September 17, 2021 NHTSA CAMPAIGN NUMBER: 21V727000
NHTSA Campaign Number: 21V727
Manufacturer Hyundai Motor America
Potential Number of Units Affected 95,515
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. Owner notification letters are expected to be mailed November 12, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 209.
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.
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.
- As of the date of this filing, Hyundai is aware of 45 fires related to the recall condition.
2 Affected Products
3 Associated Documents
Defect Notice 573 Report
Latest Recalls Documents
For the most up to date documents from NHTSA for this Recall, click the lick above
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.
What is J2534?
A single set of programming hardware consists of personal computer(PC), standard interface to a device driver and an interface hardware that connects between PC and a programmable ECU of vehicle.
The main purpose of this regulation is to program ECUs for all vehicles using a single set in the field.”
|CarDAQ Plus||Drew Technologies Inc.||4.04||1.9.28||1.9.28|
|Sun PassThru Pro||Snap-on Diagnostics||4.04||02.07u||02.07u|
|PassThru+ XS||I+ME Actia GmbH||4.04||02.07u||02.07u|
|PASS THRU PRO II||Snap-on Diagnostics||4.04||1.9.24||1.9.24|
|AEZ Flasher||AE Tools||4.04||1.9.28||1.9.28|
|CARDAQ-M||Drew Technologies Inc.||4.04||1.0.106||1.0.106|
|Universal Reprogrammer II||EASE Diagnostics||4.04||1.9.28||1.9.28|
* API, DLL and Firmware version may be controlled by the device manufacturer. Contact the manufacturer if you are unable to find the version listed above All devices were tested/verified on all Hyundai engine management systems.
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Last update on 2021-10-24 / Affiliate links / Images from Amazon Product Advertising API
Last update on 2021-10-24 / Affiliate links / Images from Amazon Product Advertising API