2003 Hyundai Sonata Recalls & Complaints

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.

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.

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.

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.

DEALERS WILL MEASURE THE THICKNESS OF THE FRONT SUB-FRAME AND INSPECT THE FRONT SUB-FRAME FOR CORROSION DAMAGE AND, IF NECESSARY, THE FRONT SUB-FRAME WILL BE REPLACED WITH A NEW SUB-FRAME THAT INCORPORATES ADDITIONAL HOLES IN THE UPPER AND LOWER PANELS. IF THE FRONT SUB-FRAME DOES NOT REQUIRE REPLACEMENT, THE DEALER WILL ADD DRAINAGE HOLES TO THE SUB-FRAME AND WILL TREAT THE SUB-FRAME WITH RUST-PROOFING MATERIAL TO STOP THE CORROSION PROCESS. THIS PROCEDURE WILL BE PERFORMED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009. OWNERS MAY CONTACT THE HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

HYUNDAI IS RECALLING 188,282 MY 2001-2004 SONATA AND MY 2001-2004 XG300 AND XG350 VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE JURISDICTIONS DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUB-FRAME ON THE VEHICLES, AND MAY RESULT IN THINNING OR PERFORATION OF THE SUB-FRAME STEEL. THE CORROSION IS FREQUENTLY VISIBLE AND OFTEN DISCOVERED DURING INSPECTION OR ROUTINE MAINTENANCE, AND OWNERS MAY ALSO HEAR NOISES OR NOTICE TIRE MISALIGNMENT AND STEERING PULL. IF THESE SIGNALS ARE UNDETECTED OR UNHEEDED, THE CORROSION MAY PROGRESS AND THE FORWARD MOUNTING OF THE LOWER CONTROL ARM MAY DETACH FROM THE SUB-FRAME.

DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JUNE 2009. OWNERS MAY CONTACT HYUNDAI CUSTOMER ASSISTANCE CENTER AT 1-800-633-5151.

HYUNDAI IS RECALLING 91,350 MY 2002-2003 HYUNDAI SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATE. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING, THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.

DEALERS WILL REPAIR THE CHROME PLATED INTERIOR DOOR HANDLE FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 16, 2009. OWNERS MAY CONTACT HYUNDAI OF PUERTO RICO AT 1-787-999-3333.

HYUNDAI IS RECALLING 82 MODEL YEAR 2002-2003 SONATA VEHICLES. REPEATED USE OF THE INTERIOR DOOR HANDLE MAY CAUSE WEAR OF THE CHROME PLATING. IF THE TOP EDGE OF THE HANDLE HAS VERY THIN CHROME PLATING THAT PORTION OF THE PLATING MAY WEAR AWAY MORE EASILY THAN MORE THICKLY PLATED AREAS AS THE DOOR HANDLE IS USED. THE WORN CHROME PLATING ON THE UPPER EDGE OF THE HANDLE MAY RESULT IN A CRACK OR SEPARATION BETWEEN THE CHROME PLATING ON THE INBOARD AND OUTBOARD SURFACES OF THE HANDLE, WHICH MAY FORM A SHARP EDGE.

DEALERS WILL REPLACE THE SPARE TIRE WITH A NEW LARGER DIAMETER T125/80R-15 COMPACT SPARE TIRE AND A NEW TIRE PRESSURE LABEL WILL BE INSTALLED ON THE DRIVER'S DOOR TO PROVIDE INFORMATION APPLICABLE TO THE T125/80R-15 COMPACT SPARE TIRE. VEHICLES PRODUCED FROM NOVEMBER 15, 2002 THROUGH DECEMBER 16 2002, ALREADY CONTAIN T125/80R-15 COMPACT SPARE TIRES, WILL ONLY REQUIRE NEW TIRE PRESSURE LABELS. OWNER NOTIFICATION BEGAN JUNE 30, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HYUNDAI AT 1-800-633-5151.

ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH A TRACTION CONTROL SYSTEM (TCS), IF THE T125/70D-15 COMPACT SPARE TIRE IS INSTALLED ON A FRONT WHEEL POSITION, THE TCS MAY INADVERTENTLY ACTIVATE BEGINNING AT SPEEDS OF 20 MPH.