NHTSA Defect Investigations for the 2007 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 2007 Hyundai Elantra, both ongoing and closed, are listed below:

  1. INVESTIGATION: ENGINE STALLING - FUEL PUMP FAILURE

    NHTSA Preliminary Evaluation #PE08044

    Component(s): Fuel System, Gasoline
    Fuel System, Gasoline:Delivery:Fuel Pump

    Summary: On August 19, 2008, Hyundai submitted a defect information report to NHTSA concerning fuel pump failure resulting in engine stall in approximately 65,000 model year 2008 Hyundai Elantra vehicles with 2.0 liter beta engines produced from November 5, 2007, through June 28, 2008 (NHTSA recall no. 08V-429, Hyundai campaign 086).the recalled vehicles are equipped with fuel pumps manufactured with upper body components from a different supplier than those manufactured prior to November 5, 2007.according to Hyundai, the new supplier's upper body components had incorrect dimensional characteristics resulting in misalignment of the armature shaft, which caused some of the fuel pumps to experience poor brush-to-commentator contact conditions that could result in engine stall. The use of ethanol blend fuel, containing up to 10 percent ethanol, causes a film build-up that creates high resistance between the brush and commutator.the misaligned armature shaft prevents the brush and commutator from making sufficient contact to overcome the high resistance film build-up, therefore producing less pumping pressure than required to supply the fuel injection system. Sixty-four of the complaints (72%), including the crash and injury allegation, involve the recalled vehicles.the complaint rate in the subject vehicle population is 98.5 per 100,000 vehicles, compared with 21.4 in the remaining population, which has on average been in service over a year longer.the warranty claim rate is also significantly higher in the recalled vehicles, which had 569 claims (0.9 percent claim rate) compared with 126 claims in the remaining population (0.1 percent claim rate). Hyundai will replace the fuel pump subassemblies in the recalled vehicles free of charge.this preliminary evaluation is closed with Hyundai's recall.

  2. INVESTIGATION: STOP LAMP SWITCH FAILURE

    NHTSA Preliminary Evaluation #PE09003

    Component(s): Electronic Stability Control
    Exterior Lighting:Brake Lights
    Exterior Lighting:Brake Lights:Switch
    Power Train:Automatic Transmission:Lever And Linkage:Column Shift
    Power Train:Automatic Transmission:Lever And Linkage:Floor Shift
    Power Train:Manual Transmission:Column Shift Assembly
    Power Train:Manual Transmission:Floor Shift Assembly
    Service Brakes, Hydraulic:Antilock
    Service Brakes, Hydraulic:Pedals And Linkages
    Vehicle Speed Control:Cruise Control

    Summary: By letter dated April 15, 2009, Hyundai notified the Agency that it will conduct a safety recall (NHTSA recall number 09V122) to replace the stop lamp switches on many of its model year 2005-2008 vehicles.see recall 09V122 for a complete list. The Agency opened its investigation based on five complaints of stop lamp failure across several 2007 Hyundai models. The Agency also received early warning (EWR) reports on this issue.most of those failures were traced to the improper operation of the stop lamp switch that controls stop lamp illumination.a malfunctioning stop lamp switch can cause the vehicle's brake lights not to light during braking, or alternatively, it can cause the brake lights to stay lit even when a driver takes the foot off the brake pedal. Failure of the stop lamps to illuminate properly creates the hazard of rear end collisions when drivers following the subject vehicle do not recognize that the vehicle is slowing or stopping. Hyundai reported one crash incident (a frontal impact), without injury, that was alleged to have been caused by this defect.the Agency reviewed the incident and cannot conclude that it is related to this defect. There are other potential problems related to failure of the stop lamp switch: Failure of the cruise control to disengage, interference with proper functioning of antilock brakes and electronic stability control, and inability to move the gear shift lever out of park position.based on the above safety recall, this investigation is closed.

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