2016 Hyundai Veloster

The defect

Hyundai Motor America (Hyundai) is recalling certain 2015-2016 Veloster, 2012 Santa Fe, 2011-2013 Sonata Hybrid, and 2016 Sonata Hybrid vehicles. The connecting rod bearings inside the engine may wear prematurely, which over time can result in engine damage.

The risk

A damaged engine can increase the risk of a fire or it can cause an engine stall, increasing the risk of a crash.

The remedy

Hyundai will notify owners, and dealers will inspect the engine. If bearing damage is found, the engine will be replaced. Dealers will also install a software update containing a new Knock Sensor Detection System (KSDS). Repairs will be performed free of charge. The recall began March 31, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 198.

Hyundai Motor America · up to 128,948 vehicles across all model years covered

Closed engineering analysis · opened December 22, 2021 · closed February 5, 2024 · led to recall 23V877

the engine

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 NHTSA.gov.

Formal complaint against Hyundai Motor America for failure to provide safety recall remedies on a U.S.-conforming vehicle. Vehicle History: This 2016 Hyundai Veloster was purchased in the U.S. territory of [XXX], manufactured to meet U.S. Federal Motor Vehicle Safety Standards (FMVSS). Years later, it was legally relocated to the U.S. mainland and is currently registered and driven in [XXX]. The Database Issue: Official factory documents from Hyundai Puerto Rico confirm this VIN has critical, active safety recalls (chassis and engine/fire campaigns). However, due to regional database fragmentation between internal networks, these active recalls do not populate on domestic U.S. systems. The …

NHTSA complaint 11751038, quoted in part. Filed by an owner and not verified by NHTSA or by us.

19,000 miles

The contact owns a 2016 Hyundai Veloster. The contact stated that gas fumes were entering inside the vehicle and exhaust fumes were present while driving the vehicle and while the vehicle was parked. The vehicle was taken to an independent mechanic on several occasions and to several dealers; however, the cause of the failure was not yet determined. The master cylinder was replaced, and the high-pressure fuel pump was replaced due to a reported internal fuel leak, but the failure persisted. The contact stated that while refueling the vehicle at a gas station, fuel leaked from the vehicle with a strong fuel odor. The manufacturer was notified of the failure. The approximate failure mileage …

NHTSA complaint 11746173, quoted in part. Filed by an owner and not verified by NHTSA or by us.

Complaint regarding 2016 Hyundai Veloster engine oil consumption and warranty denial. In late 2023, at approximately 70,000–80,000 miles, my vehicle began experiencing excessive oil consumption. I reported this issue to Hyundai and authorized dealerships while the vehicle was still under warranty. Since then, I have completed multiple oil consumption tests, inspections, combustion cleanings, and repeated service visits, none of which resulted in a permanent repair or resolution. The oil consumption has continued and worsened over time. I am required to frequently add oil between services, raising serious concerns about engine reliability, safety, and potential engine failure. Despite …

NHTSA complaint 11743640, quoted in part. Filed by an owner and not verified by NHTSA or by us.

2016 Hyundai Veloster with 1.6L Gamma engine experienced repeat catastrophic engine failure consistent with NHTSA Recall 20V746000 / Hyundai Recall 198 for connecting rod bearing failure. Failure #1: At 124,036 miles, engine developed loud knocking noise increasing with RPM, check engine light, and DTCs P0300 (random misfire) + P0303 (cylinder 3 misfire). Dealer repair order documented "broken intake valve on cylinder 3." Engine was replaced at my expense because Hyundai stated VIN was not covered under Recall 198, despite failure mode matching the recall. Failure #2: Hyundai replacement engine failed at 164,410 miles (40,374 miles on replacement engine). Identical symptoms returned: loud …

NHTSA complaint 11742811, quoted in part. Filed by an owner and not verified by NHTSA or by us.

I was driving down the highway when I lost all power to my engine and had to coast off and exit. Prior to the incident there was no indication of a problem. White smoke began coming out of my exhaust. I brought the car to a dealership and they told me that I would need a timing job and a new turbo. They said that my car was starved for oil, regular maintenance had been kept up with on the vehicle.

NHTSA complaint 11737073. Filed by an owner and not verified by NHTSA or by us.

I was driving on the highway when suddenly the car lost power and the engine light started flashing. I was able to coast into a gas station. The car would no longer start and I was stranded. The next day, we drove back to where the car was stranded and attempted to get it started again, but we were unsuccessful. We had the car towed to a mechanic shop where we were told that the entire engine was blown and needed to be replaced. We had the car towed to the local Hyundai service center so they could inspect the engine. We discovered that the make, model, and year of our Veloster had been subject to an engine recall and these cars were given an extended warranty to 15 years/150,000 miles. …

NHTSA complaint 11734400, quoted in part. Filed by an owner and not verified by NHTSA or by us.