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Hyundai and Kia are recalling nearly 1.2 million more cars in the United States for engine failures after customers reported additional failures since the original 2015 recall, according to filings with the National Highway Traffic Safety Administration (NHTSA).
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Included are the 2013–2014 Hyundai Sonata and Santa Fe, 2011–2013 Kia Sportage, 2011–2014 Optima, and 2012–2014 Sorento. During machining of the engine crankshaft and crankpins, metal shavings may have been left within the crankshaft oil passages, and the crankpins themselves may be too rough on the edges. As a result, oil may be blocked and cause the connecting rod bearings to wear, which would then cause them to fail and seize the whole engine. That, of course, would cause the car to stall during driving.
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In September 2015, Hyundai recalled 470,000 Sonata sedans from 2011 and 2012 for this exact problem and extended the powertrain warranty from the original-owner 10-year/100,000-mile contract to 120,000 miles, which would cover all subsequent owners. The engines affected are the turbocharged 2.0-liter and naturally aspirated 2.4-liter gasoline direct injection (GDI) four-cylinders that made their debut in the 2011 Hyundai Sonata and Kia Optima and Sportage.
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In January, Hyundai settled a class-action lawsuit for 2011–2014 Sonata owners after out-of-warranty owners were hit with thousands of dollars in repair bills; dealers allegedly were not honoring warranty service due to what they considered improper owner maintenance, according to owner forums as well as Girard Gibbs, the law firm in charge of the suit. In January 2016, shortly after the original Hyundai recall, Kia began investigating on its own and subsequently found problems across its vehicle range. It also offered extended powertrain warranties to Sorento, Optima, and Sportage owners after receiving elevated warranty claims on these engines. Kia also said it had to tell dealers not to refuse warranty work just because a customer couldn’t provide service records of oil changes.
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- Hyundai Recalling 569,500 Sonatas and Accents over Separate Defects
- Hyundai Recalls 305,000 Sonatas for Brake-Pedal Defects
- Hyundai Recalls 173,000 Sonatas for Power-Steering Failure
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Owners who may have serious engine problems, as indicated by a knocking sound, an oil-pressure warning light, a check-engine light, or all three, may be eligible for a new engine. Dealers will inspect all cars, although the replacement process, if needed, involves stripping certain parts off the defective engine (such as the fuel injection pump, injectors, and rail) and installing them on the replacement engine. Dealers will also replace all oil dipsticks with bright orange, instead of dark yellow, pull tabs. The recall will start in late May. No accidents or injuries have been reported, Hyundai and Kia said.
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