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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


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: (Refer to the QR link for additional video information →)
Hyundai Service Learning – Recall 209 Service Procedure
Engine Inspection – (Engine Rotation Check)
- 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)
- 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
9 Associated Documents
Remedy Instructions and TSB
RCRIT-21V727-9174.pdf 399.611KB
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
RECALL 209 ATTACHMENT A CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION
RMISC-21V727-0764.pdf 94.759KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-21V727-9247.pdf 169.409KB
Manufacturer Notices(to Dealers,etc) – Recall 209 Nu Engine 2.0L – Dealer Best Practice
RCMN-21V727-1548.pdf 244.704KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V727-8076.pdf 181.653KB
Chronology
RMISC-21V727-0957.pdf 95.319KB
Recall Acknowledgement
RCAK-21V727-1804.pdf 645.866KB
Defect Notice 573 Report
RCLRPT-21V727-2659.PDF 214.233KB
Latest Recalls Documents
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.
Hyundai
Reprogramming
J2534 Diagnostic & Reprogramming - Hyundai
J2534 Reprogramming Software:
The Hyundai Motor America (HMA) J2534 reprogramming software allows for a common method of communication between aPC and a vehicle electronic control unit (ECU). U.S. EPA and CARB regulations mandate that all 2004 and later vehicle powertrain ECUs support emission-related reprogramming.
Vehicle Communication Interfaces (VCI)
The Hyundai J2534 Reprogramming and Diagnostic Tool software supports a SAE J2534-1/2 compliant passthru VCI device for use on Hyundai
vehicles sold in the US. The devices, firmware, and application programming interfaces listed below have been tested by HMA and under no circumstances do we recommend the use of a non-approved J2534 device. HMA has worked closely with the following J2534 device manufacturers to ensure the hardware and software comply with all J2534-1/2 specifications.
https://www.hyundaitechinfo.com/external/j2534_diagnostics_and_programming.aspx
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SEOCONTENT-START
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 in the United States and Canada to address a condition of engine failures resulting in non-crash vehicle fires in certain model year 2017 Hyundai Sonata Hybrid and 2017 Hyundai Tucson vehicles in the U.S. and Canada. The purpose of this letter is to explain what the recall is about and to keep you informed of Hyundai’s recall implementation plan. We are currently making preparations to implement the safety recall remedy which when available, will be performed at no cost to you. We will send you another notification when the remedy is available. What is the problem? The engines in the subject vehicles may have been 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. If the vehicle is continually operated with a worn connecting rod bearing, the engine could become damaged and stall the vehicle during operation. In certain instances, a damaged connecting rod could puncture the engine block and cause engine oil to leak, which, in the presence of hot surfaces in the engine compartment, could increase the risk of a fire. A vehicle stall can increase the risk of a crash. If engine oil leaks onto certain engine components running at high operating temperature it could ignite and start an engine compartment fire. What should you do in the interim? We appreciate your patience. Hyundai is currently making preparations to implement the recall remedy. You will receive a second notification letter when the remedy is available. For updated information regarding this recall, please visit: www.HyundaiUSA.com/Campaign209 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 and/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 Hyundai Motor America P.O. Box 20839 Fountain Valley, CA 92728-9937 IMPORTANT SAFETY RECALL (INTERIM NOTICE) 2017 Sonata Hybrid, 2017 Tucson Nu Engine This is an important Safety Recall. • We are currently preparing the remedy. We will notify you when the remedy is ready. • For updated information, you can visit: www.HyundaiUSA.com/Campaign209 Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8” NHTSA Recall Number: 21V-727 Hyundai Recall Number: 209
