The National Highway Traffic Safety Administration announced a recall for Hyundai Sonata sedans from the 2011 and 2012 models years because of the potential for a major engine failure.

The vehicles in question were built between December 11, 2009, and April 12, 2012, at Hyundai's Alabama, manufacturing facility, equipped with either a 2.0-liter turbo or 2.4-liter four-cylinder gasoline engine. According to the NHTSA recall notice, metallic debris may not have been removed from the engine crankshaft during the manufacturing process. This could lead to restricted oil flow, damaging internal parts.

A symptom of the damage is a metallic, cyclic knocking noise from the engine, and the result is possible engine failure. This could lead to the vehicle stalling, resulting in the risk of a crash. NHTSA estimates that the problem exists with about 2 percent of the cars.

2011 Hyundai Sonata engine
2011 Hyundai Sonata

A New Engine, If Necessary

Hyundai will mail affected owners an interim recall notification by November 2, 2015, instructing them to contact their dealer for a service appointment. The dealer will inspect the vehicle and, if necessary, replace the engine free of charge. A second notification will be mailed when parts are available.

In addition, Hyundai Motor America will increase the warranty for the engine sub-assembly to 10 years/120,000 miles for both original and subsequent owners of 2011 and 2012 Sonatas manufactured at Hyundai's Alabama plant with the 2.0- and 2.4-liter gasoline engines.

These same engines, built at the same manufacturing plant, were also used in Hyundai Santa Fe SUVs, Kia Optima sedans, and Kia Sorento SUVs assembled in West Point, Georgia. According to Kia spokesperson Jame Hope, Kia is not impacted by this recall.

Owners may contact Hyundai customer service at 1-855-671-3059 or by visiting