NHTSA Defect Investigations for the 2013 Hyundai Sonata

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 2013 Hyundai Sonata, both ongoing and closed, are listed below:

  1. INVESTIGATION: Scope and Timeliness

    NHTSA Defect Investigation #RQ17004

    • Status:
    • Date Opened: May 18, 2017
    • Date Closed: N/A
    • Recall: No recall yet

    Component(s): Engine

    Summary: On September 10, 2015, Hyundai Motor America (Hyundai) filed a Defect Information Report (DIR) recalling 470,000 MY 2011 and 2012 Sonata vehicles with ""Theta II" engines (Recall No. 15V-568). Hyundai's DIR described the defect as an issue involving manufacturing debris. Hyundai limited the population of recalled vehicles to those produced on or prior to April 12, 2012, stating that a process change in April 2012 resolved the issue of manufacturing debris. On March 31, 2017, Hyundai expanded its original recall to include 572,000 MY 2013-2014 Sonata and Santa Fe Sport vehicles with "Theta II" engines (Recall No. 17V-226). The DIR continues to describe the defect as an issue involving manufacturing debris.This RQ is being opened to investigate both the timeliness and scope of Hyundai's "Theta II" engine recalls, and Hyundai's compliance with reporting requirements.

  2. INVESTIGATION: Non-crash Fires

    NHTSA Defect Investigation #DP18003

    • Status:
    • Date Opened: August 21, 2018
    • Date Closed: N/A
    • Recall: No recall yet

    Component(s): Engine
    Engine And Engine Cooling
    Engine And Engine Cooling:Cooling System
    Engine And Engine Cooling:Cooling System:Fan
    Engine And Engine Cooling:Cooling System:Hose
    Engine And Engine Cooling:Cooling System:Radiator Assembly
    Engine And Engine Cooling:Engine
    Engine And Engine Cooling:Engine:Diesel
    Engine And Engine Cooling:Engine:Gasoline
    Engine And Engine Cooling:Engine:Gasoline:Belts And Associated Pulleys
    Engine And Engine Cooling:Engine:Gasoline:Turbo-Charger
    Engine And Engine Cooling:Engine:Other Fuel Types:Turbo-Charger
    Engine And Engine Cooling:Exhaust System
    Engine And Engine Cooling:Exhaust System:Emission Control
    Engine And Engine Cooling:Exhaust System:Emission Control:Catalytic Convertor
    Engine And Engine Cooling:Exhaust System:Emission Control:Crankcase (Pcv)
    Engine And Engine Cooling:Exhaust System:Emission Control:Gas Recirculation Valve (Egr Valve)
    Engine And Engine Cooling:Exhaust System:Manifold/Header/Muffler/Tail Pipe

    Summary: On June 11, 2018, the Center for Auto Safety (CAS) petitioned NHTSA to conduct a defect investigation into non-crash fires on model year 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles.The CAS petition cited at least 120 Vehicle Owner Questionnaire (VOQ) reports of fires and additional 229 VOQs of melted wires, smoke and/or burning odors, indicating potential fires on these vehicles, as of June 7, 2018.ODI's preliminary review of the VOQs indicates the majority of the reported fires appears to be related to the engine failures covered by two current Recall Queries: RQ17-003 on Kia vehicles and RQ17-004 on Hyundai vehicles.ODI is opening a Defect Petition to review the petition, VOQs, Early Warning Data, and other information on the subject vehicles followed by a decision to grant or deny the petition.The following VOQ numbers (120 fire reports) are cited by the petitioner and can be viewed at www.nhtsa.gov.10341928 10386128 10398744 10429442 10436180 10441602 10465924 10476823 10482868 10503081 10534292 10547548 10553823 10555125 10558870 10560485 10572612 10587361 10645013 10650571 10661186 10692124 10693248 10694186 10702294 10705662 10714982 10726832 10748707 10748982 10779962 10783067 10785478 10786603 10787041 10787681 10806151 10806344 10808477 10812040 10821034 10824280 10846035 10850516 10852467 10861488 10873251 10883323 10884112 10892633 10894943 10895904 10901907 10903380 10903804 10905594 10914540 10918948 10920235 10926855 10930342 10938549 10949004 10957216 10958524 10965933 10968692 10970145 10971800 10972006 10978698 10980295 10984187 10985144 10991332 10991353 10991729 11005870 11010849 11012450 11012531 11012907 11013481 11015550 11015830 11016078 11016332 11022683 11022912 11024053 11031971 11043333 11044183 11045499 11047022 11052937 11057393 11058273 11060659 11062637 11065937 11066433 11066583 11071675 11073341 11074148 11075310 11076296 11080980 11081758 11082829 11090028 11090119 11090295 11091115 11093994 11097211 11097793 11097934 11098807

  3. INVESTIGATION: Front Passenger Seat Belt Anchor Failure

    NHTSA Preliminary Evaluation #PE16018

    Component(s): Seat Belts:Front:Anchorage
    Seat Belts:Pretensioner

    Summary: The Office of Defects Investigation (ODI) opened this investigation on December 27, 2016 based on two ODI consumer complaints reporting a failure of the front passenger seat belt to remain connected to the seat belt anchor and pre-tensioner during a crash.On March 8, 2017 Hyundai Motor America (Hyundai) filed a defect report with the agency stating that it would conduct a safety recall on 977,778 model year 2010-2014 Sonata vehicles produced from December 11, 2009 through May 29, 2014 and model year 2011-2015 Sonata Hybrid vehicles produced from December 2, 2010 through January 9, 2015.The remedy for the recall was to inspect the front seat belt anchor connector for proper attachment to the seat belt pre-tensioner.ODI continued the investigation in order to pursue a remedy that would be more lasting, rather than a one-time inspection.The connector is designed so that it can be removed from the pre-tensioner, when required, during vehicle maintenance.If it is not properly connected when originally installed or when re-installed after maintenance, the connector could potentially release in a crash. On September 4, 2017 Hyundai filed an amended defect report and advised the agency that the remedy would be modified to provide a permanent label, to be attached to the connector, at the time of inspection.The label provides graphic instructions and illustration as to the proper orientation of the connector lock when it is properly installed.On October 4, 2017 Hyundai filed an additional defect report (see 17V-671) to have the vehicles that have had only theinspection procedure performed return to dealers to have the permanent label applied to the connector.ODI is closing this investigation based on Hyundai's recall action to add a permanent label to the connector. This preliminary evaluation is closed.The ODI reports cited above can be viewed at www-odi.nhtsa.gov/complaints under the following identification numbers: 10903469 and 10926737.

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