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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 in the United States and Canada to address a condition of engine failures resulting in non-crash vehicle fires in certain model year 2017 Hyundai Sonata Hybrid and 2017 Hyundai Tucson vehicles in the U.S. and Canada. What is the problem? The engines in the subject vehicles may have been 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. If the vehicle is continually operated with a worn connecting rod bearing, the engine could become damaged and stall the vehicle during operation. In certain instances, a damaged connecting rod could puncture the engine block and cause engine oil to leak, which, in the presence of hot surfaces in the engine compartment, could increase the risk of a fire. A vehicle stall can increase the risk of a crash. If engine oil leaks onto certain engine components running at high operating temperature, it could ignite and start an engine compartment fire. What will Hyundai do? Your Hyundai dealer will perform an engine inspection test to determine the presence of any bearing damage. If the bearing is damaged, the engine will be replaced with a new one. In addition to the remedy, all affected vehicles will receive an enhanced engine control software update containing a new Knock Sensor Detection System (“KSDS”) as part of a product improvement campaign enhancing the engine’s protection from internal wear. The KSDS continuously monitors engine vibrations for unusual patterns potentially indicating an abnormal condition with the engine, such as a damaged connecting rod bearing, that could lead to an engine failure. The remedy 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 repair will take approximately one hour or less, however your vehicle may be needed longer. If the engine requires replacement, the repair will take approximately 7 hours to complete. 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 without charge, or 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 Hyundai Motor America P.O. Box 20839 Fountain Valley, CA 92728-9937 IMPORTANT SAFETY RECALL 2017 Sonata Hybrid, 2017 Tucson Nu Engine Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8” NHTSA Recall Number: 21V-727 Hyundai Recall Number: 209 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/Campaign209
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Recall 209: ENGINE INSPECTION / REPLACEMENT – Dealer Best Practice (TSB# 21-01-073H) December 09, 2021 Updates to this Document Date • TSB # 21-01-073H – Remedy Available 12/09/2021 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. Description of Campaign: 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 TSB# 21-01-073H to inspect the vehicle to determine the applicable repair procedure based on the inspection results and replace the engine, if needed. Affected Vehicles: • Certain 2017MY Sonata HEV (LF HEV) with Nu 2.0L GDI Hybrid engines • Certain 2017MY Tucson (TL) with Nu 2.0L GDI engines To check vehicle specific recall and campaign applicability, access the “Vehicle Information” screen via WebDCS. The Fix: Hyundai dealers will inspect the engine using procedures outlined in TSB 21-01-073H. Based on the results of the engine inspection, engine replacement may be necessary. Per HMA Warranty policy, PA submission is required prior to engine replacement. • Estimated Repair Time (Based on Warranty Op Time): Up to 1.2 hours for the inspection. Addition time required if engine replacement is necessary. • Recommended Technician Training Level: • For Internal Combustion Engine (ICE) drivetrain: • Minimum Certified Level: Certified • For Hybrid Electric Vehicle (HEV) drivetrain: • Minimum Certified Level: Expert Recommended Alternative Transportation: It is advisable to have an SRC reserved for the customer(s) in anticipation of the vehicle remaining at the dealership for potential extensive repairs. Customer Talk Tracks It is advisable to communicate to customers this recall may take additional time to complete in addition to other requested service repairs. Best Practice Checklist Reservation: Did you check WebDCS for additional campaigns or recalls? Yes No Readiness: Are parts in stock to complete this campaign? Yes – Provide customer with ETA No – Contact parts and get ETA Reception: Did you explain to the customer the expected repair time based on the repair? Yes No Reception: Did you offer the customer Alternative Transportation? Yes No Repair: Does the Technician meet the recommended training requirements to complete this recall/campaign? Yes No Return: Did you get the customer’s signature on all warranty lines in addition to the final RO? Yes No Additional Training & Resources Hyundai Learning Portal 1. For Internal Combustion Engine (ICE) drivetrain: – Successful completion of the Engine Technology – Classroom (#SVCET28_208) or the Engine Tech vILT Final Exam – Web (#SVCDENGVILTEXITW20_865) Course 2. For Hybrid Electric Vehicle (HEV) drivetrain: – Successful completion of the Engine Technology – Classroom (#SVCET28_208) or the Engine Tech vILT Final Exam – Web (#SVCDENGVILTEXITW20_865) Course – Successful completion of Hybrid Vehicle Service Safety – Web (#SVCHYBRIDSFTY15W_736) – Successful completion of Hybrid Vehicle Training – Classroom (#SVCHHYBVEHTRN218_800 Parts • There are no required replacement parts for the inspection. If an engine replacement is needed, follow the applicable shop manual for the long block engine. • Follow the standard Warranty policy and use a new engine (long block) if vehicle is within 5 years/60,000 miles (“5/60”) and a Reman engine when beyond 5/60 (if