2017 Hyundai Tucson & Sonata Hybrid Recall 209 Engine Damage May Cause Stall or Fire

September 17, 2021 NHTSA CAMPAIGN NUMBER: 21V727000

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: 21V727

Manufacturer Hyundai Motor America

Components ENGINE

Potential Number of Units Affected 95,515

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2017 Tucson and Sonata Hybrid vehicles. The connecting rod bearings inside the engine may wear prematurely, which can result in engine damage.

 

Remedy

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. Owners were notified of the defect on November 16, 2021. Owner notification letters were mailed January 15, 2022. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 209.

 

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.nhtsa.gov.

 

Check if your Hyundai has a Recall

 


2017 Hyundai Tucson
2017 Hyundai Tucson

 


 

Technical Service Bulletin

GROUP

RECALL

NUMBER

21-01-073H

DATE

DECEMBER 2021

MODEL(S)

APPLICABLE

VEHICLES BELOW

ENGINE INSPECTION / REPLACEMENT

SUBJECT:

(RECALL CAMPAIGN 209)

 

IMPORTANT

*** Retail Vehicles ***

As required by federal law, dealers must not deliver new vehicles 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 any maintenance or repair.

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

 

Description:  Certain applicable vehicles may have engines produced with conditions that can cause premature wear of the connecting rod bearings.  A worn connecting rod bearing could result in abnormal knocking noise from the engine and/or illumination of the oil pressure warning light. Follow the procedure to inspect the vehicle to determine the applicable repair procedure based on the inspection results.

 

Applicable Vehicles:

Certain 2017 MY Sonata Hybrid (LF HEV) vehicles with Nu 2.0L GDI Hybrid engines Certain 2017 MY Tucson (TL) vehicles with Nu 2.0L GDI engines

 

Service Procedure Flowchart:

Service Procedure Flowchart RECALL CAMPAIGN 209

 

Service Procedure: (Refer to the QR link for additional video information →)

Hyundai Service Learning Recall 209 Service Procedure

Hyundai Service Learning – Recall 209 Service Procedure

https://vimeo.com/652267505/52478150b0

 

Engine Inspection – (Engine Rotation Check) 

  1. Rotate the crankshaft with the crank rotator SST.
  • If the crankshaft cannot be turned with a moderate force, then measure the force required to turn the crankshaft with a torque wrench.
  • If the SST or shop tools do not fit the specific vehicle type, remove the front RH wheel, and wheel liner or underbody tray as needed to rotate the crankshaft.
    • If the crankshaft rotates normally, go to Step 2 below for “Bearing Clearance Test”.
    • If the force required for rotating the crankshaft is greater than 94 lb-ft., documentation through STUI video is required.
      • Bearing Clearance Test is not possible.
      • Take a STUI picture of the engine oil level on the dipstick with the VIN clearly visible in the photo using a copy of the RO or last 6-digits of VIN on paper.
      • Submit PA for engine replacement approval.
      • Use appropriate Op Code for “Crankshaft Cannot Rotate” from the Warranty Information table to complete the inspection procedure.
      • Please submit the engine replacement as a separate warranty claim using standard LTS labor operations for the applicable model for long block engine replacement.

 

Engine Inspection – (Bearing Clearance Test)

  1. Refer to TSB # 21-EM-004H-1 to complete the Service Procedure for Bearing Clearance Test. ❖ If the test result is “PASS”:
  • Save a screenshot of the results screen.
  • Follow the remaining steps of the inspection TSB. o Reinstall all components in the reverse order of removal.
  • Check for DTCs and perform the appropriate diagnostic service. Ensure no warning lights are present to complete the procedure.
  • Refer to Campaign 966 to update the Engine ECM if new software is available.
  • Use appropriate Op Code for “BCT Pass” from the Warranty Information table to complete the inspection procedure.

 

NOTICE

If other engine accessory components are seized, remove the engine accessory belt prior to completing the engine rotation check.

 

❖ If the test result is “NO PASS”:

*** IMPORTANT *** Please note that a PA and Engine Diagnosis Worksheet will be auto generated and SAVED in DRAFT if a “NO PASS” result is achieved.

  • Save a screenshot of the results screen. o Submit PA for engine replacement approval. o Follow the remaining steps of this TSB to replace the engine (upon PA approval).
  • Check for DTCs and perform the appropriate diagnostic service. Ensure no warning lights are present to complete the procedure.
  • Refer to Campaign 966 to update the Engine ECM if new software is available.
  • Use appropriate Op Code for “BCT No Pass” from the Warranty Information table to complete the inspection procedure.
  • Please submit the engine replacement as a separate warranty claim using standard LTS labor operations for the applicable model for long block engine replacement.

