2023 Hyundai Tucson Hybrid Engine Problems

I am reporting a critical Exhaust Gas Recirculation (EGR) valve failure on my 2023 Hyundai Tucson Hybrid. The failure resulted in an immediate loss of engine power, reduced vehicle performance, reduced fuel efficiency, and the vehicle entering limp mode while driving, creating a significant safety hazard in traffic. Diagnostic & Technical Details: Error Codes Captured: Diagnostic trouble codes in the P0400 series (EGR system flow/circuit malfunction) were confirmed during diagnostic inspection. Root Cause: The component failure is directly linked to an internal short circuit in the EGR valve assembly, caused by solder flux contamination during manufacturing. Manufacturer Response & Escalation Denial: When contacting Hyundai regarding this failure, I was informed that my vehicle’s VIN is "not included in Safety Recall 260" (NHTSA Campaign 24V-308). I formally escalated this claim to Hyundai Corporate, but my request for reimbursement and coverage was explicitly denied on the grounds that my VIN falls outside the designated recall parameters. However, this exact failure mode, part assembly line, and manufacturing defect (solder flux contamination) are identical to the safety defect described in Recall 260 as well as Hyundai Service Campaign 9B3. Hyundai is restricting coverage based on narrow VIN manufacturing windows despite identical, defective parts being installed across non-recalled vehicles. Because a sudden EGR failure causes unexpected loss of power while traveling in traffic, and because Hyundai Corporate has refused to cover this out-of-pocket repair, I am requesting that NHTSA investigate this issue and compel Hyundai to expand the scope of Recall 260 to protect affected owners and mandate reimbursement for out-of-pocket repair costs.

NHTSA ID

11753488

Incident

Jun 8, 2026

On June 3, 2025, I experienced a terrifying and dangerous incident while driving my 2023 Hyundai Tucson Hybrid on a three-lane road at approximately 50 mph. Without any warning, the gas pedal became completely unresponsive, and the car abruptly decelerated from 50 to 20 mph. This sudden loss of acceleration was incredibly frightening, especially with vehicles close behind me that nearly collided with mine. There were no warning lights or check engine alerts. Fortunately, I was able to safely cross all lanes and pull over before having the vehicle towed to a local Hyundai dealership. I shudder to think what might have happened if this had occurred on a highway at higher speeds. This is not the first time I’ve experienced serious issues with this vehicle. In February 2024, at about 17,000 miles, I received an urgent alert recommending a system check. At that time, the car was revving while idle and would occasionally lurch at low speeds. The dealership had difficulty diagnosing and resolving the issue, and my vehicle remained in the shop for over a month before they ultimately replaced the oxygen sensor. Since then, the car has continued to lurch intermittently — for example, when backing out of a parking space or in stop-and-go traffic. In fact, approximately 10 minutes before the June 3 incident, the vehicle lurched several times while moving slowly in traffic. When the car began to lose speed during the most recent incident, I pressed the gas pedal all the way down, but it failed to respond at all. I believe the current issue may be related to the unresolved problems from last year and represents a significant and recurring safety concern. I’ve also read in Tucson owner forums that other drivers have experienced similar issues, suggesting this may be part of a broader, systemic defect. At this point, I do not feel safe driving this vehicle. I truly believe this car is a lemon. This vehicle is still at the dealership, but they have not given me any updates yet.

NHTSA ID

11665014

Incident

Jun 3, 2025

Oil was leaking when we bought the car. By the time of the first service at the dealer (~7,500 miles), I had noticed the plastic underbody cover has some smeared oil that was making it past the plastic cover and fasteners. I had assumed they would catch any problems, but after the service they did not mention seeing anything, so I kept a closer eye on it. Brought it back about 1 to 2 months later (fall 2023) after dripping started occurring (oil was leaking faster, and making it past plastic underbody cover). They sent me home after wiping it up and telling me that there was no leak (there was clearly a leak, and I even showed them photos I had taken). I watched it for 2 more weeks, then brought it back in after taking more photos and showing them again that there was definitely a leak. They confirmed leak (after seeing the car for the 3rd time). Said it was the oil pan gasket, so they put a new gasket in. Earlier in 2024, started noticing oil leak again. Brought it back to the dealer's service department, and they said it's the same problem. They are planning to replace the oil pan this time to fix the issue, but have to wait on part. At this point, vehicle has been at the dealership's service department 4 separate times for the same issue that has not yet been resolved. Brand new car leaking oil that they are struggling to fix.