available). Warranty Information Claim Process: • Inspection will be submitted under the campaign claim entry screen; utilize the TSB op codes in the Warranty Information table • If engine replacement is needed based on the inspection results, submit the engine replacement as a separate warranty claim using standard LTS and follow the published service information from the applicable shop manual to remove and replace the engine assembly. • If a part that is not covered by this recall is found in need of replacement while performing this recall, and the affected part is still within warranty, include it with the separate engine warranty claim. If the affected part is out of warranty, submit a Prior Approval request for goodwill consideration prior to performing the work. Warranty Information Table: Customer FAQ Q1: What is the safety concern? A1: A vehicle stall at highway speeds can increase the risk of a crash. If engine oil leaks onto certain engine components running at high operating temperature, it could ignite and start an engine compartment fire. Q2: What will be done during the recall service at the dealer? A2: Hyundai Motor America will notify owners of affected vehicles to return their vehicles to their Hyundai dealers for an engine inspection test to determine the presence of any bearing damage. If the bearing is damaged, the engine will be replaced with a new one. In addition to the remedy, all affected vehicles will receive an enhanced engine control software update containing a new Knock Sensor Detection System (“KSDS”) as part of a product improvement campaign enhancing the engine’s protection from internal wear. The KSDS continuously monitors engine vibrations for unusual patterns potentially indicating an abnormal condition with the engine, such as a damaged connecting rod bearing, that could lead to engine failure. 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. Customer Notification Owners will be mailed with notification letters in late December 2021/January 2022 with a remedy available letter for this recall. Owners were previously mailed interim notification letters in late November 2021 notifying that a remedy was in development. Contact Reference Please see the following page for commonly referred to contacts. Thank you for your prompt attention to this important safety matter and continued commitment to Hyundai customers. Hyundai Motor America 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 Technicians Warranty HELPREP Line 1‐877‐446‐2922 Warranty Claim questions for Hyundai Dealers Warranty Prior Approval (PA) Center PA@hmausa.com 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 AutoLoop Technical Support Support@autoloop.com 1-877-850-2010 Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes CDK Technical Support https://serviceconnect.support.cdk.com/ 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/recall 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 dealer best practices. 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 SRC Documentation: www.HyundaiDealer.com > Service tab > Documents Library > Service Rental Car TSD: www.HyundaiDealer.com > Service tab > SRC Fleet Mgmt Software Insurance: www.HyundaiDealer.com > Service tab > SRC Insurance 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 (New, SRC, CPO, etc.) and Retailed. Recall Campaign Website www.hyundaiusa.com/recall NHTSA Website www.safercar.gov Appendix Updates To This Document Date • Remedy Not Yet Available 09/22/2021
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Recall 209 – Nu Engine 2.0L – Dealer Best Practice September 22, 2021 To see if your vehicle is affected, please access Hyundai Motor America’s “Warranty Vehicle Information Screen (VIS)” via WEBDCS to identify open campaigns/recalls. Description of Campaign: The engines in the subject vehicles may have been 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. If the vehicle is continually operated with a worn connecting rod bearing, the engine could become damaged and eventually stall the vehicle during operation. In limited instances, a damaged connecting rod could puncture the engine block and cause engine oil to leak, which, in the presence of hot surfaces in the engine compartment, could increase the risk of a fire. Stop Sale Action: No, a “stop sale” is not needed as these vehicles are no longer in production or offered for retail. However, please note that vehicles in dealer’s used stock inventory must have the recall completed prior to placing them into customer use. Affected Vehicles: • Certain 2017 model year Hyundai Tucson vehicles equipped with 2.0-liter “Nu” GDI engines produced by Hyundai Motor Company (“HMC”) • Certain 2017 model year Hyundai Sonata Hybrid vehicles equipped with 2.0-liter “Nu” GDI engines produced by Hyundai Motor Company (“HMC”) The Fix: Remedy is currently under development. Recommended Alternative Transportation: Be prepared to hold the vehicle and put customers in an SRC or alternative transportation, if