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2005 Hyundai Elantra

Component

Steering:Linkages:Tie Rod Assembly

Consequence of Defect

certain passenger vehicles may have been built with threaded portions of the steering gearbox assembly's left and right inner ball joint assemblies that contain internal cracks in the material structure.

Corrective Action

if the inner ball joint assembly was to break as a result of the internal crack, the tie rod end assembly would not longer be attached to the steering gear box. this would prevent steering control of that front wheel by the separated tie rod which could result in a crash.

Recall Notes

dealers will replace the steering gearbox assemblies on these vehicles free of charge. owners were contacted by telephone beginning on april 8, 2005, and instructed not to drive their vehicles. hyundai will arrange to pick up and return their vehicles after repair. owners may contact hyundai at 1-800-633-5151.

2005 Hyundai Elantra

Component

Air Bags

Consequence of Defect

certain vehicles equipped with an advanced air bag system. the occupant classification system (ocs) installed in the right front seat of the vehicle may misclassify a child restraint seat (crs) as an adult. this may occur if the crs is installed after an adult has been seated in the right front seat. if there has not been a 'key on' ' key off' cycle with the right front passenger seat empty prior to installation of the crs.

Corrective Action

the possibility of misclassification of a crs as an adult may allow the right front airbag or side impact airbag to deploy in a crash and could result in injury to the right front occupant.

Recall Notes

dealers will reprogram the vehicle's ocs electronic control unit (ecu) to remove the feature that may cause the crs to be recognized as an adult. the recall began on november 15, 2005. owners may contact hyundai of puerto rico at 1-800-981-0188.

2005 Hyundai Elantra

Component

Air Bags

Consequence of Defect

certain vehicles equipped with an advanced air bag system. the occupant classification system (ocs) installed in the right front seat of the vehicle may misclassify a child restraint seat (crs) as an adult. this may occur if the crs is installed after an adult has been seated in the right front seat. if there has not been a 'key on' ' key off' cycle with the right front passenger seat empty prior to installation of the crs.

Corrective Action

the possibility of misclassification of a crs as an adult may allow the right front airbag or side impact airbag to deploy in a crash and could result in injury to the right front occupant.

Recall Notes

dealers will reprogram the vehicle's ocs electronic control unit (ecu) to remove the feature that may cause the crs to be recognized as an adult. the recall began on october 31, 2005. owners may contact hyundai at 1-800-633-5151.

2004 Hyundai Elantra

Component

Fuel System, Gasoline:Delivery:Hoses, Lines/Piping, And Fittings

Consequence of Defect

during an insurance institute for highway safety (iihs) offset frontal barrier impact test on certain passenger vehicles, fuel spillage occurred as a result of fuel tank damage caused by contact between a vapor tube hose clamp ear and the fuel tank. the vapor tube hose clamp ear was found to be mispositioned and facing toward the fuel tank.

Corrective Action

in the event of a crash, damage to the vehicle could cause the mispositioned clamp to puncture the fuel tank causing fuel leakage. fuel leakage, in the presence of an ignition source, could result in a fire.

Recall Notes

dealers will inspect the position of the vapor tube hose clamp and correctly position the clamp, if necessary. owner notification began on may 24, 2004. owners should contact hyundai at 1-800-633-5151.

2004 Hyundai Elantra

Component

Air Bags

Consequence of Defect

on certain vehicles, if the front passenger seat is unoccupied or is occupied by someone lighter than 56.4 pounds, the passenger air bag is deactivated and will not deploy if a crash occurs. however, the occupant classification sensor may incorrectly interpret that a seated adult is an infant seat and deactivate the passenger air bag if someone heavier than 56.4 pounds who is seated with one leg resting on the outboard or inboard edge of the seat; with legs spread; or positioned off-center toward the center console and with his or her arm leaning on the console.

Corrective Action

in the event of a vehicle crash, the air bag may not deploy, possibly resulting in serious injury to the right front passenger.

Recall Notes

the occupant classification sensor will be reprogrammed.

