Hyundai Sonata

Issue: Hyundai Auto Canada is conducting a Product Improvement Campaign that provides an update to the engine control module to detect potential problems before an engine fails. An engine failure would cause a sudden loss of power with an inability to restart. Note: This only affects certain vehicles equipped with a 2.0 L Nu GDI engine. For the Sonata model, only the Sonata Hybrid and Plug-In Hybrid (PHEV) models are affected by this campaign. This is an expansion of R0180 (Transport Canada #2021-575). Any vehicle that received a software update under campaign R0180 does not require this update. Safety Risk: A sudden loss of engine power could increase the risk of an accident. An engine failure could also create the risk of a fire. Corrective Actions: Hyundai will notify owners by mail and advise you to take your vehicle to a dealer to update the software for the engine control module. Note: Hyundai recommends that you should always follow the correct vehicle maintenance schedule, which is printed in the Owner's Manual. If you experience unusual engine noise, reduced power, or a check engine/oil warning light, Hyundai advises you to immediately visit a Hyundai dealership to have your vehicle diagnosed.

Issue: On certain vehicles, the software update that was installed during campaign R0180 (Transport Canada recall numbers 2021-034 or 2021-575) may not be effective. As a result, a second repair is required. Hyundai Auto Canada is conducting a Product Improvement Campaign that provides an update to the engine control module to detect potential problems before an engine fails. An engine failure would cause a sudden loss of power with an inability to restart. Note: This campaign only affects certain Sonata Hybrid (HEV) and Sonata Plug-in Hybrid (PHEV) models equipped with a 2.0 L Nu GDI engine. Safety Risk: A sudden loss of engine power could increase the risk of an accident. An engine failure could also create the risk of a fire. Corrective Actions: Hyundai will notify owners by mail and advise you to take your vehicle to a dealer to update the software for the engine control module. Note: Hyundai recommends that you should always follow the correct vehicle maintenance schedule, which is printed in the Owner's Manual. If you experience unusual engine noise, reduced power, or a check engine/oil warning light, Hyundai advises you to immediately visit a Hyundai dealership to have your vehicle diagnosed.

Issue: Hyundai Auto Canada is conducting a Product Improvement Campaign that provides an update to the engine control module to detect potential problems before an engine fails. An engine failure would cause a sudden loss of power with an inability to restart. Note: This only affects vehicles equipped with a 2.4 L MPI engine. For the Sonata model, only the Sonata Hybrid is affected by this campaign. All vehicles previously included in TC # 2021-033 are now part of this new campaign. Vehicles that were previously repaired under campaign R0181 (Transport Canada #2021-033) do not require this software update. Safety Risk: A sudden loss of engine power could increase the risk of an accident. An engine failure could also create the risk of a fire. Corrective Actions: The company will notify owners by mail. Owners will be instructed to take their vehicle to a dealer to update the software for the engine control module. Note: Hyundai recommends that you should always follow the correct vehicle maintenance schedule, which is printed in the Owner's Manual. If you experience unusual engine noise, reduced power, or a check engine/oil warning light, Hyundai advises you to immediately visit a Hyundai dealership to have your vehicle diagnosed.

Issue: On certain vehicles equipped with a 2.0 L Nu GDI engine, the connecting rod bearings could wear prematurely. As a result, there could be an abnormal knocking noise from the engine and/or the oil pressure warning light may turn on. If you continue to drive the vehicle with worn connecting rod bearings, the engine could fail. An engine failure would cause a sudden loss of power with an inability to restart. In some cases, a damaged connecting rod could puncture the engine block and cause an oil leak. Note: For the Sonata model, only the Sonata Hybrid is affected by this recall. Additional Note: Engine compartment fires can happen for many different reasons. In some cases, there is too much damage to find the cause of a fire. Safety Risk: A sudden loss of engine power could increase the risk of a crash. Oil that leaks onto a hot component could cause a fire. Corrective Actions: Hyundai will notify owners by mail and instruct you to take your vehicle to a dealer for an engine inspection test, to determine if there is bearing damage. If damage is found, the engine will be replaced. Dealers will also update the software for the engine control module. Note: Hyundai recommends that you should always follow the correct vehicle maintenance schedule, which is printed in the Owner's Manual.

Issue: On certain vehicles, the connection between the high-pressure fuel pipe and fuel pump may not be properly sealed. As a result, a fuel leak could occur. Safety Risk: A fuel leak can create the risk of a fire. Corrective Action: Hyundai will notify owners by mail and instruct you to bring your vehicle to a dealer to inspect and replace the high-pressure fuel pipe, as required.

