2011 Hyundai Sonata problems

What is wrong

Hyundai Motor America (Hyundai) is recalling certain 2011-2014 Sonata and 2013-2014 Santa Fe Sport vehicles previously repaired under recall numbers 15V‑568 and 17V‑226. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned, or improperly torqued during the engine replacement procedure, allowing fuel to leak from the pipe.

Risk

A fuel leak in the presence of an ignition source can increase the risk of a fire.

Remedy

Hyundai will notify owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began March 1, 2019. Owners may contact Hyundai customer service at 1‑855‑371‑9460. Hyundai's recall number for this recall is 180.

Recall number 18V934000 · Recall details

What is wrong

Hyundai Motor America (Hyundai) is recalling certain 2011-2013 Sonata and 2011-2012 Sonata Hybrid vehicles. On February 27, 2018, Hyundai Motor Company (Hyundai) notified the federal safety agency that they were recalling 154,753 model year 2011 Sonata vehicles. On April 18, 2018, Hyundai expanded the recall to include an additional 425,305 model year 2012-2013 Sonata and 2011-2012 Sonata Hybrid vehicles. In the event of a crash, the air bag control unit (ACU) may short circuit, preventing the frontal air bags, seat belt pretensioners, and side air bags from deploying.

Risk

If the frontal air bags, seat belt pretensioners, and side air bags are disabled, there is an increased risk of injury to the vehicle occupants in the event of a vehicle crash that necessitates deployment of these safety systems.

Remedy

Hyundai will notify owners, and dealers will install an external wire filter kit, free of charge. The recall began October 15, 2018. Owners may contact Hyundai customer service at 1‑855‑371‑9460. Hyundai's number for this recall is 174.

Recall number 18V137000 · Recall details

What is wrong

Hyundai Motor America (Hyundai) is recalling certain 2011-2014 Sonata and 2011-2015 Sonata Hybrid vehicles previously repaired under recall campaign 17V‑152. The seat belt linkages for both front seat belts may detach from the seat belt anchor pretensioners.

Risk

If the seat belt linkage detaches from the seat belt anchorage, it can not properly restrain the occupant in the event of a crash, increasing the risk of injury.

Remedy

Hyundai will notify owners, and dealers will again verify the connection between the seat belt linkage and the pretensioner and additionally install a warning label to prevent future seat belt linkage detachment, free of charge. The recall began November 6, 2017. Owners may contact Hyundai customer service at 1‑855‑371‑9460. Hyundai's number for this recall is 169.

Recall number 17V617000 · Recall details

What is wrong

Hyundai Motor America (Hyundai) is recalling certain 2011-2014 Sonata and 2011-2015 Sonata Hybrid vehicles. In the affected vehicles, the seat belt linkages for both front seat belts may detach from the seat belt anchor pretensioners.

Risk

In the event of a crash, if the seat belts detach from the anchor pretensioners, it can increase the risk of injury.

Remedy

Hyundai will notify owners and dealers will inspect the connection between the seat belt linkages and the seat belt anchor pretensioners, repairing them as necessary, free of charge. The recall is expected to begin April 7, 2017. Owner's may contact Hyundai customer service at 1‑855‑371‑9460. Hyundai's number for the recall is 160.

Recall number 17V152000 · Recall details

What is wrong

Hyundai Motor Company (Hyundai) is recalling certain model year 2011 Sonata vehicles manufactured December 11, 2009, to October 31, 2010. In the affected vehicles, the Electronic Power Steering (EPS) circuit board may be damaged and result in a loss of power steering assist.

Risk

With a loss of power steering assist, extra steering effort will be required, especially at lower speeds, increasing the risk of a crash.

Remedy

Hyundai will notify owners, and dealers will replace the EPS control unit, free of charge. The recall began May 30, 2016. Owners may contact Hyundai customer service at 1‑855‑371‑9640. Hyundai's number for this recall is 143.

Recall number 16V190000 · Recall details

What is wrong

Hyundai Motor America (Hyundai) is recalling certain model 2011-2012 Sonata vehicles. The brake pedal stopper pad can deteriorate allowing the brake light switch plunger to remain extended when the brake pedal is released.

Risk

If the brake light switch plunger does not retract as it should when the brake pedal is not being pressed, the brake lights may stay illuminated preventing accurate communication to rearward following vehicles that the vehicle is slowing or stopping. Additionally, if the brake switch plunger is not retracted, then the transmission can be shifted out of PARK without depressing the brake pedal. Either condition increases the risk of a crash.