2004 Hyundai Elantra

Component

Fuel System, Gasoline:Delivery:Hoses, Lines/Piping, And Fittings

Consequence of Defect

during an insurance institute for highway safety (iihs) offset frontal barrier impact test, it was determined that fuel tan damage could occur. on certain passenger vehicles, a vapor tube hose clamp that is located near the fuel tank may not be positioned properly and could cause fuel leakage.

Corrective Action

fuel leakage in the presence of an ignition source may result in a fire.

Recall Notes

dealers will inspect the position of the vapor tube hose clamp ears and correctly position the clamp, if necessary. the recall began on october 5, 2004. owners should contact hyundai de puerto rico at 1-800-981-0188.

2004 Hyundai Elantra

Component

Air Bags

Consequence of Defect

certain vehicles equipped with an advanced air bag system. the occupant classification system (ocs) installed in the right front seat of the vehicle may misclassify a child restraint seat (crs) as an adult. this may occur if the crs is installed after an adult has been seated in the right front seat. if there has not been a 'key on' ' key off' cycle with the right front passenger seat empty prior to installation of the crs.

Corrective Action

the possibility of misclassification of a crs as an adult may allow the right front airbag or side impact airbag to deploy in a crash and could result in injury to the right front occupant.

Recall Notes

dealers will reprogram the vehicle's ocs electronic control unit (ecu) to remove the feature that may cause the crs to be recognized as an adult. the recall began on november 15, 2005. owners may contact hyundai of puerto rico at 1-800-981-0188.

2004 Hyundai Elantra

Component

Air Bags

Consequence of Defect

certain vehicles equipped with an advanced air bag system. the occupant classification system (ocs) installed in the right front seat of the vehicle may misclassify a child restraint seat (crs) as an adult. this may occur if the crs is installed after an adult has been seated in the right front seat. if there has not been a 'key on' ' key off' cycle with the right front passenger seat empty prior to installation of the crs.

Corrective Action

the possibility of misclassification of a crs as an adult may allow the right front airbag or side impact airbag to deploy in a crash and could result in injury to the right front occupant.

Recall Notes

dealers will reprogram the vehicle's ocs electronic control unit (ecu) to remove the feature that may cause the crs to be recognized as an adult. the recall began on october 31, 2005. owners may contact hyundai at 1-800-633-5151.

2003 Hyundai Elantra

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

some passenger vehicles contain a fuel tank assembly valve that may not close properly. if a vehicle with a fuel tank assembly valve that is not properly closed were to roll over, fuel spillage may occur.

Corrective Action

fuel spillage in the presence of an ignition source may result in a fire.

Recall Notes

dealers will install an additional fuel tank assembly valve. owner notification began on june 30, 2004. owners should contact hyundai at 1-800-633-5151.

2003 Hyundai Elantra

Component

Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings

Consequence of Defect

on certain passenger vehicles, the brake tubes for the rear brakes can contact the steering gearbox mounting brackets.

Corrective Action

contact between the rear brake tubes and the steering gearbox mounting brackets may result in rear brake tube wear and corrosion, increasing the risk of brake fluid leakage. brake fluid leakage could result in reduced braking capability, which could result in a crash.

Recall Notes

dealers will reposition the rear brake tubes, install brake tube clips, and apply anti-corrosion material to the rear brake tubes. owner notification began january 22, 2004. owners should contact hyundai of puerto rico at 1-800-633-5151.

2003 Hyundai Elantra

Component

Fuel System, Gasoline:Storage

Consequence of Defect

certain passenger vehicles fail to comply with the requirements of federal motor vehicle safety standard no. 301, "fuel system integrity" a valve on the fuel tank assembly may not close properly. if a vehicle rolls over and the fuel tank assembly valve is not properly closed, fuel spillage may occur.

Corrective Action

fuel spillage in the presence of an ignition source may result in a fire.

Recall Notes

dealers will install an additional fuel tank assembly valve. the recall began on october 5, 2004. owners should contact hyundai de puerto rico at 1-800-981-0188.

