2020 Hyundai Kona

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

My 2020 Kona 2.OL failed an oil test losing 2.5 quarts in 960 miles, stalled on the highway, and blows oil out the tailpipe. Hyundai (Case #43141313) is denying repair coverage because my VIN was excluded from Recall 21V301000. This recall needs to be expanded to include my VIN.

NHTSA ID

11773096

Incident

Aug 26, 2026

The contact owns a 2020 Hyundai Kona. The contact stated that while driving at 35 MPH, the accelerator pedal was depressed, but the vehicle hesitated, and there was white smoke coming from the exhaust. The vehicle was towed to an independent mechanic, where the contact was advised to take the vehicle to a dealer. The dealer was made aware of the failure. The contact referenced an unknown recall; however, the VIN was not associated with a recall related to the failure. The manufacturer was made aware of the failure. The failure mileage was approximately 53,976.

NHTSA ID

11770764

Incident

Sep 10, 2026

Mileage

53,976 mi

COMPONENT THAT FAILED: The engine short block piston rings (related to NHTSA recall 203) failed, causing severe cylinder wall scoring. The vehicle is currently located at an authorized Hyundai dealership and is available for manufacturer or NHTSA inspection. SAFETY RISK; The defective piston rings caused severe internal oil consumption, resulting in hydraulic oil starvation. This creates a high risk of sudden engine stalling, catastrophic engine seizure, and complete loss of motive power while driving in traffic. CONFIRMATION AND INSPECTION: Yes, the defect has been confirmed. The current Hyundai dealership performed a boroscope inspection, which physically confirmed severe vertical metal scoring in cylinder 3. They also documented that the engine was 1.5q low on oil with zero external leaks, confirming internal consumption. Despite physical proof of the recall defect, the manufacturer is currently refusing to honor the recall repair. WARNING LAMPS/SYMPTOMS: The check engine light illuminated, logging exhaust camshaft timing correlation codes (P0017). This first April 2026 at 169,000 miles. This timing code is a secondary hydraulic symptom caused by the severe internal oil starvation originating from priary lower block cylinder scoring defect.

NHTSA ID

11767813

Incident

Aug 19, 2026

I was fortunate to check my daughter's oil and noticed that it was almost empty. I alerted the dealer because I recently got an oil change and thought there was a leak, but no oil was on the driveway. The dealer performed an oil consumption test. They said it was 1 quart per 1,000 miles and this is acceptable. There are other models that are on the recall list, but mine is not. The dealer and Hyundai said that they will not pay for repairs because it is out of warranty. The bigger issue here is that Hyundai is aware of this issue (oil burning fast in these vehicles) and they are not warning owners to check their oil. This is a cute car and it is driven by college age girls who do not think about checking oil. If the oil runs dry, the engine can seize up and the car will stop. This can cause an accident and possible fatality. I am very concerned about the safety of my daughter and others. I have 5 quarts of oil in my daughters trunk to top it off regularly. This information needs to be given to owners of these vehicles to increase awareness of the problem an prevent a tragedy.

NHTSA ID

11767214

Incident

May 14, 2026

The contact owns a 2020 Hyundai Kona. The vehicle was taken to the dealer to be repaired under NHTSA Campaign Number: 21V301000 (Engine); however, the dealer was unable to perform the recall repair because the vehicle had not experienced a failure associated with the recall and there were no fault codes displayed or retrieved associated with the recall. However, an independent mechanic recommended that the engine be replaced. The contact provided the dealer with the fault codes and the failures that the independent mechanic had found; however, the dealer was unable to retrieve the same fault codes. The contact stated that the check engine warning light was illuminated. The manufacturer was notified of the failure and agreed with the dealer and refused additional assistance. The vehicle was not repaired.

NHTSA ID

11763068

Incident

Sep 9, 2026

The contact owns a 2020 Hyundai Kona. The contact stated that the vehicle was repaired under NHTSA Campaign Number: 21V301000 (Engine); however, the recall repair failed to prevent the failure from occurring. The contact stated that while driving at various speeds, the vehicle lost motive power and failed to restart using the ignition key. The vehicle was towed to a dealer, Capital Hyundai of Greensboro (801 E Bessemer Ave, Greensboro, NC 27405), where it remained for further diagnosis. The contact stated that during the prior recall repair, the Continuously Variable Valve Timing (CVVT) assembly, Engine Control Module (ECM), and Body Control Module (BCM) were replaced, a solenoid was installed, and the engine was inspected but not replaced. The manufacturer was notified of the failure, and a case was opened. The failure mileage was approximately 72,000.

NHTSA ID

11760900

Incident

Jan 15, 2025

Mileage

72,000 mi

Leaking oil...burns exceptionally fast even with dealership services. Pistons not sealed, melts new spark plugs, misfire on cylinder 3

NHTSA ID

11759906

Incident

Aug 24, 2026

My 2020 Hyundai Kona experienced an engine-related malfunction. An authorized Hyundai dealer inspected the vehicle, confirmed diagnostic code P1327, and determined that the complete engine required replacement. Hyundai authorized the replacement, and the vehicle remained out of service for approximately two weeks. The engine defect created a safety concern because an engine malfunction could cause reduced or complete loss of motive power while driving, increasing the risk of a crash. The dealer inspected and removed the original engine; I do not know whether it remains available for further inspection, but the repair order and diagnostic records are available. I am filing this complaint so NHTSA can document this engine failure and determine whether it is related to NHTSA Campaign 21V301 / Hyundai Recall 203 and whether additional investigation or corrective action is warranted.

NHTSA ID

11759509

Incident

Mar 16, 2026

This bulletin provides information related to the navigation and head unit software changes introduced in the 2026 2nd Navigation Map and Software Update. The changes may vary depending on vehicle type, model, and navigation system. Refer to the 2026 2nd Navigation Map and Software Update Key Improvements and Additional Improvements tables in this TSB for a list of specific changes. The software can be downloaded via Navigation Updater (NAU) and updated by USB.

Some Hyundai vehicles may be equipped with a parking distance warning (PDW) sensor(s) that may trigger various DTCs and display warning messages on the instrument cluster, resulting in the PDW sensor(s) failing to detect nearby objects or triggering multiple false alarms. This condition may be a result of external damage to the PDW sensor membrane or sensor cover from rock chips or road debris, a collision, or previous vehicle repairs or modifications.

Some vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin outlines the combustion chamber cleaning procedure for vehicles diagnosed with this condition. All internal combustion engines consume some engine oil during normal operation, depending on driving conditions and mileage, and this procedure should only be performed when deemed necessary based on inspection and diagnosis of the vehicle as outlined in TSB 26-EM-015H, Engine Oil Consumption – Inspection & Repair Guidelines, or the latest revision.

Certain vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin provides the inspection and repair procedures for vehicles exhibiting this condition. All internal combustion engines consume engine oil as part of normal engine operation. Oil consumption rates may vary based on mileage, operating conditions, driving habits, and maintenance history. Hyundai recommends following the prescribed maintenance schedule and periodically checking the engine oil level using the dipstick to maintain proper engine oil level.

Some vehicles may exhibit difficulty starting in cold weather. This bulletin provides the procedure to perform an inspection on the starter magnetic switch for potential freezing and, if necessary, replace the starter magnetic switch (solenoid) assembly.

The National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driver‑side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN), that have been identified in U.S. vehicles following prior crashes, theft, or non‑certified airbag replacements. These inflators are not approved for use, may rupture during deployment, and have caused serious injuries and fatalities. Please see attached announcement, provided by NHTSA, for more details.