Hyundai Motor America is recalling 470,000 model year 2011-2012 Sonatas manufactured December 11, 2009, to April 12, 2012, at Hyundai Motor Manufacturing Alabama and equipped with either a 2.0 liter or 2.4 liter Gasoline Direct injection engine.
Metallic debris may not have been fully removed during manufacturing of the engine crankshaft. If the debris was not completely removed, oil flow may be restricted through the connecting rod bearings, causing connecting rod damage. A worn connecting rod bearing will produce a metallic, cyclic knocking noise from the engine and possible engine failure.
Engine failure would result in a vehicle stall, increasing the risk of a crash.
Hyundai will notify owners, and dealers will inspect the vehicles and replace the engine assembly, as necessary, free of charge. Additionally, Hyundai will increase the warranty for the engine sub-assembly (short block) to 10 years/120,000 miles for both original and subsequent owners of the recalled vehicles.
An interim notification will be mailed by November 2, 2015. A second notification will be mailed when parts are available.
Owners may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for this recall is 132.