Remedy

Hyundai will notify owners, and dealers will replace the brake pedal stopper pad with an improved part, free of charge. The recall began on January 6, 2016. Owners may contact Hyundai customer service at 1‑855‑671‑3059. Hyundai's number for this recall is 136.

Recall number 15V759000 · Recall details

What is wrong

Hyundai Motor America (Hyundai) is recalling certain model year 2011 Elantra vehicles manufactured November 12, 2010, to March 31, 2011, and Sonata vehicles manufactured December 11, 2009, to February 28, 2010, originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. Road salt may corrode the front coil springs, possibly resulting in the coil springs fracturing.

Risk

If a front coil spring fractures, it may contact the tire, possibly puncturing it, increasing the risk of a crash.

Remedy

Hyundai will notify owners, and dealers will replace the front coil springs, free of charge. Interim notifications were mailed on November 17, 2015. The recall began on January 6, 2016. Owners may contact Hyundai customer service at 1‑855‑671‑3059. Hyundai's number for this recall is 133. Note: Vehicles that were previously registered in salt belt states but are currently registered elsewhere are eligible to be inspected and repaired.

Recall number 15V629000 · Recall details

What is wrong

Hyundai Motor America (Hyundai) is recalling certain model year 2011-2012 Sonata vehicles manufactured December 11, 2009, to April 12, 2012 at Hyundai Motor Manufacturing Alabama and equipped with either a 2.0 liter or 2.4 liter Gasoline Direct injection engine. In the affected vehicles, metallic debris may not have been fully removed during manufacturing of the engine crankshaft. If the debris was not completely removed, oil flow may be restricted through the connecting rod bearings, causing connecting rod damage. A worn connecting rod bearing will produce a metallic, cyclic knocking noise from the engine and possible engine failure.

Risk

Engine failure would result in a vehicle stall, increasing the risk of a crash.

Remedy

Hyundai will notify owners, and dealers will inspect the vehicles and replace the engine assembly, as necessary, free of charge. Additionally, Hyundai Motor America will increase the warranty for the engine sub-assembly (short block) to 10 years/120,000 miles for both original and subsequent owners of 2011 and 2012 Sonatas manufactured at Hyundai Motor Manufacturing Alabama equipped with 2.0 liter and 2.4 liter Gasoline Direct injection engines. Interim notifications were mailed to owners starting on October 8, 2015. A second notification will be mailed when parts are available. Owners may contact Hyundai customer service at 1‑855‑671‑3059 or by visiting www.HyundaiUSA.com/Campaign132. Hyundai's number for this recall is 132.

Recall number 15V568000 · Recall details

What is wrong

Hyundai Motor Company (Hyundai) is recalling certain model year 2011 Sonata vehicles manufactured from December 11, 2009, through September 1, 2010. The affected vehicles may experience a brake fluid leak from the two brake lines that connect the brake system's master cylinder to the Hydraulic Electronic Control Unit (HECU) due to insufficient seal between the inner brake hose and metal brake line fitting.

Risk

If the brake lines leak brake sufficient fluid, the brake warning lamp in the instrument cluster will illuminate and longer stopping distance will be required, increasing the risk of a vehicle crash.

Remedy

Hyundai will notify owners, and dealers will replace the brake hoses with a revised service part, free of charge. The recall began in September 2014. Owners may contact Hyundai customer service at 1‑800‑633‑5151. Hyundai's number for this recall is 122.

Recall number 14V433000 · Recall details

What is wrong

Hyundai Motor Company (Hyundai) is recalling certain model year 2011-2014 Sonata vehicles manufactured December 11, 2009, through May 29, 2014. In the affected vehicles, the transmission shift cable may detach from from the shift lever pin.

Risk

If the transmission shift cable detaches, the transmission gear selection may not match the indicated gear and the vehicle may move in an unintended or unexpected direction, increasing the risk of a crash. Furthermore, when the driver parks the vehicle, despite selecting the 'PARK' position, the transmission may not be in 'PARK.' If the vehicle is not in the 'PARK' position and the parking brake is not applied, there is a risk the vehicle will roll away as the driver and other occupants exit the vehicle or anytime thereafter. A vehicle rollaway increases the risk of injury to exiting occupants and bystanders.