2003 Hyundai Elantra

Component

Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings

Consequence of Defect

on certain passenger vehicles, the rear brake tubes pass behind the front suspension crossmember. two steering gearbox mounting brackets are welded to the crossmember. on vehicles equipped with an antilock brake system (abs), the rear brake tubes could contact both steering gearbox mounting brackets. on vehicles that are not equipped with abs, the rear brake tubes may contact only the left mounting bracket. contact between the rear brake tubes and the steering brackets could cause wear and corrosion that could result in brake fluid leakage.

Corrective Action

fluid leakage could result in reduced braking capability increasing the risk of a crash.

Recall Notes

dealers will reposition the rear brake tubes so they do not contact the mounting brackets, install brake tube clips to control the location of the rear brake tubes, and apply anti-corrosion material to the tubes in the areas where contact with the mounting brackets may have occurred. owner notification began on october 13, 2003. owners should contact hyundai at 1-800-633-5151.

2002 Hyundai Elantra

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

some passenger vehicles contain a fuel tank assembly valve that may not close properly. if a vehicle with a fuel tank assembly valve that is not properly closed were to roll over, fuel spillage may occur.

Corrective Action

fuel spillage in the presence of an ignition source may result in a fire.

Recall Notes

dealers will install an additional fuel tank assembly valve. owner notification began on june 30, 2004. owners should contact hyundai at 1-800-633-5151.

2002 Hyundai Elantra

Component

Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings

Consequence of Defect

on certain passenger vehicles, the brake tubes for the rear brakes can contact the steering gearbox mounting brackets.

Corrective Action

contact between the rear brake tubes and the steering gearbox mounting brackets may result in rear brake tube wear and corrosion, increasing the risk of brake fluid leakage. brake fluid leakage could result in reduced braking capability, which could result in a crash.

Recall Notes

dealers will reposition the rear brake tubes, install brake tube clips, and apply anti-corrosion material to the rear brake tubes. owner notification began january 22, 2004. owners should contact hyundai of puerto rico at 1-800-633-5151.

2002 Hyundai Elantra

Component

Fuel System, Gasoline:Storage

Consequence of Defect

certain passenger vehicles fail to comply with the requirements of federal motor vehicle safety standard no. 301, "fuel system integrity" a valve on the fuel tank assembly may not close properly. if a vehicle rolls over and the fuel tank assembly valve is not properly closed, fuel spillage may occur.

Corrective Action

fuel spillage in the presence of an ignition source may result in a fire.

Recall Notes

dealers will install an additional fuel tank assembly valve. the recall began on october 5, 2004. owners should contact hyundai de puerto rico at 1-800-981-0188.

2002 Hyundai Elantra

Component

Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings

Consequence of Defect

on certain passenger vehicles, the rear brake tubes pass behind the front suspension crossmember. two steering gearbox mounting brackets are welded to the crossmember. on vehicles equipped with an antilock brake system (abs), the rear brake tubes could contact both steering gearbox mounting brackets. on vehicles that are not equipped with abs, the rear brake tubes may contact only the left mounting bracket. contact between the rear brake tubes and the steering brackets could cause wear and corrosion that could result in brake fluid leakage.

Corrective Action

fluid leakage could result in reduced braking capability increasing the risk of a crash.

Recall Notes

dealers will reposition the rear brake tubes so they do not contact the mounting brackets, install brake tube clips to control the location of the rear brake tubes, and apply anti-corrosion material to the tubes in the areas where contact with the mounting brackets may have occurred. owner notification began on october 13, 2003. owners should contact hyundai at 1-800-633-5151.

2001 Hyundai Elantra

Component

Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings

Consequence of Defect

on certain passenger vehicles, the brake tubes for the rear brakes can contact the steering gearbox mounting brackets.

Corrective Action

contact between the rear brake tubes and the steering gearbox mounting brackets may result in rear brake tube wear and corrosion, increasing the risk of brake fluid leakage. brake fluid leakage could result in reduced braking capability, which could result in a crash.

Recall Notes

dealers will reposition the rear brake tubes, install brake tube clips, and apply anti-corrosion material to the rear brake tubes. owner notification began january 22, 2004. owners should contact hyundai of puerto rico at 1-800-633-5151.

