2022 Hyundai Tucson Hybrid

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.

We were involved in a forward collision at 40mph with a vehicle that crossed the highway to turn into a gas station. None of the airbags deployed. The vehicle was inoperable due to the damage and my wife sustained a knee injury due to hitting the dash durring the wreck.

NHTSA ID

11775466

Incident

Oct 30, 2026

My wife was driving her 2022 Hyundai Tucson Hybrid, when she suddenly heard a bang and then the vehicle had very little engine power and would not accelerate properly. This turned out to be because the gas engine would not turn on and only the small hybrid motor was functioning. She was able to safely pull into a parking lot. The vehicle was tow to a Hyundai dealership where they diagnosed the issue as a broken/snapped Hybrid Starter Generator (HSG) drive belt tensioner spring. Because this spring failed, the accessory drive belt lost complete tension, and so the HSG could not start the gas engine. This made the vehicle unsafe to drive due to sever lack of power. The dealership replaced the entire HSG tensioner assembly under warranty. Researching this online shows that others have had the same issue and the replacement part appears to have a different and more robust spring. I have a second Tuscon PHEV and now worried the spring in that one will fail suddently. They do not sell just the spring, the whole tensioner has to be replaced which is very expensive. I think this is a safety hazard, as a sudden failure of the HSG tensioner spring while actively driving in traffic causes an unexpected loss of motor power and propulsion, increasing the risk of collisions.

NHTSA ID

11775294

Incident

Oct 28, 2026

The contact owns a 2022 Hyundai Tucson. The contact stated that while driving 5 MPH, the brake pedal was depressed; however, the vehicle failed to stop. The contact stated that the vehicle independently accelerated. The contact stated that the brake pedal was depressed with force and the vehicle came to a stop. The failure occurred intermittently at first but became a persistent failure. The dealer was contacted by phone and made aware of the failure. The failure mileage was approximately 17,000.

NHTSA ID

11769292

Incident

Aug 17, 2026

Mileage

17,000 mi

My vehicle suffered a disabling failure 325 miles from home due to an open Safety Recall campaign. The vehicle is repaired under Campaign Claim #43195279, but Hyundai Corporate is actively denying both a reunite transport tow and travel rental accommodations to retrieve the vehicle. The manufacturer is failing to provide a reasonable or accessible remedy, leaving me completely carless at home for 3 days due to an admitted safety defect with no way to retrieve my vehicle 325 miles from home.

NHTSA ID

11761059

Incident

Aug 27, 2026

System/Component Failed & Inspection: The vehicle suffers from recurring failures across the engine, powertrain, electronic throttle control, and exhaust gas recirculation (EGR) control systems (DTCs P0524, P0642, P2118, P022100). The vehicle is fully available for inspection upon request. Safety Risk: While driving, the vehicle suffered a complete, sudden loss of motive power on an active highway entrance ramp. The engine stalled in moving traffic with zero throttle response, creating an immediate collision hazard before requiring a tow. Confirmation by Dealer: Technicians formally confirmed these defect patterns. In May 2026, diagnostics logged major engine and emission/EGR control codes, but corporate refused goodwill repair. In August 2026, the highway stall recurred. Diagnostics confirmed active low oil pressure and throttle failure codes, which the dealer resolved by applying 4 factory ECU software updates under TSB 25-01-010H. Service personnel explicitly confirmed these engine control issues are manufacturing defects, not wear-and-tear or mileage-related. Inspections: Inspected, diagnosed, and serviced by authorized dealership service department technicians during both the May and August 2026 failure events. Warning Symptoms & History: Engine issues began at 341 miles when purchased new (settled). In May 2026, check engine lights returned with diagnostic codes for engine and EGR/emissions systems. In August 2026, total power loss occurred, preceded by check engine, forward collision camera, and radar sensor warnings.

