolant temperature is not warm enough to be tested.

 

NOTE: If the measured input value is abnormally lower or higher than the expected range, then a sensor check message will be displayed with the inspection test being canceled.

 

13. Press the accelerator pedal to maintain an engine rpm target of 1500±100 rpm.

  • Maintain a steady engine speed between 1400-1600 rpm for five seconds.

 

NOTE:  If the engine rpm deviates from the specified target range, the engine speed value will be indicated in red color and the time count will be halted.

 

  • When the engine speed is within the target rpm range, the green status bars will continue to illuminate for each measurement cycle.
  • Repeat the 1500±100 rpm engine speed test to complete the 3 measurement cycles.

 

14. When the inspection test is completed, the result will be displayed.  Save a screenshot of the results screen for records.

 

  • If the test result is PASS, the measured engine vibration level is determined to be normal. The engine inspection is complete.

 

  • If the test result is NO PASS, the measured  engine vibration level is determined to be abnormal.

1) The PA and Engine Diagnosis Worksheet will be automatically created and saved in DRAFT.

2) Complete the information in the Engine Diagnosis Worksheet and apply the Service Manager’s signature before         submitting the PA.

3) Place the customer in a SRC and await further direction on the remedy.

 

  • If the test result is RETEST, there is an error    detected in measuring the vibration value. Check the inspection tool connections and perform the inspection test again.

 

15. When the inspection is completed, the inspection results are automatically sent to the server.

  • KS measured value, inspection time, dealer code, VIN, vehicle information, mileage, and sensor recording file will be sent.
  • Be sure to check the status in the Results Preview screen and select “Send All Pending” if the test results have not been sent from the tablet to the server.

 

NOTICE

The basic inspection history and the results sent to the server are available to review through by selecting the “Review Result” button from the Results Preview screen.

 


IMPORTANT SAFETY RECALL

2019 – 2020 Elantra, 2019 – 2021 Kona, 2019 – 2021 Veloster Nu Engine

Piston Oil Ring

 

This is an important Safety Recall.

  • Please contact your nearest Hyundai dealer to schedule the repair as soon as possible.
  • This repair will be performed at NO CHARGE to you.
  • To locate your nearest Hyundai dealer and schedule your appointment please visit:

www.HyundaiUSA.com/Campaign203

 

This notice applies to your Hyundai, VIN:

 

Dear

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Hyundai has decided that a defect which relates to motor vehicle safety exists in your vehicle with the VIN shown above. Hyundai is conducting a safety recall to address a condition involving engine failures resulting in a vehicle stall and/or fire in certain model year 2019 – 2020 Hyundai Elantra, 2019 – 2021 Hyundai Kona, and 2019 – 2021 Hyundai Veloster vehicles equipped with 2.0-liter “Nu” MPI engines and produced for sale in the U.S. and Canada.

 

What is the problem?

The engines in the subject vehicles may have been assembled using piston oil rings that were produced with inconsistent heat treating by the piston oil ring supplier resulting in excessive oil ring hardness. Excessive hardness can cause chipping of the piston oil ring’s outer periphery, which could lead to scuffing of the engine’s cylinder bore. A damaged cylinder bore could create accelerated oil consumption, which may then cause abnormal knocking noise from the engine and/or illumination of the oil pressure warning light. Continual operation of the vehicle in this condition could result in a seized connecting rod bearing, which could cause damage to the engine block and stall the vehicle, increasing the risk of a crash. A seized connecting rod could puncture the engine block and cause engine oil to leak onto hot surfaces, increasing the risk of a fire.

 

What will Hyundai do?

Your Hyundai dealer will inspect the engine to determine the presence of damage on the cylinder bore and piston skirt, and if necessary, will replace the engine. As an added level of protection, all affected vehicles will receive an enhanced engine control software update containing a new Piston Noise Sensing System (“PNSS”) program. The PNSS is currently under development and will be applied when available. This procedure will be performed at NO CHARGE to you.

 

What should you do?

Please contact your nearest Hyundai dealer to schedule the recall repair as soon as possible.

If the Malfunction Indicator Light is illuminated in your vehicle, you should seek service at your Hyundai dealer as soon as possible. The actual time required to perform the inspection is expected to take less than one hour, however if your vehicle needs repairs, your vehicle may be needed longer. Therefore, we recommend scheduling a service appointment to minimize inconvenience.

 

If you have other questions

If you require further assistance, you may contact the Hyundai Customer Care Center at 1-855-371-9460. If you believe that the dealer or Hyundai has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1-800-424-9153), or go to https://www.safercar.gov.

 

Thank you for your attention to this important safety matter. We apologize for any inconvenience this may have caused you.