Remedy

Hyundai will notify owners, and dealers will inspect and, as necessary, repair the connection between the shift cable and shift lever, free of charge. The recall began in September 2014. Owners may contact Hyundai customer service at 1‑800‑633‑5151. Hyundai's number for this recall is 123.

Recall number 14V434000 · Recall details

What is wrong

Hyundai Motor Company (Hyundai) is recalling certain model year 2006-2009 Accent, model year 2007-2011 Azera, Sonata and Sante Fe,2006-2011 Tucson, 2009-2011 Elantra Touring, 2007-2010 Elantra, 2008-2011 Veracruz, 2009-2011 Genesis, 2010-2011 Genesis Coupe, 2007-2008 Entourage, and 2006-2008 Tiburon vehicles. Originally, in April 2013, Hyundai recalled 1,059,824 model year 2007-2009 Accent and Tucson, model year 2007-2010 Elantra, model year 2007-2011 Santa Fe, model year 2008-2009 Veracruz, model year 2010-2011 Genesis Coupe, and model year 2011 Sonata vehicles. In September 2013, Hyundai informed the agency that it was adding more vehicles to this campaign, representing an additional 652,512 units. The total number of vehicles being recalled is now 1,712,336. In the affected vehicles, the stop lamp switch may malfunction. A malfunctioning stop lamp switch may cause the brake lights to not illuminate when the brake pedal is depressed or may cause an inability to deactivate the cruise control by depressing the brake pedal. Additionally, a malfunctioning stop lamp switch may also result in intermittent operation of the push-button start feature, affect the operation of the brake transmission shift interlock feature, preventing the shifter from being moved out of the PARK position and cause the Electronic Stability Control (ESC) malfunction light to illuminate.

Risk

Failure to illuminate the stop lamps during braking or inability to disengage the cruise control could increase the risk of a crash. Additionally, when the ignition is in the 'ON' position, the transmission shifter may be able to be moved out of Park without first applying the brake. This may lead to unintentional movement of the car which may increase the risk of a crash.

Remedy

Hyundai will notify owners, and dealers will replace the stop lamp switch, free of charge. The safety recall began on April 22, 2013. Owners may contact Hyundai at 1‑800‑633‑5151. Hyundai's recall campaign number is 110.

Recall number 13V113000 · Recall details

What is wrong

Hyundai is recalling certain model year 2011 sonata vehicles manufactured from december 11, 2009, through september 10, 2010. On some of these vehicles the steering column intermediate shaft universal joint connections may have been either improperly assembled or insufficiently tightened.

Risk

Improper assembly or insufficient tightening of the connections could result in a complete separation or compromised attachment of the connections, such that the driver could experience a loss of, or reduction in, steering capability increasing the risk of a crash.

Remedy

Dealers will inspect the steering column intermediate shaft universal joint connections for proper assembly and torque. In addition dealers will update the power steering software free of charge. The safety recall began on october 11, 2010. Owners may contact hyundai customer service center at 1‑787‑999‑3333.

Recall number 10V457000 · Recall details

What is wrong

Hyundai is recalling certain model year 2011 sonata vehicles manufactured from december 11, 2009, through september 10, 2010. On some of these vehicles the steering column intermediate shaft universal joint connections may have been either improperly assembled or insufficiently tightened.

Risk

Improper assembly or insufficient tightening of the connections could result in a complete separation or compromised attachment of the connections, such that the driver could experience a loss of, or reduction in, steering capability increasing the risk of a crash.

Remedy

Dealers will inspect the steering column intermediate shaft universal joint connections for proper assembly and torque. In addition dealers will update the power steering software free of charge. The safety recall is expected to begin during october 2010. Owners may contact hyundai customer assistance center at 1‑800‑633‑5151.

Recall number 10V426000 · Recall details

What is wrong

Hyundai-kia has notified the federal safety agency about a defect in certain model year 2011 sonata vehicles manufactured from december 11, 2009 through february 15, 2010. The front inside door lock switch can remain in the unlatched position.

Risk

The door may not be in the locked position and may open while the vehicle is in motion, possibly resulting in injury to the driver or passenger.

Remedy

Hyundai-kia will notify owners and dealers will repair the vehicles by replacing latches affected by this recall campaign free of charge. The safety recall began on march 12, 2010. Owners may contact hyundai customer assistance center at 1‑800‑633‑5151.