NHTSA ID

11758103

Incident

May 11, 2026

While driving my 2022 Hyundai Tucson Hybrid, the vehicle suddenly lost power, began shaking, and all warning lights illuminated at once. The car would not accelerate properly and became unsafe to operate in traffic. After pulling over and restarting the vehicle, the warnings cleared, but the issue has occurred more than once. It first occurred 3/25/26. The dealer was not able to reproduce the issue but found numerous faults and reset them. This is a serious safety concern because the vehicle can unexpectedly lose motor power while driving, creating a risk of collision. The problem is intermittent and unpredictable.

NHTSA ID

11755202

Incident

Aug 4, 2026

I am reporting a critical Exhaust Gas Recirculation (EGR) valve and electrical circuit failure on my 2022 Hyundai Tucson Hybrid. The failure resulted in the check engine light illuminating, diagnostic codes identifying an EGR system malfunction, and visible corrosion found within the EGR connector and extension harness. This component breakdown causes severe performance risks, risk of sudden loss of engine power, and compromises vehicle safety. Diagnostic & Technical Details: Error Codes Captured: Diagnostic trouble codes in the P0400 series (EGR system flow/circuit malfunction) along with connector/wiring degradation were confirmed during inspection. Root Cause & Symptoms: The failure stems from degradation and electrical shorting risks in the EGR valve assembly and its immediate wiring harness connection. Manufacturer Response & Escalation Denial: When addressing this failure, I discovered that Hyundai has acknowledged widespread EGR valve assembly defects, electrical short risks, and solder flux contamination issues across multiple model years and production lines (such as NHTSA Campaign 24V-308 and subsequent service campaigns like 9B3). However, Hyundai restricts safety recall and warranty coverage strictly based on narrow VIN manufacturing parameters, leaving owners with identical, failing hardware to shoulder exorbitant out-of-pocket repair costs—in my case, quoted at over $2,013.  Because a compromised EGR system and corroded electrical harness can cause sudden engine performance failures while driving in traffic, and because Hyundai is limiting its accountability through arbitrary production windows, I am requesting that NHTSA investigate this systemic EGR and harness failure on 2022 Tucson Hybrid models and compel Hyundai to expand its safety coverage and reimburse affected owners for necessary repairs.

NHTSA ID

11754790

Incident

Jun 26, 2026

On XXX the vehicle lost motive power while my wife was accelerating to merge onto a highway with our two young children aboard. It would not accelerate and she was forced to pull over in an active merge area. Simultaneous warnings illuminated: Electronic Parking Brake, ESC, Forward Collision Avoidance, Blind Spot Detection, and hybrid system, with "Check Hybrid System" displayed. No crash or injury occurred, but loss of propulsion during a highway merge created serious collision risk. This is a recurring defect documented since early 2023: Hyundai's own Blue Link telematics auto-flagged an Engine Control System DTC on XXX; a jump-start was required XXX (dealer RO #XXX); check engine light and stored CAN-bus codes U100387, U100100, U004600, U010100 on 08/10/2023 (RO #XXX); and a September 2023 incident in which the center display shut off during reverse, disabling the backup camera. Hyundai performed Service Campaign 9B4 (BMS software update, DTC P1BB20, TSB 25-01-010H-1) on this VIN on XXX; the same failure category recurred 84 days later. The vehicle was towed to Safford Hyundai of [XXX] onXXX and has remained there 65+ consecutive days. The dealer replaced the 12V battery (defect persisted) and the Hybrid Power Control Unit (HPCU); per Hyundai Consumer Affairs' own written email ofXXX, the check engine light returned after the HPCU replacement and the cause "remains unidentified." The dealer states it cannot determine the root cause. The vehicle IS available for inspection at Safford Hyundai of Springfield, [XXX]. Five Hyundai Consumer Affairs cases exist on this VIN (current: #XXX). INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11753579

Incident

May 19, 2026

Certain Tucson (NX4, NX4A), Tucson Hybrid (NX4 HEV), and Tucson Plug-in Hybrid (NX4 PHEV) vehicles may be eligible for the installation of the latest OEM tow hitch harness on the vehicle.