 

Hyundai Motor America

 

Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8”

 

If you are a vehicle lessor, Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

 

Reimbursement Notification

If you paid for repairs related to this recall prior to receiving this notification letter, you may submit your reimbursement request electronically or obtain additional information at www.HyundaiUSA.com/Campaign203 or 1-855-371-9460.

 

No longer own this vehicle?

Changes to your name, address, or if you no longer own this vehicle — Update your information online at: https://owners.hyundaiusa.com/content/myhyundai/us/en/contact-us/update-vehicle-ownership.html

You can easily connect to this web page by using your cell phone to point your camera (or QR code reader app) at the code below. Then select the link which will be displayed on your phone.

 


[AMENDED] RECALL 203 ATTACHMENT A

CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

 

  • October 2020 – April 2021

Kia Motors North America (“KMNA”) became aware of a Vehicle Owner Questionnaire (“VOQ”) involving a model year 2020 Kia Soul vehicle alleging engine noise and eventual vehicle stall while stopped.  KMNA conducted a review of internal records on the incident VIN and was able to confirm the engine had seized.  The incident engine was recovered and subsequent tear-down inspection revealed a chipped piston oil ring, scuffed bore, and seized connecting rod bearing.

 

KMNA conducted a review of engine replacement claims for Nu 2.0L MPI engines to identify instances of a loss of motive power.  According to KMNA, analysis of targeted claims through January 31, 2021 indicated that instances of loss of motive power while driving was low at that time.  KMNA’s analysis also indicated a potential engine concern through claims for engines manufactured at its Hwasung assembly plant.  Kia conducted a joint investigation with the supplier and was able to identify a supplier production running change involving the nitride treatment process of the piston oil rings, which correlated jointly with engine replacement claims.  KMNA decided to conduct a safety recall based on the outcome of their investigation.

 

  • April 2021

On April 1, 2021, HMC informed HMA’s NASO of KMNA’s investigation and intent to conduct a safety recall.  Based on the information received, NASO conducted a targeted review of all identified and previously analyzed non-crash engine compartment fires involving Hyundai vehicles equipped with “Nu” MPI engines to assess the potential of the subject condition in Hyundai products sharing the same engine as Kia’s affected vehicles.  NASO identified five (5) fires that were previously reviewed with an undetermined root cause.  HMA reviewed the results of their analysis with NHTSA’s Office of Defect Investigations on April 20, 2021.

 

On April 21, 2021, NASO convened its North American Safety Decision Authority (“NASDA”) and decided to conduct a safety recall to address the defect condition in affected vehicles in the U.S. market.

 

  • June 2021

On June 2, 2021, HMC informed NASO that additional vehicles containing engines produced at the Hyundai Shandong WIA plant in China would need to be added to the original vehicle population affected by Recall 203.  NASO informed NHTSA’s ODI of HMC’s findings on June 3, 2021.  On June 4, 2021, NASO convened its NASDA and decided to amend Recall 203 to include vehicles containing suspect engines produced at the Shandong WIA plant in the involved vehicle population.

 

As of the date of this filing, Hyundai is not aware of any confirmed crashes or injuries attributable to the recall condition.  Five (5) vehicle fires with an undetermined root cause have been confirmed in the U.S. market.

 


 


8 Affected Products

Vehicles

MAKE MODEL YEAR
HYUNDAI ELANTRA 2019-2020
HYUNDAI KONA 2019-2021
HYUNDAI VELOSTER 2019-2021

 


11 Associated Documents

Miscellaneous Document – Amended Chronology

RMISC-21V301-9026.pdf 82.593KB

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Recall 573 Report – Amendment 1

RCLRPT-21V301-4965.PDF 215.787KB

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Interim Owner Notification Letter(Part 577)

RIONL-21V301-2289.pdf 322.139KB

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Defect Notice 573 Report

RCLRPT-21V301-7764.PDF 215.66KB

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Recall Acknowledgement

RCAK-21V301-4815.pdf 646.048KB

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Chronology

RMISC-21V301-7358.pdf 80.544KB

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Remedy Instructions and TSB

RCRIT-21V301-4558.pdf 996.714KB

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Manufacturer Notices(to Dealers,etc)- HMA Recall 203 Nu 2.0L Atkinson Engine Inspection and Replacement – (TSB #21-01-054H-1) – Remedy Available v3, October 12, 2021

RCMN-21V301-6992.pdf 570.128KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V301-3165.pdf 182.05KB

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Manufacturer Notices(to Dealers,etc) – 2.0 Nu MPI Engine Piston Oil Ring

RCMN-21V301-5782.pdf 188.456KB

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Recall Quarterly Report #2, 2021-4

RCLQRT-21V301-6036.PDF 211.253KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V301&docType=RCL

 


 

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