NHTSA ID

11583472

Incident

Jan 15, 2024

2023 Hyundai Tucson Hybrid Blue Issue: no power /accelerator response from slow speed. Since 4/23- 9 instances involving this issue none resulted in crashes but did result in near misses and 2 cases coasting off the edge of the road to avoid being hit. 6 of the instances happened when attempting a left turn in traffic at an intersection. 3 of the instances involved when trying to enter a traffic circle(turning right). In all of the instances the vehicle was in Eco mode. Description of Intersection Instances: Left turn with a blinking yellow arrow traffic light signal. I approached the intersection in the left turn lane slowed and was coasting forward. The vehicle had shift to EV mode. There was a gap in oncoming traffic and I hit the accelerator to cross. No response I pressed the accelerator to the floor and still no response. I lifted my foot off the accelerator and jammed it back down and had power but now the oncoming traffic was on me. Fortunately, only one car that did hit their brakes and honk. This same scenario happened two more times at the same intersection as well as three other times in city traffic. No power when entering a traffic circle: I approached the traffic circle slowed and coasted forward waiting for the cars in the traffic circle to clear. There was a gap and I hit the gas and not power. Pedal to the floor and no power. Traffic was on me and I turned the steering wheel hard to the right and drove off the edge of the road to not get hit. I had three passengers with me at the time. The same scenario happened two more times- where I hit the gas no response but these times I let up off the accelerator all the way and then pressed it down and had full power. This resulted in about a 3-4 second delay from when I first realized I did not have power to having power. I did check 4 a recall and none found. However, I did notice another complaint citing the same issue w-Hybrid on NHTSB site. but in error listed under reg Tucson.

NHTSA ID

11550145

Incident

Apr 25, 2023

On four occasions in the last five weeks, I have been driving at relatively low speed (20-30 MPH), and when I attempt to accelerate, the vehicle will not accelerate when I press the gas pedal. The tachometer shows the RPMs are maxed out, but the vehicle does not accelerate no matter how hard I press the gas pedal. I have to pull off the road, turn off the vehicle, and restart to fix it. I am certain I have not accidentally hit any buttons or switches each time. I have tried changing drive modes (eco/normal/sport) and using the paddle shifters and that has no effect. Cruise control is off, and no other speed limiting system is activated. There are no warning lights or indicators when this occurs. This is incredibly dangerous, as I am unable to get up to speed on a main road. A few instances led me to be unable to successfully merge onto a main road, which has led to me almost being rear-ended on one occasion, and the most recent instance I was in the left lane of a main road and attempting to pass a large truck and could not maintain speed. I was fortunate to come upon a slight downhill slope and was able to coast across the right lane and get off the road, but it was a near-accident. The dealer service center was unable to diagnose the issue, and therefore could not repair it.

NHTSA ID

11549579

Incident

Oct 11, 2023

Oil pan leak. A lot of owners aren’t aware their oil pan is leaking cause the dealer offer a 3 years complimentary service. I only notice mine is leaking cause I changed my own oil now. Dealers won’t fix anything under warranty unless customer tell them. Hyundai mechanic on YouTube say it’s a common problem.

NHTSA ID

11531594

Incident

Jun 1, 2023

Unknown what fails. After driving approximately 30 minutes on a highway, car suddenly stops accelerating and bucks a bit as it slows. Must turn off car and turn it back on to accelerate again. Happens on the highway frequently. Very dangerous as there’s no way to accelerate. Only stop. It’s like it can’t find a gear and the engine revs. It happened 6 times during a 2.5 hour drive.

NHTSA ID

11527493

Incident

Jun 16, 2023

My son was backing out of a parking spot at a strip mall. He released some pressure on the brake and indicated that the car lurched backwards and even though he reapplied full pressure to the brakes, he hit the car at the curb resulting in damage to our Tucson, but luckily not the to the other car. The Rear Cross-Traffic Collision-Avoidance Assist system did not engage, but my son indicated that the rear distance warning system did beep. I am concerned due to the sudden acceleration/lurching incident my son experienced and this is not acceptable in any car. I ask the NHTSA to see if other Hyundai Tucson or Kia Sportage owners, especially with the Hybrid engine are experiencing this.

NHTSA ID

11522976

Incident

May 18, 2023

ATTEMPT TO ACCELERATE AND WILL NOT ACCELERATE AND CAR START OVERHEATING AND BAD ODOR SMOG COMING OUT FROM THE EXHAUST. DEALER FOUD THE FOLLOWING, CONCERN SCANNED FOR CODES, FOUND CODES P111100, P030000. P030100, P030300, P030400 ABNORMAL COMBUSTION DETECTION FOR ANY CYLENDER, RAMDON CYLINDER MISFIRE DETECTED CYLINDER #1,2,3,4 MISFIRE DETECTED, PERFORMED FUEL TEST FOUND ALCOHOL AT 5% FOUND FUEL WAS DISCOLORED AND SMELL VARNISH OR CONTAMINATED, DEALER STILL HAVE THE CAR AND THEY WANT US TO PAY FOR THE REPAIRS AND VOID THE WARRANTY, WE CONTACT THE STATE TO DO A FUEL TEST TO THE GAS STATION AND EVERYTHING IS WITH THE GUIDELINES BASE ON THE REPORT, LOOKS LIKE THE CAR IS DEFFECTIVE AND SOMETHING NEEDS TO CHECK

NHTSA ID

11514805

Incident

Mar 15, 2023

I was driving to work taking the same route I have since I purchased the vehicle when I lost acceleration on the road. I was unable to go above 40 MPH and I had the gas pedal pressed all the way to the floor. I was going uphill and the lack of acceleration could have caused an accident if there was not enough space behind me and the vehicle behind me.

NHTSA ID

11497198

Incident

Dec 13, 2022