 

❖ If the test result is “No BCT”:

  • This screen may result if one or more cylinders were skipped in the BCT Process. o Save a screenshot of the results screen. o Record Error Code Number on Repair Order.
  • Follow “Skipped Cylinder STUI Video Submission” steps on page 10 of TSB 21-EM004H-1 (or latest version) for recording appropriate STUI video of Skipped Cylinder Test.
  • Submit PA for engine replacement approval. o Follow the remaining steps of this TSB to replace the engine (upon PA approval).
  • Check for DTCs and perform the appropriate diagnostic service. Ensure no warning lights are present to complete the procedure.
  • Refer to Campaign 966 to update the Engine ECM if new software is available.
  • Use appropriate Op Code for “No BCT” from the Warranty Information table to complete the inspection procedure.
  • Please submit the engine replacement as a separate warranty claim using standard LTS labor operations for the applicable model for long block engine replacement.

 

NOTICE

PA Approval is required for engine replacement. Submit PA and refer to the Dealer Best Practices guide for the latest requirements for engine approval.

➢ A picture of the lower end damage is required if present

➢ Use STUI feature on the GDS to take and submit pictures and videos.

 

*** IF ENGINE REPLACEMENT IS REQUIRED AND APPROVED BY PA ***

Follow the published Service Information from the applicable Shop Manual to remove and replace the Engine Assembly.

 

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

 

a) Be sure to connect the (2) oil coolant hoses between the oil cooler and the water temperature control assembly (if equipped).

  • Fill the cooling system with 50/50 ~ 70/30 (Water/Anti-Freeze) coolant mixture.

 

b) Fill the engine crankcase:

  • Add engine oil amount specified for the engine for the initial dry fill of the crankcase.
  • With the fuel system disabled temporarily, crank the engine for several seconds to prime the lubrication system prior to starting the engine.

 

  • Recommended Oil Specifications:
    • 5W-30 Full Synthetic type with API SN/SN+/SP, ILSAC GF4/GF5 or higher service grade

 

c) Start the engine to warm it up and begin the cooling system air bleeding process.

  • Check for any leaks during this time.
  • 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 up the “F” mark as shown.

 

d) Check for additional TSB to update the Engine ECM if new software is available.

 

e) When all fluids have been fully filled and all work quality checks are completed:

  • Set the customer’s audio station presets. o Relearn the Steering Angle Sensor using the GDS.
  • Clear any DTC’s (if present) with engine ON.
    • Certain DTC’s may reset if it’s not cleared with the engine running.
    • Perform the appropriate diagnostic service for any DTC’s.
    • Ensure no warning lights are present.
  • Reset the engine adaptive values using the GDS.
  • Perform a short road test to confirm normal vehicle drivability.

 

NOTICE

➢ Clear any DTC’s (if present) with engine ON. Certain DTC’s may reset if not cleared with the engine running.

➢ Reset engine adaptive values.

 


RECALL 209 ATTACHMENT A

CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

 

  • March 2019

NHTSA opened Preliminary Evaluation no. 19-003 “to assess the scope, frequency, and potential safety-related consequences of alleged defects relating to non-collision vehicle fires in the 20112014 Sonata Investigation and 2011-2014 Santa Fe.”

 

  • April 2019

In connection with PE 19-003, NHTSA issued an Information Request to HMA that sought data and information regarding non-collision fire incidents within an expanded range of Hyundai vehicles, namely all HMA vehicles of all model years equipped with Theta II, Lambda II, Gamma and Nu engines, thereby bringing into scrutiny a wide range of Hyundai model and model year vehicles.  Further, the Information Request sought information regarding non-collision fire incidents based on the definition of fire under 49 CFR § 579.4, which also includes “thermal events and fire-related phenomena such as smoke and melt,” thereby requiring HMA to search, collect, and produce a substantial volume of documents and data referring to potentially fire-related phenomena standing alone (such as “smoke” or “melt”) without any evidence of flame, burning, or combustion.  HMA also understood that at about the same time, NHTSA was seeking to collect similar information on the incidence of non-collision fires from other automakers in the United States market.

