2012 Hyundai Tucson

The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.

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.

On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles.  During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types.  The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement.  Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia.  The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio.  The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires.  In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines.  The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS.  It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension.  For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied.  Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates.  To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years.  In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires.  Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis.  Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023).  The agency reserves the right to take additional action if warranted by future circumstances.  To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

Vehicle suddenly slipped into limp mode. Vehicle was then immediately taken to have code read. Code came back P1326. Was advised due to previous recall campaign(s) to contact Hyundai of America for guidance. Was told that vehicle needed to be confirmed per the BCT at any Hyundai dealership to which the agent scheduled the appointment myself and that i should get the other 4 recalls fixed as well. My spouse drove the vehicle there and that was our last true communication verbally with Hyundai of America. Vehicle barely made it to the dealership and then spouse was offered a ride home an hour and a half later without paperwork or any type of understanding other than it would take time for the service team to get it on the BCT. A week later I was told it would cost $250. We have argued that we were never told it would cost anything as it relates to this major recall nor the others and in fact it would be performed at zero cost. Then, a service manager stated that now the vehicle needed $10k worth of work and began having finance firms contact me that he said were employed by Hyundai but are not. Here we are a month later, and still no vehicle and we have contacted Hyundai of America numerous times and have all communications regarding such contact and have gotten nowhere. We have yet to actually speak to someone over the phone. We were assigned a case manager who is now on vacation. We're without an income now because after not having transportation to work my partner has lost his job, and we are in dire condition. Inside of my vehicle that this dealership is holding hostage is my infant’s car seat and a brand new catalytic converter. They have refused to communicate with me and supposedly with this case manager according to her emails. We are in need of help.

NHTSA ID

11753637

Incident

Jul 5, 2026

Engine started knocking luckily I was right by my mechanics place. They said needs new engine. Not to drive as a rod might go right through the engine. Only 98000 miles on it. Maintenance always done on time.

NHTSA ID

11736110

Incident

May 6, 2026

got vehicle registration notice and recall notice was on the form regarding a possible electrical fire while parked or driving. I just got this car about 9 months ago, dmv is still showing nothing has been done.

NHTSA ID

11692419

Incident

Oct 9, 2025

Airbag located in the steering wheel partially deployed during a moderate/serious accident. It came out of the front of the steering wheel but never inflated. I have pictures available of the partially deployed airbag. No other airbags were deployed during this front end crash. The seatbelt tensioner did activate and prevented serious injury during the crash. There was no indication, via warning lights or any other messages, that the system was not working properly. All outstanding recalls for the vehicle had been addressed. It is unknown if the partial deployment was indicated in the police report. No other inspections of the system have been done. Insurance adjuster from at-fault party will be performing an assessment of damage this week. Thankfully the most serious injury is from the seat belt and this partial deployment of the airbag did not cause a more serious injury.

NHTSA ID

11686195

Incident

Sep 8, 2025

The contact owns a 2012 Hyundai Tucson. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic); however, the part to do the recall repair was not yet available. An unknown dealer was contacted and confirmed that the recall repair parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue and confirmed that the parts were not yet available. The contact had not experienced a failure.

NHTSA ID

11677502

Incident

Jul 31, 2025

Car suddenly stalled on the interstate (sudden deceleration, could barely make it to the shoulder; engine and oil lights, loud knocking sound, burning smell); per Hyundai dealership, it is sudden engine rod failure. Hyundai recall 181 described this exact situation. If not for quick thinking and moving to the shoulder/shutting down the engine immediately, there was a high chance of either being hit by other vehicles or engine fire. I could have been killed or severely injured. Yes, problem was confirmed by Hyundai dealership. No warning prior to sudden deceleration. Engine and oil warning lamps did not appear until after sudden drop in speed, followed by burning smell.

NHTSA ID

11627693

Incident

Nov 9, 2024

The contact owns a 2012 Hyundai Tucson. The contact stated while the vehicle was at an independent mechanic for an oil change, the contact was informed that the subframe was significantly rusted. Additionally, the contact stated while driving 25-35 MPH, she was losing control of the vehicle. The contact was able to pull to the side of the roadway. The contact stated that upon inspecting the vehicle, she noticed that the rear passenger's side wheel was dislocated. The vehicle was towed to an independent mechanic, where it was diagnosed that the subframe and other parts were severely rusted. The vehicle was then towed to the dealer, where it was determined that the frame and the suspension were damaged and needed to be replaced. The contact was provided a cost for the repair. The vehicle was not repaired. The contact stated that an undercoating spray was previously applied to the underbody of the vehicle as a corrosion preventative service under TSB Number: 16-01-045. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 105,576.

NHTSA ID

11611423

Incident

Aug 20, 2024

Mileage

105,576 mi

My 2012 Tucson started dumping large amounts of oil. Would be ok not dumping then would start drastically using then stop again. Vehicle ran fine then it started doing this maybe 3 months into this approx a week ago it started making noises coming from the motor. It is doing as I was told the motors Hyunda has recalled already done yet it is not listed in that recall. From what I understand it is a fire hazard as well as a road safety hazard due to it possible stalling. I have has 2 mechanics tell me it's pertains to the recalled motors. To see if it's a issue I'm expected to pay the dealership to evaluate this issue which is unfair to me You can clearly hear and see the issue is there. Why is it I am having to miss work, delay bills, be without transportation for them to acknowledge this concern. Please tell me there is a alternate solution help anything?!

NHTSA ID

11609346

Incident

Aug 15, 2024

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.

The National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous driver’s-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN). These inflators were not supplied, approved, or authorized by the vehicle manufacturers and have primarily been found in vehicles that previously experienced a crash and underwent airbag replacement using non-genuine parts. These dangerous inflators have ruptured during deployment, posing a serious risk of injury or death due to metal fragments entering the vehicle cabin. To date, Hyundai is aware of three people who have died while driving a Hyundai vehicle with one of these substandard replacement airbag inflators that deployed in what likely would have been a survivable crash. NHTSA has issued a public advisory urging vehicle owners and service professionals to have vehicles inspected if there is reason to believe that a non-genuine replacement airbag may have been installed. Vehicles with salvage or rebuilt titles, prior airbag deployments, or unknown repair histories may present a higher risk. NHTSA strongly cautions against self-inspection by vehicle owners and recommends inspection by trained technicians.

This TSB references the Op codes to use for claim submission and the Parts required based on the vehicle’s inspection results from TSB 22-01-023H (DTC P1326 – Engine Bearing Inspection/Engine Replacement) or the latest version.

This TSB references the Op codes to use for claim submission and the Parts required based on the vehicle’s inspection results from TSB 22-01-023H-2 (DTC P1326 – Engine Bearing Inspection/Engine Replacement) or the latest version.

In response to this trend, we engineered a software upgrade that addresses the social media theft method and made it available to owners of eligible models free of charge at authorized Hyundai dealers since early 2023. In addition to the anti-theft software, we’ve developed a new zinc-reinforced ignition cylinder protector hardware upgrade that can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Because your Hyundai vehicle with the VIN listed above (“Subject Vehicle”) was not factory-equipped with an engine immobilizer and was previously eligible for the software upgrade, you are now eligible until March 31, 2027 to have the ignition cylinder protector installed — if you request it — at no cost to you through an authorized Hyundai dealership.

This bulletin provides the service procedure for installation of a key cylinder reinforcement protector assembly and two anti-theft decals on the front windows.