needed, until a remedy is available. Best Practice Checklist Additional items will be added to the checklist once a remedy becomes available. Reservation: Did you check WebDCS for additional campaigns or recalls? Yes No Additional Training & Resources Hyundai Learning Portal Remedy is currently under development. Applicable training courses related to this recall, if applicable, will be provided once a remedy has been released by HMA. Hyundaidealer.com A WebDCS announcement will be provided on Hyundaidealer.com informing dealers of a remedy not yet available for this recall. Parts Parts, if applicable, will be provided once a remedy has been released by HMA. Customer FAQ Q1: What is the safety concern? A1: A vehicle stall at highway speeds can increase the risk of a crash. If engine oil leaks onto certain engine components running at high operating temperature, it could ignite and start an engine compartment fire. Q2: Have there been any accidents or injuries? A2: As of the date of this filing, Hyundai is not aware of any confirmed crashes, injuries, or fires attributable to this condition. Q3: What will be done during the recall service at the dealer? A3: 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 any bearing damage. If the bearing is damaged, the engine will be replaced with a new one. In addition to the remedy, all affected vehicles will receive an enhanced engine control software update containing a new Knock Sensor Detection System (KSDS) as part of a product improvement campaign enhancing the engine’s protection from internal wear. The KSDS continuously monitors engine vibrations for unusual patterns potentially indicating an abnormal condition with the engine, such as a damaged connecting rod bearing, that could lead to an engine failure. The remedy procedure will be performed at no charge. Hyundai will provide reimbursement to owners for repairs according to the plan submitted on May 16, 2018. Customer Notification Owners will be notified beginning in mid-November 2021. NHTSA has been notified of this recall. Reference Please see the following page for commonly referred to contacts. 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 Technicians Warranty HELPREP Line 1‐877‐446‐2922 Warranty Claim questions for Hyundai Dealers Warranty Prior Approval (PA) Center PA@hmausa.com 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 AutoLoop Technical Support Support@autoloop.com 1-877-850-2010 Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes CDK Technical Support https://serviceconnect.support.cdk.com/ 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/recall 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 dealer best practices. 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 SRC Documentation: www.HyundaiDealer.com > Service tab > Documents Library > Service Rental Car TSD: www.HyundaiDealer.com > Service tab > SRC Fleet Mgmt Software Insurance: www.HyundaiDealer.com > Service tab > SRC Insurance 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 (New, SRC, CPO, etc.) and Retailed. Recall Campaign Website www.hyundaiusa.com/recall NHTSA Website www.safercar.gov
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Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service Advisors, Technicians, Body Shop Manager, Fleet Repair Technical Service Bulletin GROUP NUMBER RECALL 21-01-073H DATE MODEL(S) DECEMBER 2021 APPLICABLE VEHICLES BELOW SUBJECT: ENGINE INSPECTION / REPLACEMENT (RECALL CAMPAIGN 209) 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 Warranty Information: MODEL OP CODE INSPECTION / OPERATION OP TIME CAUSAL P/N NATURE CODE CAUSE CODE Sonata Hybrid (LF HEV) 11D196R0 BCT Pass 0.6 M/H 2D312-2EU02A E74 ZZ7 11D196R1 BCT No Pass 0.9 M/H 11D196R2 No BCT 1.2 M/H 11D196R3 BCT Pass w/ Abnormal Noise 1.2 M/H 11D196R4 Crankshaft Cannot Rotate 0.5 M/H Tucson (TL) 11D196R5 BCT Pass 0.6 M/H 2D352-2EU02 E74 ZZ7 11D196R6 BCT No Pass 0.9 M/H 11D196R7 No BCT 1.2 M/H 11D196R8 BCT Pass w/ Abnormal Noise 1.2 M/H 11D196R9 Crankshaft Cannot Rotate 0.5 M/H *** Retail Vehicles *** As required by federal law, dealer s must not deliver new vehicle s for sale or for lease to customers until all open recalls have been performed. Dealer s 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. IMPORTANT ENGINE INSPECTION / REPLACEMENT (RECALL CAMPAIGN 209) TSB #: 21-01-073H Page 2 of 6 SUBJECT: SUBJECT: NOTE 1: *** Claim Submission Details *** ➢ Inspection: Submit for the inspection using the campaign claim entry screen & table specified above. ➢ Engine Replacement: If it is determined that the vehicle requires engine replacement based on the inspection results, submit the engine replacement as a separate warranty claim using standard LTS and follow the published service information from the applicable shop manual to remove and replace the engine assembly. Please ensure to follow standard warranty policy and use a new engine (long block) if vehicle is within 5 years/60,000 miles (“5/60”) and a Reman when beyond 5/60 (if available). NOTE 2: If a part that is not covered by this recall is found in need of replacement while performing this recall, and the affected part is still within warranty, include it with the separate engine warranty claim. If the affected part is out of warranty, submit a Prior Approval request for goodwill consideration prior to performing the work. ENGINE INSPECTION / REPLACEMENT (RECALL CAMPAIGN 209) TSB #: 21-01-073H Page 3 of 6 SUBJECT: SUBJECT: Service Procedure Flowchart: ENGINE INSPECTION / REPLACEMENT (RECALL CAMPAIGN 209) TSB #: 21-01-073H Page 4 of 6 SUBJECT: SUBJECT: Service Procedure: (Refer to the QR link for additional video information →) Hyundai Service Learning – Recall 209 Service Procedure 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. o Bearing Clearance Test is not possible. o 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. o Submit PA for engine replacement approval. o Use appropriate Op Code for “Crankshaft Cannot Rotate” from the Warranty Information table to complete the inspection procedure. o 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) 2. Refer to TSB # 21-EM-004H-1 to complete the Service Procedure for Bearing Clearance Test. ❖ If the test result is “PASS”: o Save a screenshot of the results screen. o Follow the remaining steps of the inspection TSB. o Reinstall all components in the reverse order of removal. o Check for DTCs and perform the appropriate diagnostic service. Ensure no warning lights are present to complete the procedure. o Refer to Campaign 966 to update the Engine ECM if new software is available. o Use appropriate Op Code for “BCT Pass” from the Warranty Information table to complete the inspection procedure. If If other engine accessory other engine accessory components are seized, remove the components are seized, remove the engine accessory belt prior to engine accessory belt prior to completing the engine rotation completing the engine rotation check. NOTICE NOTICE ENGINE INSPECTION / REPLACEMENT (RECALL CAMPAIGN 209) TSB #: 21-01-073H Page 5 of 6 SUBJECT: SUBJECT: ❖ 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. o 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). o Check for DTCs and perform the appropriate diagnostic service. Ensure no warning lights are present to complete the procedure. o Refer to Campaign 966 to update the Engine ECM if new software is available. o Use appropriate Op Code for “BCT No Pass” from the Warranty Information table to complete the inspection procedure. o 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”: o 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. o Follow “Skipped Cylinder STUI Video Submission” steps on page 10 of TSB 21-EM-004H-1 (or latest version) for recording appropriate STUI video of Skipped Cylinder Test. o Submit PA for engine replacement approval. o Follow the remaining steps of this TSB to replace the engine (upon PA approval). o Check for DTCs and perform the appropriate diagnostic service. Ensure no warning lights are present to complete the procedure. o Refer to Campaign 966 to update the Engine ECM if new software is available. o Use appropriate Op Code for “No BCT” from the Warranty Information table to complete the inspection procedure. o Please submit the engine replacement as a separate warranty claim using standard LTS labor operations for the applicable model for long block engine replacement. PA Approval is required PA Approval is required for engine replacement. Submit for engine replacement. Submit PA and refer to the Dealer Best PA and refer to the Dealer Best Practices guide for the latest requirements for engine approval. 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. NOTICE NOTICE ENGINE INSPECTION / REPLACEMENT (RECALL CAMPAIGN 209) TSB #: 21-01-073H Page 6 of 6 SUBJECT: SUBJECT: *** 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). o Fill the cooling system with 50/50 ~ 70/30 (Water/Anti-Freeze) coolant mixture. b) Fill the engine crankcase: o Add engine oil amount specified for the engine for the initial dry fill of the crankcase. o With the fuel system disabled temporarily, crank the engine for several seconds to prime the lubrication system prior to starting the engine. o Recommended Oil Specifications: o 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. o Check for any leaks during this time. o 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: o Set the customer’s audio station presets. o Relearn the Steering Angle Sensor using the GDS. o Clear any DTC’s (if present) with engine ON. o Certain DTC’s may reset if it’s not cleared with the engine running. o Perform the appropriate diagnostic service for any DTC’s. o Ensure no warning lights are present. o Reset the engine adaptive values using the GDS. o Perform a short road test to confirm normal vehicle drivability. Optimum Engine Oil Fill L Optimum Engine Oil Fill Level ➢ 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. NOTICE NOTICE
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