Issue: Hyundai Auto Canada is conducting a Product Improvement Campaign that provides an update to the engine control module to detect potential problems before an engine fails. An engine failure would cause a sudden loss of power with an inability to restart. Note: This only affects vehicles equipped with a 2.4 L MPI engine. For the Sonata model, only the Sonata Hybrid is affected by this recall. Safety Risk: A sudden loss of engine power could increase the risk of an accident. An engine failure could also create the risk of a fire. Corrective Actions: The company will notify owners by mail. Owners will be instructed to take their vehicle to a dealer to update the software for the engine control module. Note: Hyundai recommends that you should always follow the correct vehicle maintenance schedule, which is printed in the Owner's Manual. If you experience unusual engine noise, reduced power, or a check engine/oil warning light, Hyundai advises you to immediately visit a Hyundai dealership to have your vehicle diagnosed.

Issue: Over time, the fuel feed line to the high-pressure fuel pump could crack. If this happens, there could be a fuel odour or fuel leak in the engine compartment. Safety Risk: A fuel leak can create the risk of a fire. Corrective Actions: Hyundai will notify owners by mail and instruct you to take your vehicle to a dealer to complete the required repairs.

Issue: Hyundai Auto Canada is conducting a Product Improvement Campaign that provides an update to the engine control module to detect potential problems before an engine fails. An engine failure would cause a sudden loss of power with an inability to restart. Note: This affects Sonata and Santa Fe Sport equipped with a 2.4 L GDI or 2.0 L Turbo GDI engine, as well as Tucson equipped with a 2.4 L GDI engine. Safety Risk: A sudden loss of engine power could increase the risk of an accident. Corrective Actions: The company will notify owners by mail. Owners will be instructed to take their vehicle to a dealer to update the software for the engine control module. Note: Vehicles repaired under Service Campaigns, C0336, C0344, or C0347, already have this software update. Owners can find additional information at www.hyundaiengineinfo.ca.

On certain gasoline and hybrid engine vehicles, the circuits within the airbag control unit may become damaged. This could cause the airbags and seat belt pretensioners to not deploy in certain collisions where deployment is warranted, which could increase the risk of injury to vehicle occupants. Correction: Dealers will install a wire harness kit between the ACU connector and vehicle harness connector as necessary. Note: This recall does not affect the 2013 model year Sonata Hybrid.

On certain vehicles equipped with an anti-lock brake system (ABS), the ABS module remains powered on when the vehicle is turned off. If moisture were to enter the module, over time, an electrical short could occur, which could increase the risk of an underhood fire causing injury and/or property damage. Correction: Dealers will install a relay in the vehicle’s main junction box to ensure the ABS module is powered off upon the vehicle being turned off.

On certain vehicles equipped with 2.0L and 2.4L engines, the engine may contain residual metallic debris from factory machining operations. If debris is present, it could potentially restrict oil flow to the main bearings and rod bearings and could lead to premature wear. If the vehicle continues to be driven with worn bearings, the bearings could fail, which could cause an engine stall while the vehicle is in motion, resulting in loss of motive power which could increase the risk of a crash causing injury and/or property damage. Worn bearings could also result in the illumination of the oil pressure lamp in the instrument cluster. Correction: Dealers will inspect, and if necessary, replace the engine sub-assembly.

On certain vehicles equipped with a panoramic sunroof, the wind deflector anchor plate of the sunroof may have insufficient bonding. If the wind deflector becomes partially detached from its mounting points after the sunroof is opened, it can interfere with the moveable sunroof panel while the sunroof is being closed and could allow the glass panel to separate from the vehicle while driving, creating a road hazard which could increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will repair the wind deflector anchor plate.

On certain vehicles, the front suspension coil springs may be susceptible to corrosion. Over time, corrosion could cause the springs to fail, potentially damaging front tires and causing rapid air loss and/or tire failure, which could increase the risk of a crash causing injury and/or property damage. Correction: Dealers will inspect and repair or replace coil springs as necessary. Note: This recall supersedes recall 2015-469. Vehicles repaired under the previous recall will require re-inspection and repair.

On certain vehicles, the electric power steering (EPS) control circuit board could become damaged and fail. If this occurs, a red "EPS" warning lamp will illuminate in the instrument cluster to inform the driver that steering assist is no longer provided. Steering control can be maintained, as the vehicle will revert to a manual steering mode, but will require greater driver effort. The sudden change in steering effort may increase the risk of a crash causing injury and/or property damage. Correction: Dealers will replace the EPS control unit.

On certain vehicles, the front suspension coil springs may be susceptible to corrosion. Over time, corrosion could cause the springs to fail, potentially damaging front tires and causing rapid air loss and/or tire failure, which could increase the risk of a crash causing injury and/or property damage. Correction: Dealers will inspect and repair or replace coil springs as necessary. Note: This recall is superseded by recall 2016310. Please see recall 2016310 for more information. Click here for more information.

On certain vehicles, if the front passenger seat belt buckle tongue is inserted into the buckle forcibly at an extreme angle, it could damage the buckle and prevent the front passenger seat belt from being fastened. If this occurs, the front passenger's seat belt warning lamp will also illuminate. If the vehicle were to be driven in this condition, it could increase the risk of injury to the front passenger occupant in the event of a crash. Correction: Dealers will repair or replace the front passenger seat belt buckle.

