NHTSA Defect Investigations for the 2004 Hyundai Elantra

The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2004 Hyundai Elantra, both ongoing and closed, are listed below:

  1. INVESTIGATION: POST-CRASH FUEL TANK LEAK

    NHTSA Preliminary Evaluation #PE04041

    Component(s): Fuel System, Gasoline:Storage:Tank Assembly

    Summary: PE04-041 was opened to investigate a fuel leak incident that occurred during an insurance institute for highway safety (iihs) frontal crash offset test on the subject vehicle.this investigation revealed that the vapor tube hose clamp ear was mispositioned and facing toward the fuel tank, which enabled the vapor tube hose clamp ear to puncture the fuel tank and the fuel tank to leak stoddard fluid during the iihs crash test.on April 30, 2004, Hyundai motor company (Hyundai) notified NHTSA of a safety defect in certain MY 2004 Elantra vehicles produced from September 1, 2003 through April 14, 2004.the notification identified the mispositioning of the vapor tube hose clamp, which resulted from an early September manufacturing change at the supplier that installed the hose clamp on the vapor tube hose, as the factor contributing to this defect.if the vapor tube hose clamp is mispositioned so that one of its ears is facing the fuel tank and that vehicle is involved in high speed crash, the clamp may puncture the fuel tank resulting in fuel leakage.fuel leakage, in the presence of an ignition source, could result in a fire.Hyundai will instruct owners to bring their vehicles to a dealer to have the position of the vapor tube hose clamp inspected and correctly repositioned, if necessary.

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