2001 Hyundai Elantra

Component

Air Bags:Side/Window

Consequence of Defect

vehicle description: passenger vehicles. the supplemental restraint system side air bag satellite sensors installed were improperly manufactured, causing the air bag warning light to illuminate and the side air bags to not deploy as intended in the event of a crash.

Corrective Action

non-deployment of the side air bags could increase the risk of injury during a crash where side air bag deployment is intended.

Recall Notes

dealers will replace the two satellite sensors.

2001 Hyundai Elantra

Component

Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings

Consequence of Defect

on certain passenger vehicles, the rear brake tubes pass behind the front suspension crossmember. two steering gearbox mounting brackets are welded to the crossmember. on vehicles equipped with an antilock brake system (abs), the rear brake tubes could contact both steering gearbox mounting brackets. on vehicles that are not equipped with abs, the rear brake tubes may contact only the left mounting bracket. contact between the rear brake tubes and the steering brackets could cause wear and corrosion that could result in brake fluid leakage.

Corrective Action

fluid leakage could result in reduced braking capability increasing the risk of a crash.

Recall Notes

dealers will reposition the rear brake tubes so they do not contact the mounting brackets, install brake tube clips to control the location of the rear brake tubes, and apply anti-corrosion material to the tubes in the areas where contact with the mounting brackets may have occurred. owner notification began on october 13, 2003. owners should contact hyundai at 1-800-633-5151.

2000 Hyundai Elantra

Component

Electrical System:Wiring

Consequence of Defect

vehicle description: some sonata vehicles equipped with 2.5 liter v-6 engines and all elantra model vehicles may have experienced intermittent low-speed engine stalling, which could occur if the maf (mass air flow) sensor electrical signal is interrupted as a result of engine vibration transmitted to the maf sensor connector wiring harness.

Corrective Action

this condition can cause the engine to stall, increasing the risk of a crash.

Recall Notes

dealers will re-route the maf sensor connector wiring harness.

1999 Hyundai Elantra

Component

Electrical System:Wiring

Consequence of Defect

vehicle description: some sonata vehicles equipped with 2.5 liter v-6 engines and all elantra model vehicles may have experienced intermittent low-speed engine stalling, which could occur if the maf (mass air flow) sensor electrical signal is interrupted as a result of engine vibration transmitted to the maf sensor connector wiring harness.

Corrective Action

this condition can cause the engine to stall, increasing the risk of a crash.

Recall Notes

dealers will re-route the maf sensor connector wiring harness.

1999 Hyundai Elantra

Component

Power Train:Automatic Transmission

Consequence of Defect

vehicle description: passenger vehicles equipped with automatic transmissions. the automatic transmission pressure control solenoid valve seals do not remain sufficiently elastic, resulting in transmission fluid leakage. this leakage can result in reduced pressure application to the clutches, brake, and kickdown servo, allowing them to slip.

Corrective Action

such slippage can cause premature deterioration of the friction element surfaces and could cause the vehicle not to accelerate, or not accelerate as expected, when the driver presses the accelerator pedal.

Recall Notes

dealers will replace the pressure control solenoid valve.

1997 Hyundai Elantra

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

vehicle description: passenger vehicles. the evaporative emission control systems can apply excessive vacuum to the fuel tanks during the canister purge cycle. if excessive vacuum is applied, minor fuel tank distortion can result. a small crack could develop on the upper fuel tank surface. the "check engine" light would then illuminate and, in some cases, the vehicle driver may notice a gasoline odor.

Corrective Action

fuel leakage in the presence of an ignition source could result in a fire.

Recall Notes

dealers will pressure check the vehicle's fuel tank to determine if it has cracked. if the fuel tank has cracked, it will be replaced.

1997 Hyundai Elantra

Component

Visibility:Windshield Wiper/Washer:Motor

Consequence of Defect

the windshield wiper motor circuit breaker electrical contacts were contaminated during assembly.