Recall number 10V070000 · Recall details

the federal safety agency received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to the federal safety agency which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in the federal safety agency's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, the federal safety agency does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing the federal safety agency’s reasons for denial of the petition will be published. The reference numbers for the complaints to the federal safety agency cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to

DP22003

On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles. During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types. The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement. Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia. The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio. The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V‑568, 17V‑226, 20V‑746, and 21V‑727; and Kia recalls 17V‑224, 19V‑120, 20V‑750, and 21V‑844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires. In December 2023, Kia issued recall 23V‑877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines.  The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS.  It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension. For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied. Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates. To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years. In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires. Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis. Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023). The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to

EA21003

The Office of Defects Investigation (ODI) of the federal safety agency received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. the federal safety agency's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in the federal safety agency's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, the federal safety agency does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing the federal safety agency?s reasons for denial of the petition will be published.

DP21003

During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Hyundai Sonata and Santa Fe vehicles equipped with Theta II and Lambda II engines (approximately 1.3 million vehicles). ODI also reviewed field data of other Hyundai vehicles equipped with Theta II, Gamma, Nu and Lambda engines (approximately 4.8 million). As a result of this PE, Hyundai has issued the federal safety agency Recalls 20V‑746 and 21V‑727 to address potential engine failures and fires in certain Hyundai vehicles equipped with various engine types. Additional information on these and other related recall actions is available in the downloadable version of this resume available at In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure rewlated recalls mentioned above and conducted previously. See the EA21-003 Opening Resume available at for more information. Also available in the downloadable version of this resume is a list of the reference numbers for the 302 ODI reports, or Vehicle Owner Questionnaires (VOQs), cited above which ODI received through mid-November 2021. Note that the Manufacturer reports cited above are customer complaints received through March 2019.

PE19003

In a letter dated June 11, 2018, the Center for Auto Safety (CAS) petitioned the federal safety agency 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 the federal safety agency regarding non-crash fires on these vehicles compared to other similar vehicles. The Office of Defects Investigation (ODI) had already opened Recall Queries (RQ17-003 and RQ17-004) on all Kia and Hyundai vehicles equipped with Theta II engines for engine failures that may cause stalling and fires.The queries cover most of the petition subject Optima, Sorento, Sonata, and Santa Fe vehicles but not any of the subject Soul vehicles.On August 21, 2018, ODI opened a Defect Petition (DP18-003) to evaluate whether to grant or deny the CAS petition. ODI sent Information Request letters to Kia and Hyundai (September and October 2018) requesting information on all engine and non-engine related fires in the petition vehicles.ODI performed extensive analysis on the information obtained from Kia and Hyundai. During the DP18-003 analysis, Kia and Hyundai each initiated three additional safety recalls related to engine compartment fires on certain petitioned and non-petitioned vehicles (nearly 740,000 total vehicles: Recalls 18V‑907, 18V‑934, 19V‑101, 19V‑063, 19V‑120, and 19V‑204). 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, the federal safety agency decided to grant the petition.The CAS petition was granted on March 29, 2019. Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) have 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 Kia Optima and Sorento, 2011-2014 Hyundai Sonata and Santa Fe, and 2010-2015 Kia Soul.Attached is a list of the reference numbers for the 404 VOQs cited above.

DP18003

The Office of Defects Investigation (ODI) opened PE18-003 on 3/16/18 to investigate incidents involving crashes, resulting in significant collision related damage, where the frontal airbags failed to deploy. ODI reviewed complaint data, available design, test, and field data on the model year (MY) 2011 Hyundai Sonata, MY 2012-2013 Kia Forte and Forte Koup vehicles. ODI also evaluated data from the automotive air bag system supplier, ZF-TRW (ZF), to review vehicles that may contain the same air bag control unit (ACU) used in the subject vehicles. Hyundai Motor America (HMA) issued recall No. 18V‑137 for MY 2011-2013 Sonata and MY 2012 Sonata Hybrid vehicles. Kia Motors America (KMA) issued recall No. 18V‑363 for MY 2010-2013 Kia Forte and Forte Koup, MY 2011-2013 Optima, MY 2011-2012 Optima Hybrid, and MY2011-2012 Sedona vehicles. The two recalls address vehicles containing ACUs manufactured without adequate circuit protection by installing a wire harness filter kit to prevent internal damage to the ACU. In the event of a crash, ACU damage may result in the disablement of the vehicle's airbags. Each respective manufacturer has mailed letters to affected vehicle owners informing them of the remedy and its availability. ODI plans to evaluate the susceptibility of the subject ACU to electrical signals, as well as other vehicle factors that can either lead to, or reduce the likelihood of, an electrical overstress event in other vehicles manufactured with the subject ZF ACU.Accordingly, this Preliminary Evaluation has been upgraded to an Engineering Analysis (EA19-001), to expand the scope of the investigation to include the Tier-one supplier and any manufacturers who installed the subject ACU in production vehicles. Additional information is available with the closing resume available at (see Associated Documents).The ODI complaints cited above can be viewed at under the following ODI identification numbers: 10781050, 10849839, 11099038, 11080341.