 

  • August 2019

HMA completed its response to NHTSA’s Information Request.   As was discussed with NHTSA shortly thereafter, HMA reasonably believed that while certain vehicles already subject to recall had an arguably higher incidence of non-collision fires that were already being addressed by ongoing vehicle recalls, in the absence of additional, comparative data, HMA’s data did not indicate elevated or unusual rates of non-collision related fires in Hyundai vehicles.

 

  • April 2020 – June 2020

On April 30, 2020, HMA proactively shared information with the agency on the Product

Improvement Campaign completion rate and effectiveness of the Knock Sensor Detection System (“KSDS”) software available for applicable models aimed at enhancing the detection of gradual engine damage/wear, in mitigating non-collision fires.  HMA continued to provide recurring updates on the deployment and effectiveness of KSDS to NHTSA.

 

  • July 2020 – November 2020

NHTSA shared with HMA its views on the data produced in relation to the aforementioned

Information Request, as well as the data apparently shared by competitor automakers with the Agency.  With NHTSA’s understanding and agreement, HMA updated and re-analyzed the occurrence of non-collision fire incidents in certain vehicles in discussion.  While the precise cause of non-collision fires can sometimes vary and information is often inconclusive due to the limitations of fire investigations, certain vehicles appeared to have experienced above average rates of hole-in-block engine fires that ordinarily result from a seized engine that causes a connecting rod to break, puncture the engine block, and potentially allow engine oil to escape the block, come in contact with other hot surfaces in the engine compartment, and produce localized smoke and then fire in the engine compartment.  Following additional discussion with the agency, HMA determined a population of affected vehicles to be addressed under Recall 198 and committed resources to continue to actively monitor other vehicles for trends.

 

  • December 2020 – June 2021

On December 17, 2020, HMA’s NASO informed ODI during its recurring monthly meeting that certain Hyundai vehicles equipped with 2.0-liter “Nu” GDI engines would be added to its KSDS implementation campaign.  NASO prioritized these models as part of its ongoing active monitoring of non-crash fires and provided updates to the agency during the January 2021 and May 2021 monthly meetings regarding KSDS deployment status.

 

  • July 2021

Through active monitoring of field information and warranty claims, NASO’s Data Review Committee (“DRC”) recommended to launch an investigation into alleged non-crash fires on certain Hyundai Tucson and Sonata Hybrid vehicles equipped with 2.0-liter “Nu” GDI engines and escalate the matter to the Technical Review Committee (“TRC”) on July 19, 2021.

 

  • August 2021

NASO’s TRC continued analyzing field information and determined the subject vehicles appeared to have experienced above average rates of hole-in-block engine fires similar to rates derived in prior assessments associated with Recall 198.  NASO reviewed the topic of 2.0-liter “Nu” GDI engines with ODI during its recurring monthly meeting on August 25, 2021.

 

  • September 2021

September 8, NASO conferred further with ODI regarding incident rates on the subject vehicles equipped with 2.0-liter “Nu” GDI engines. On September 10, HMA’s NASO convened its North American Safety Decision Authority and decided to conduct a safety recall to address the above condition in affected vehicles in the U.S. market.

 

  • Regarding field claim counts from all available data sources at the time of the filing, Hyundai is aware of 45 fires documented between July 18, 2017 and July 30, 2021.

 


2 Affected Products

Vehicles

MAKE MODEL YEAR
HYUNDAI SONATA HYBRID 2017
HYUNDAI TUCSON 2017

 


9 Associated Documents

Remedy Instructions and TSB

RCRIT-21V727-9174.pdf 399.611KB

RCRIT-21V727-9174

 


Manufacturer Notices(to Dealers,etc) – Recall 209: ENGINE INSPECTION / REPLACEMENT – Dealer Best Practice (TSB# 21-01-073H): December 9, 2021

RCMN-21V727-7825.pdf 337.588KB

RCMN-21V727-7825

 


RECALL 209 ATTACHMENT A CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

RMISC-21V727-0764.pdf 94.759KB

RMISC-21V727-0764

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V727-9247.pdf 169.409KB

RIONL-21V727-9247

 


Manufacturer Notices(to Dealers,etc) – Recall 209 Nu Engine 2.0L – Dealer Best Practice

RCMN-21V727-1548.pdf 244.704KB

RCMN-21V727-1548

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V727-8076.pdf 181.653KB

RCONL-21V727-8076

 


Chronology

RMISC-21V727-0957.pdf 95.319KB

RMISC-21V727-0957

 


Recall Acknowledgement

RCAK-21V727-1804.pdf 645.866KB

RCAK-21V727-1804

 