Corrective Action

this contamination interferes with the electrical circuit continuity and prevents the windshield wiper motor from operating. inoperative windshield wipers can contribute to reduced visibility during inclement weather increasing the risk of a vehicle crash.

Recall Notes

dealers will remove the contaminants from the windshield wiper motor circuit breaker contacts.

1997 Hyundai Elantra

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

vehicle description: passenger vehicles. the evaporative emission control systems can apply excessive vacuum to the fuel tanks during the canister purge cycle. if excessive vacuum is applied, minor fuel tank distortion can result. a small crack could develop on the upper fuel tank surface. the "check engine" light would then illuminate and, in some cases, the vehicle driver may notice a gasoline odor.

Corrective Action

fuel leakage in the presence of an ignition source could result in a fire.

Recall Notes

dealers will pressure check the vehicle's fuel tank to determine if it has cracked. if the fuel tank has cracked, it will be replaced.

1996 Hyundai Elantra

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

vehicle description: passenger vehicles. the evaporative emission control systems can apply excessive vacuum to the fuel tanks during the canister purge cycle. if excessive vacuum is applied, minor fuel tank distortion can result. a small crack could develop on the upper fuel tank surface. the "check engine" light would then illuminate and, in some cases, the vehicle driver may notice a gasoline odor.

Corrective Action

fuel leakage in the presence of an ignition source could result in a fire.

Recall Notes

dealers will pressure check the vehicle's fuel tank to determine if it has cracked. if the fuel tank has cracked, it will be replaced.

1996 Hyundai Elantra

Component

Visibility:Windshield Wiper/Washer:Motor

Consequence of Defect

the windshield wiper motor circuit breaker electrical contacts were contaminated during assembly.

Corrective Action

this contamination interferes with the electrical circuit continuity and prevents the windshield wiper motor from operating. inoperative windshield wipers can contribute to reduced visibility during inclement weather increasing the risk of a vehicle crash.

Recall Notes

dealers will remove the contaminants from the windshield wiper motor circuit breaker contacts.

1996 Hyundai Elantra

Component

Fuel System, Gasoline:Storage:Tank Assembly

Consequence of Defect

vehicle description: passenger vehicles. the evaporative emission control systems can apply excessive vacuum to the fuel tanks during the canister purge cycle. if excessive vacuum is applied, minor fuel tank distortion can result. a small crack could develop on the upper fuel tank surface. the "check engine" light would then illuminate and, in some cases, the vehicle driver may notice a gasoline odor.

Corrective Action

fuel leakage in the presence of an ignition source could result in a fire.

Recall Notes

dealers will pressure check the vehicle's fuel tank to determine if it has cracked. if the fuel tank has cracked, it will be replaced.

1995 Hyundai Elantra

Component

Air Bags:Frontal

Consequence of Defect

the driver's side air bag was improperly assembled and could cause the air bag warning light to illuminate from increased electrical resistance.

Corrective Action

an increase in the electrical resistance might prevent the air bag from activating during a vehicle crash.

Recall Notes

dealers will inspect the air bag assembly wiring harness connector to determine if it contains a terminal holder. if it does not, one will be installed.

1994 Hyundai Elantra

Component

Air Bags:Frontal

Consequence of Defect

the driver's side air bag was improperly assembled and could cause the air bag warning light to illuminate from increased electrical resistance.

Corrective Action

an increase in the electrical resistance might prevent the air bag from activating during a vehicle crash.

Recall Notes

dealers will inspect the air bag assembly wiring harness connector to determine if it contains a terminal holder. if it does not, one will be installed.

1994 Hyundai Elantra

Component

Electrical System:Alternator/Generator/Regulator

Consequence of Defect

in some vehicles, the manufacturer's protective internal coating of the electronic crank angle sensor does not meet specifications, which can cause an open circuit at high operating temperatures. this can cause the vehicle to stall.

Corrective Action

engine stalling has the potential to result in a vehicle crash if it occurs while the vehicle is moving.

Recall Notes

dealers will inspect the crank angle sensor to determine whether the sensor is involved in the recall, and replace any sensor found with the defective internal coating.