2019 Hyundai Kona

The defect

Hyundai Motor America (Hyundai) is recalling certain 2019-2020 Elantra, 2019-2021 Kona and Veloster vehicles equipped with 2.0L Nu MPI engines. The piston oil rings may not have been properly heat-treated, which could result in engine damage.

The risk

A damaged engine may stall, increasing the risk of a crash. In addition, oil may leak onto hot exhaust components, increasing the risk of a fire.

The remedy

Dealers will inspect and, if necessary, replace the engine, free of charge. In addition, Hyundai will deploy Piston Ring Noise Sensing System (PNSS) software. Owner notification letters were mailed August 24, 2021. Owners may contact Hyundai customer service at 1-855-371-9460.

Hyundai Motor America · up to 158,493 vehicles across all model years covered

Closed defect petition · opened January 27, 2023 · closed August 7, 2023 · led to recall 22V063000

the electrical system

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

Closed defect petition · opened September 12, 2022 · closed December 12, 2023

the engine

The National Highway Traffic Safety Administration (NHTSA) 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 NHTSA.gov 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 NHTSA 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 NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA 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 NHTSA.gov.

The vehicle suffered a sudden, severe loss of power while driving, causing the engine to stall unexpectedly. This created an immediate hazard to myself and other motorists on the road, as I was forced to navigate a dead vehicle out of active traffic without power steering or power braking assist. Prior to the total failure, the engine exhibited severe mechanical knocking, loss of acceleration, and high oil consumption without any visible external oil leaks. This engine failure is a direct result of the manufacturing defect detailed in NHTSA Safety Recall 203 (NHTSA Campaign 21V301000) concerning improperly heat-treated piston oil rings that cause severe cylinder scuffing and engine stall. …

NHTSA complaint 11750800, quoted in part. Filed by an owner and not verified by NHTSA or by us.

First notice was exterior top railing coating wearing down after just 3 years of having car. Notified dealership of this issue and was stated that my car was out of warranty. (Now 7yo) Exterior Paint is peeling off hood; exposing primer layering, as well as in some spots, the main body itself. This is a known defect caused by factory laquer coating and of which dealership states they STILL will not cover repair.

NHTSA complaint 11749136. Filed by an owner and not verified by NHTSA or by us.

My 2019 Hyundai Kona has been burning oil, I’ve done great upkeep on it, including topping the oil off in between services. This is because it obviously has been burning oil, well recently it started stalling, then starting/turning it over has been acting up. The RPM’s have not been stable at all an I’ve ran two diagnostic test on it, they came back as a “camshaft error” I can’t remember the exact code at the moment. However the mechanics I have questioned said it’s probably from the oil pressure being messed up from the oil burning up. Whether it be the sensor not regulating properly or the engine itself not getting enough lubricant. I have heard from others with Hyundais an it’s not just …

NHTSA complaint 11746808, quoted in part. Filed by an owner and not verified by NHTSA or by us.

113,000 miles

The contact owns a 2019 Hyundai Kona. The contact stated that the vehicle had experienced excessive oil consumption. The contact stated that while driving 70 MPH on the highway, the vehicle stalled. The contact was unable to pull over to the side of the road. The contact was able to restart the vehicle and continued driving. The contact stated that the failure recurred while driving into a parking lot. The battery warning light illuminated on several occasions. Additionally, the contact stated that the check engine and low oil pressure warning lights were intermittently illuminated. The vehicle was taken to Auto Zone and to an independent mechanic, where it was diagnosed and determined that …

NHTSA complaint 11744406, quoted in part. Filed by an owner and not verified by NHTSA or by us.

100,000 miles

The contact owns a 2019 Hyundai Kona. The contact stated that while driving on several occasions at various speeds, the AWD warning light illuminated and was reset each time the vehicle was restarted. The contact also stated that over a couple of months, while downshifting, stopping, or decelerating, the vehicle stalled on several occasions. Additionally, the contact stated that while driving at approximately 30 MPH, the Check Engine warning light illuminated. The vehicle was then taken to an AutoZone, where a handheld diagnostic machine retrieved diagnostic trouble codes: P0017 (crankshaft) and P0171 (system too lean), and it was observed that the oil reservoir was empty. Two quarts of oil …

NHTSA complaint 11742887, quoted in part. Filed by an owner and not verified by NHTSA or by us.

105,000 miles

The contact owns a 2019 Hyundai Kona. The contact stated that while making left turns on several occasions, the vehicle stalled. The vehicle was shifted into park (P) and restarted. The vehicle was not diagnosed or repaired. However, during routine maintenance, an independent mechanic noticed that the oil reservoir was empty, and an oil change was completed. The manufacturer was notified of the failure. The failure mileage was approximately 105,000.

NHTSA complaint 11742657. Filed by an owner and not verified by NHTSA or by us.