Certain Tucson (NX4, NX4A), Tucson Hybrid (NX4 HEV), and Tucson Plug-in Hybrid (NX4 PHEV) vehicles may be eligible for the installation of the latest OEM tow hitch harness on the vehicle. This bulletin provides the procedure to install the latest OEM tow hitch harness.

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.

Certain Santa Fe Hybrid (TM HEV), Santa Fe Plug-in Hybrid (TM PHEV), Tucson Hybrid (NX4 HEV), andTucson Plug-in Hybrid (NX4 PHEV) vehicles may experience intake air line freezing and Exhaust GasRecirculation (EGR) valve corrosion due to excessive condensation accumulating within the EGR system.This condition can lead to drivability concerns related to the following DTCs: - P040400: (Exhaust Gas Recirculation Control Circuit Range) - P049D00: (EGR 'A' Control Position Exceeded Learning Limit) - P047100: (Exhaust Pressure Sensor 'A' Circuit Range/Performance) - P012800: Coolant Thermostat (Coolant Temperature below Thermostat Regulation Temperature) - P262B00: (Control Module Power Off Timer Performance) - P050C00: Cold Start Engine Coolant Temperature Performance - P1DFD00: (EVAP System Purge Pump Target Speed) - P2DFD00: (EVAP System Purge Pump Performance) - P112000: (Inlet Metering Valve – Malfunction) - P033500: (Crankshaft Position Sensor A)

Certain Santa Fe Hybrid (TM HEV), Santa Fe Plug-in Hybrid (TM PHEV), Tucson Hybrid (NX4 HEV), and Tucson Plug-in Hybrid (NX4 PHEV) vehicles may experience intake air line freezing and Exhaust Gas Recirculation (EGR) valve corrosion due to excessive condensation accumulating within the EGR system. This condition can lead to drivability concerns related to the following DTCs: • P040400: (Exhaust Gas Recirculation Control Circuit Range) • P049D00: (EGR 'A' Control Position Exceeded Learning Limit) • P047100: (Exhaust Pressure Sensor 'A' Circuit Range/Performance) • P012800: Coolant Thermostat (Coolant Temperature below Thermostat Regulation Temperature) • P262B00: (Control Module Power Off Timer Performance) • P050C00: Cold Start Engine Coolant Temperature Performance • P1DFD00: (EVAP System Purge Pump Target Speed) • P2DFD00: (EVAP System Purge Pump Performance) • P112000: (Inlet Metering Valve – Malfunction) • P033500: (Crankshaft Position Sensor A)

Certain Santa Fe Hybrid (TM HEV), Santa Fe Plug-in Hybrid (TM PHEV), Tucson Hybrid (NX4 HEV), and Tucson Plug-in Hybrid (NX4 PHEV) vehicles may experience intake air line freezing and Exhaust Gas Recirculation (EGR) valve corrosion due to excessive condensation accumulating within the EGR system. This condition can lead to drivability concerns related to the following DTCs: • P040400: (Exhaust Gas Recirculation Control Circuit Range) • P049D00: (EGR 'A' Control Position Exceeded Learning Limit) • P047100: (Exhaust Pressure Sensor 'A' Circuit Range/Performance) • P012800: Coolant Thermostat (Coolant Temperature below Thermostat Regulation Temperature) • P262B00: (Control Module Power Off Timer Performance) • P050C00: Cold Start Engine Coolant Temperature Performance • P1DFD00: (EVAP System Purge Pump Target Speed) • P2DFD00: (EVAP System Purge Pump Performance) • P112000: (Inlet Metering Valve – Malfunction) • P033500: (Crankshaft Position Sensor A) The bulletin below provides instructions to perform a software update for the Engine Control Module (ECM).