Defect Notice 573 Report

RCLRPT-21V727-2659.PDF 214.233KB

RCLRPT-21V727-2659

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V727&docType=RCL

 


1 Associated Investigation

Non-crash Vehicle Fires
NHTSA ID: PE19003
Dated opened: March 29, 2019

In a letter dated Jun 11, 2018, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a safety defect investigation into non-collision related fires on model year (MY) 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles. In a letter dated July 24, 2018, CAS requested that MY 2010-2015 Kia Soul vehicles be added to the petition. CAS stated that there is a higher number of complaints to NHTSA regarding non-crash fires on these vehicles compared to other similar vehicles. The Office of Defects Investigation (ODI) had already opened a Recall Query (RQ17-004) on all Hyundai vehicles equipped with Theta II engines for engine failures that may cause stalling and fires. The query covers most of the petition subject Sonata and Santa Fe vehicles.

On August 21, 2018, ODI opened a Defect Petition (DP18-003) to evaluate whether to grant or deny the CAS petition. ODI sent an Information Request letter to Hyundai (September 2018) requesting information on all engine and non-engine related fires in the petition Hyundai vehicles. ODI performed extensive analysis on the information obtained from Hyundai. During the DP18-003 analysis, Hyundai initiated three additional safety recalls related to engine compartment fires on certain petitioned and non-petitioned vehicles, (nearly 240,000 total vehicles: Recalls 18V-934, 19V-063, and 19V-204). In addition to engine compartment fires, ODI has received allegations of vehicle fires affecting other components, including taillight housings, taillight wire harnesses, and/or light bulbs. Based on ODI’s review of the applicable materials, including responses to Information Requests sent to multiple manufacturers, Vehicle Owner Questionnaires (VOQ), and Early Warning Data, NHTSA has decided to grant the petition.

The petition is hereby granted. A Preliminary Evaluation has been opened to assess the scope, frequency, and potential safety-related consequences of alleged defects relating to non-collision vehicle fires in the 2011-2014 Sonata and 2011-2014 Santa Fe. While prior recalls of vehicles covered by this PE have primarily related to engine fires, NHTSA’s Preliminary Evaluation is not limited to engine components and may cover additional vehicle systems or components as well.

Attached is a list of the reference numbers for the 160 VOQs cited above.


 

J2534 Diagnostic & Reprogramming – Hyundai

J2534 Diagnostic & Reprogramming – Hyundai

 

J2534 Reprogramming Software:

The Hyundai Motor America (HMA) J2534 reprogramming software allows for a common method of communication between a PC and a vehicle ECU. US EPA and CARB regulations mandate that all 2004 and later vehicle powertrain ECUs support emission-related reprogramming.

2017 Hyundai Tucson & Sonata Hybrid Recall 209 Engine Damage May Cause Stall or Fire » small light CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
2017 Hyundai Tucson & Sonata Hybrid Recall 209 Engine Damage May Cause Stall or Fire » small light CarDAQ-Plus
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2017 Hyundai Tucson & Sonata Hybrid Recall 209 Engine Damage May Cause Stall or Fire » small light Drew Tech Mongoose Pro USB to CAN ISO9141 Interface

 

https://www.hyundaitechinfo.com/external/j2534_diagnostics_and_programming.aspx

 

www.hyundaitechinfo.com

 


 

