NHTSA Opens Investigation Into Hyundai's Theta II Engine Debris Recalls

The timeliness of a recall of Hyundai and Kia vehicles equipped with Theta II four-cylinder engines is the focus of a formal National Highway Traffic Safety Administration investigation revealed today.

Metal engine debris resulting from a faulty production process is behind the expansive recall of nearly 1.7 million vehicles, but the NHTSA wants to know if the recall expanded too slowly. Just how much Hyundai knew about the widespread issue is a big question mark, made all the more pressing by the testimony of a company whistleblower.

According to Reuters, filings published today show the NHTSA opened an investigation on May 18th into “both the timeliness and scope” of the recalls, as well as Hyundai’s “compliance with reporting requirements.”

The automaker has stated it will cooperate with the investigation.

The issue facing older 2.4-liter and turbocharged 2.0-liter Theta II powerplants involves metal shavings surrounding the crankshaft of the engines. That debris can contaminate the engine oil, leading to restricted oil circulation, component wear, and the potential for engine failure.

While the recalls eventually covered numerous Hyundai and Kia vehicles in the U.S., Canada and South Korea, the company appears to have been slow to address the problem. The first recall, in 2015, involved just 470,000 Sonata sedans sold in the U.S., despite the exact same engine appearing in other models. Earlier this year, the company recalled a slew of 2013 and 2014 Sonata and Santa Fe vehicles, while Kia called back over half a million 2011-2014 model year Optima, Sorento and Sportage models to address the engine debris problem.

A former longtime Hyundai engineer, Kim Gwang-ho, has loomed over the issue since the recalls began. Last August, Kim delivered a stack of internal documents to the NHTSA, explaining his concerns that the problem was far more widespread than the automaker let on. The engineer claims to have attended a July 2015 meeting in Seoul where colleagues discussed downplaying the problem to avoid a huge repair bill.

The latest recall has cost the company $322 million.

[Image: Hyundai]