PE18003

the federal safety agency opened Recall Query (RQ) 17-004 to investigate the timeliness and scope of Hyundai?s Theta II GDI engine recalls (Recall Nos. 15V‑568 and 17V‑226), and Hyundai?s compliance with reporting requirements. On November 23, 2020, the Agency entered into a Consent Order with Hyundai to administratively resolve the federal safety agency?s assertions of violations of law in connection with RQ17-004. the federal safety agency?s assertions included that Hyundai may be liable for civil penalties on multiple grounds, including the untimeliness of Recall Nos. 15V‑568 and 17V‑226, inaccuracies in Hyundai?s recall reports, and that a required report describing potential safety-related issues contained certain inaccuracies or omissions.Under the Consent Order, Hyundai agreed to a total civil penalty of $140,000,000. The total civil penalty included payment of $54,000,000 as a Non-Deferred Amount. Hyundai also agreed to a sum of $46,000,000 as an Abeyance Amount to be deferred and held in abeyance pending its satisfactory completion, as reasonably determined by the federal safety agency, of the requirements of the Consent Order.Additionally, Hyundai agreed to a $40,000,000 Performance Obligation Amount to be expended by Hyundai to fulfill specified Safety Data Analytics Infrastructure obligations and Test and Inspection Laboratory obligations. The Consent Order also includes other terms designed to enhance Hyundai?s safety practices, and requires Hyundai to retain a Third-Party Auditor who directly reports to the federal safety agency.Other than RQ17-004, the Consent Order is not intended to affect any other current or future investigation which may involve vehicles equipped with Theta II GDI engines. In particular, Engineering Analysis (EA) 21-003 (which is upgraded from Preliminary Evaluation (PE) 19-003) continues the federal safety agency?s evaluation of certain performance and design issues relating to the Theta II and other engines.Nothing in the Consent Order discharges Hyundai from any obligation to comply with the Safety Act or regulations thereunder, including the obligation to carry out recalls in accordance with law, and to initiate a recall upon any future determination by Hyundai, or upon any finally adjudicated order from the federal safety agency, that vehicles equipped with Theta II GDI engines contain a defect related to motor vehicle safety or do not comply with an applicable FMVSS.This RQ is closed. Closure of this RQ has no bearing on the terms of the Consent Order, including Hyundai's ongoing performance obligations, and does not represent a determination by the agency as to Hyundai?s performance under the Consent Order to date.

RQ17004

The Office of Defects Investigation (ODI) is aware of 7 complaints and field reports and 10 warranty claims on the subject vehicles that allege the intermediate steering shaft became loose or in some cases separated from the upper steering column and/or the steering gearbox, causing (or potentially causing) the hand wheel to become mechanically de-coupled from the road wheels resulting in a complete loss of steering capability.The reported causes include excessive free play or separation of the intermediate steering shaft upper and/or lower universal joint cross shaft/yoke; missing, loose or damaged universal joint pinch bolts; improperly assembled intermediate steering shafts with misaligned splines or insufficient spline engagement preventing the universal joint pinch bolt from being secured in the retaining groove when fastened.On September 20, 2010, the manufacturer notified the agency that it would conduct a safety recall (the federal safety agency Recall No. 10V‑426) to address the alleged defect in approximately 139,500 subject vehicles produced from December 11, 2009 through September 10, 2010.In addition to inspecting the steering shaft, the manufacturer will also update the electric power-assist steering control software to address complaints that the steering wheel vibrates or shakes as a result of a a motor driven power steering malfunction.The manufacturer began notifying affected owners by written letter on October 14, 2010.To date, 119,383 subject vehicles have been serviced under the recall campaign and 58 subject vehicles have received replacement parts as a result.Accordingly, this investigation is closed.

PE10035