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  • Currently covers BMW, Chrysler, Ford, GM, Toyota, Honda, Hyundai / Kia, Mercedes and Nissan.
Bestseller No. 8
BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles
  • [J2534 COMPLIANT] - The Mastertech II is a J2534-1 and J2534-2 compliant VCI for OEM reprogramming and diagnostic applications
  • [FULLY VALIDATED BY TOP 6 OEMS] - Mastertech II has been fully validated to operate with the top 6 OEM reprogramming applications: GM, Ford, FCA, Nissan/Infinity, Honda/Acura, and Toyota/Lexus
  • [PRE-CONFIGURED] - The pre-configured wireless and wired connections make it quick and easy to connect to a vehicle from your PC (requires PC compliant with OE specifications and software)
  • [RIGHT TO REPAIR] - Supports 'Right to Repair' (R2R) initiatives
  • [COMPREHENSIVE KIT] - Kit includes: VCI, WiFi adapters (wireless PC to VCI), J1962 Cable (connect to vehicle), USB cable (connect to PC for firmware updates and setup), and Quick Start Guide
Bestseller No. 9
Autel MaxiSys MS908S Pro Automotive Diagnostic Scan Tool with J2534 ECU Programming/ ECU Coding/ Adaption, 2022 US Ver. of MaxiCOM MK908P, Same as Elite, Bi-Directional Control Full Scan, 36+ Services
  • 👍【2022 Newest Updates: AutoAuth Access & Cloud Service】Two long-awaited features for old customers!✅(Since June 2022)Autel original MS908S Pro scanner supports "AutoAuth" gateway access on 2018 and newer Fiat Chrysler vehicles, such as Chrysler, Dodge, Jeep, etc, still growing. ✅(Support Cloud Report Management, you can upload diagnostic reports to Autel Cloud and share reports with your customers through QR Code/email/text message easily, and they can view the reports anytime.
  • 👍【A Must for Garage and Workshop】If you need to program Benz/BMW, Autel MS908S Pro scanner is definitely an expert, this is what it does best! MS908S Pro is a mature product that has been tested and approved by workshops across US. Besides ECU Programming for Benz/BWM, MS908S Pro can perform ECU Coding, Active Tests, 36+ Services, All System Diagnostic, FCA “AutoAuth” Access, etc.🚦📢👉 Note: MS908S Pro is for North & South America only and supports English only.
  • 👍【One-Stop ECU Programming for BENZ/ BMW】Coming with J2534 ECU programming device, Autel MS908S Pro is competent for ECU programming and ECU coding/ adaption. It can program blank ECU, adapt existed ECU, match components, reflash second-hand ECU, unlock hidden functions, etc. In order to reduce operational burden, MaxiSys MS908S Pro provides one-stop operation to meet the needs of different experienced technicians, no worries about missing some steps and causing failure.
  • 👍【Advanced ECU Coding, Customize your Car】Automotive diagnostic scan tool MS908S Pro features Advanced ECU Coding, so you can use it to customize your car as needed by disabling some unneeded OEM settings (like auto start-stop, chimes, etc), or activating the hidden features pre-programmed to car computer to get high-end functions (like US-style daytime light, auto door look at a particular speed, etc).👉Compatible with BWM, VW, Audi, Skoda, etc.
  • 👍【OE-level Diagnostic Capability & Guided Function】Auto diagnostic tool MS908S Pro, with J2354 device for BT communication up to 210ft/70m working range, can access all available vehicle modules such as PCM, ECM, TCM, BCM, SCCM, etc, to read codes, clear codes, view live data, perform active tests, etc. Guided functions provides step by step specific guidances to complete some complex service operations. 👉Compatible with VW, Audi, Skoda, Seat, etc.
Bestseller No. 10
Autel MaxiFlash Elite Reprogramming Device Vehicle Communication Interface J2534 PassThru Bluetooth ECU Programming Device Work with Autel Maxisys Autel MS908S PRO MS908CV MK908 MK908P MS Elite and PC
  • As a multi-protocol Pass-Thru vehicle interface, MaxiFlash Elite is a fully compliant SAE J2534-1 & SAE J2534-2 (March 2006) device. Specially designed to provide users with convenient PC communication and ECU reprogramming capabilities on any modern vehicle diagnostic bus, MaxiFlash Elite offers the most significant features desired by OEM customers: reliability, fast performance and flexibility.
  • Fully compatible with both SAE J2534-1 and J2534-2 reprogramming standards. Compatible with Toyota Techstream, Volvo VIDA, Honda HDS, Jaguar-Land Rover IDS and BMW 3G for OEM diagnostics. Fast performance ensures quickly reprogramming even the newest controllers.
  • Wireless with advanced networking functions. Built-in wireless and data storage. Rugged design capable of withstanding harsh environments. Internet updateable.
  • MaxiFlash Elite is compatiable with MaxiSYS MS908S, MaxiSYS MS908S II, MaxiSYS MS908S Pro, MaxiSys MS908S Pro II, MaxiSYS MS908CV, MaxiCOM MK908, MaxiCOM MK908 Pro, MaxiCOM MK908 Pro II, MaxiSYS Elite, MaxiSYS Elite II and Personal Computer
  • Supports simultaneous communication definition in J2534-1, running 3 protocols at the same time, which greatly improves reprogramming and diagnostic speed. Embedded with the ARM9 Dual-core processor (clocked up to 500MHz), which further boosts the communicating speed.Rugged aluminum case with non-slip rubber end caps, capable of withstanding harsh environment.

Last update on 2022-11-28 / Affiliate links / Images from Amazon Product Advertising API

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