On certain vehicles, brake lines connecting the master cylinder to the Hydraulic Electronic Control Unit may be defective and could either leak, or restrict fluid flow in the brake line. This would either cause a gradual loss of brake fluid and illuminate the brake warning lamp in the instrument panel, or restrict fluid flow to the brake calipers, which could illuminate the vehicle stability control warning lamp in the instrument cluster. Either condition could affect brake system function, potentially increasing stopping distances and the risk of a crash causing injury and/or damage to property. Correction: Dealers will replace the brake hoses with a revised part.

On certain vehicles, a pin socket in one of the wiring harness joint connectors may have been damaged during the manufacturing process. This could result in the illumination of the instrument cluster's indicator lamps, inability to remove the vehicle's shifter from the park position, or a reduction of steering assist. This would unexpectedly increase the steering effort force necessary to steer the vehicle at lower vehicle speeds, which could increase the risk of a crash causing injury and/or damage to property. Note: All vehicles have been inspected and repaired at distribution centers prior to being shipped to dealers.

On certain vehicles, road salt can corrode the rear crossmember assembly, which may ultimately lead to separation of the control arm at the mounting point. This would allow the wheel to rotate off its designed axis, and could result in a loss of vehicle control and a crash causing property damage and/or personal injury. Correction: Dealers will repair or replace the rear crossmember assembly.

On some vehicles, due to a defect in manufacturing of the inflator module, the side curtain airbag(s) could deploy without warning. Unintended airbag deployment, in a non-warranted (non-impact) situation, could startle the driver, which could result in a vehicle crash causing property damage and/or personal injury. In some instances, inadvertent deployment could cause injuries to vehicle occupants. Correction: Dealers will replace the affected side curtain airbag(s).

On certain vehicles, if a front inside door lock switch is held in the locked position while the inside door handle is pulled, the door latch inside handle lever may become out of position relative to the door latch master link. If this occurs, the inside door handle will not return to its normal, stowed position and the door latch will remain in the unlatched position when attempting to close the door. If the driver or front seat passenger does not notice that a front door is unlatched, the door may open while the vehicle is being driven, which increases the risk of personal injury or death to the driver or front seat passenger. Correction: Dealers will inspect and, if necessary, replace the door latch assemblies.

On certain vehicles operated in areas of heavy road salt usage (Ontario, Quebec, New Brunswick, Nova Scotia, Prince Edward Island, and Newfoundland & Labrador), road salt can collect in the rear portion of the side members of the subframe and may result in internal corrosion leading to thinning or perforation of the subframe steel. The corrosion may ultimately lead to separation of the lower control arm at the forward mounting point to the subframe. When separation occurs, in most cases, the movement of the arm will cause the axle to pull out of the transaxle and the vehicle will no longer have drive power to the wheels. In extreme cases, the wheel can also rotate off its designed axis and make contact with the fender or the wheel well. Both outcomes could result in a loss of vehicle control and a crash causing property damage, personal injury or death. Correction: Dealers will inspect and, if necessary, replace the front subframe assembly. Should the subframe not require replacement, drainage holes will be added, as well as treatment with rust-proofing material to arrest the corrosion process.

On certain vehicles equipped with an advanced airbag system, the Occupant Classification System (OCS), installed in the right front seat of the vehicle, may misclassify a small stature adult as a child and deactivate the passenger airbag. This would cause the right front airbag to not inflate in a crash that merits airbag deployment, and may result in injury to the right front seat occupant. Correction: Dealers will verify that the OCS does not recognize a properly seated adult occupant. After verification, the right front seat cushion assembly will be removed and reprogrammed.

During a government 65 km/h 40% offset frontal barrier test, the driver's seat belt may have interfered with the manual front seat back recliner knob, inadvertently releasing the seat back recliner mechanism. The release of a seat back recliner during a vehicle crash could result in injury to vehicle occupants. Correction: Dealers will replace the front seat back recliner knob with an revised part. Note: The revised part was placed into vehicle production on July 28, 2005 on four cylinder engine equipped models and on August 16, 2005 on six cylinder models.

On certain vehicles, the fuel tank assembly valve may not close properly. If a vehicle with a fuel tank assembly valve that is not properly closed were to roll over, fuel spillage could occur. Fuel spillage in the presence of an ignition source may result in a fire. Correction: Dealer will install an additional fuel tank assembly valve.

Certain Sonata GLS vehicles. The SRS air bag warning light could illuminate. The intermittent condition that leads to SRS warning light illumination related with codes b 1378 or b 1382 could result from unusual motion of the side impact air bag wiring harness and side impact air bag wiring harness connector which mount to the adjustable seat cushion assembly. This condition only relates to the driver and/or passenger seat mounted side impact air bag (s). Correction: dealers will service the front seat side impact air bag wiring harness.