2019 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.

The contact owns a 2019 Hyundai Tucson. The contact stated that while driving approximately 30 MPH and depressing the brake pedal, the vehicle responded as intended; however, several unknown warning lights were illuminated. The vehicle was taken to the dealer, where it was diagnosed and determined that the ABS had failed and needed to be replaced. The vehicle was repaired at the owner's expense. The contact became aware that notification for NHTSA Campaign Number: 20V543000 (Service Brakes, Hydraulic); was previously received; however, the VIN was no longer included in the recall. The contact was unsure if the recall repair was performed. The contact requested a reimbursement from the dealer, but the request was denied. The manufacturer was not notified of the failure. The failure mileage was approximately 56,000.

NHTSA ID

11754470

Incident

Sep 20, 2025

Mileage

56,000 mi

I have noticed that the engine oil level in my vehicle drops significantly between regular oil changes. Despite adhering to the manufacturer's recommended maintenance schedule, I frequently have to add a quart of oil after driving only about [800~1,000 마일] miles.I understand that this is a widely reported issue with Hyundai Owners Forum affecting 2019 models. Many experts and fellow owners have identified that this rapid oil loss is often caused by manufacturing defects, such as faulty piston rings, which can eventually lead to catastrophic engine failure.As a Hyundai owner, I am highly concerned about the safety, reliability, and decreased resale value of my vehicle. Running low on oil without warning creates a high risk of sudden engine breakdown while driving on the highway.I kindly request that Hyundai Corporate or my local authorized dealer investigate and resolve this matter. Specifically, I am asking for:An official engine inspection and a proper Oil Consumption Test.Necessary repairs or a full engine replacement under the applicable powertrain warranty at no cost to me.

NHTSA ID

11751036

Incident

May 1, 2024

The 2019 Tucson has 60,413 miles. My daughter drives it very low mileage - a couple of miles a day back and forth to school. Friday she was driving and the car lost engine power and it stopped driving. No warning lights. There was a cloud of smoke and it smelled like burning plastic. She was on a busy road but pulled over and quickly exited the vehicle. I had it towed and the mechanic says the engine oil was empty and the engine has seized. We do regularly scheduled oil changes. No lights or warnings and the car just stopped in traffic.

NHTSA ID

11744669

Incident

Jun 12, 2026

While driving, the check engine light began flashing and the vehicle shook severely due to engine misfiring. The vehicle has had a recurring cylinder 3 misfire throughout ownership. Spark plugs and ignition coils were first replaced around 40,000 miles and replaced again in December 2025 for the same recurring issue. A Hyundai dealership inspected the vehicle and found codes P0300 random misfire and P0303 cylinder 3 misfire. The dealership technician documented that the piston rings did not look good and confirmed the catalytic converter was damaged as a result of the misfires. The vehicle has had an engine rattle at idle, oil consumption, and blow-by since early in ownership. The engine defect is progressive and predates the current mileage. The flashing check engine light and severe shaking while driving at highway speeds created an unsafe condition with other vehicles on the road. The problem has been confirmed by a Hyundai dealership. Hyundai Motor America was contacted and denied goodwill warranty assistance. The vehicle is available for inspection upon request.

NHTSA ID

11740933

Incident

May 7, 2026

The vehicle will not get to highway speed causing it to impede traffic and presenting a safety risk for collision.

NHTSA ID

11739697

Incident

May 8, 2026

The contact owns a 2019 Hyundai Tucson. The contact stated while driving at an undisclosed speed, the contact noticed an abnormal sound and the engine seized. The check engine warning light illuminated. The contact stated that while attempting to start the vehicle, the vehicle started. The failure reoccurred. The contact stated while attempting to start the vehicle, the vehicle started and the engine spuddered. The vehicle was towed to an independent mechanic where it was diagnosed with a failed engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The contact was advised to take the vehicle to the dealer. The vehicle was towed to the dealer where it was diagnosed with a failed engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was filed. The contact was advised to take the vehicle to the dealer for diagnostic testing. The contact was later informed that the repair was not covered under the recall because of open recalls associated with the contact's VIN. The failure mileage was approximately 81,000.

NHTSA ID

11738126

Incident

May 1, 2026

Mileage

81,000 mi

The contact owns a 2019 Hyundai Tucson. The contact stated while the contact's husband was driving, the contact noticed an abnormal loud sound. In addition, the contact noticed smoke coming from the front of the vehicle. No warning lights were illuminated. The contact noticed an unusual odor in the interior of the vehicle. The contact's husband drove the vehicle to the shoulder of the road. The contact stated that the engine seized. In addition, the contact stated that the smoke and the unusual odor subsided. The vehicle was towed to the contact's residence. In addition, the contact stated that when the failure occurred, the contact's minor children were occupants of the vehicle. The contact stated that the minor children were frightened. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The manufacturer was made aware of the failure. The contact was informed of an open recall associated with the contact's VIN, NHTSA Campaign Number: 20V543000 (Service Brakes, Hydraulic). In addition, the contact was informed that her contact information was not updated in the database. The failure mileage was approximately 49,400.

NHTSA ID

11738088

Incident

Apr 12, 2026

Mileage

49,400 mi

I purchased this vehicle from CarMax about 5 months ago. It had 74,XXX miles. CarMax showed no open recalls and a printed sheet from your site showing the same. Several weeks ago, while driving, the engine seized. I sent it to one of the local Hyundai dealers for repair. Hyundai said because recall Campaign #966 had not been performed, they would not replace the engine under the extended warranty. When I purchased the vehicle, I had the foresight to purchase an extended warranty from Assurant. Eventually I found they will cover the repair. I have to pay the $600 deductible, plus a $350 labor charge for diagnostic work. Here is my problem, CarMax told me there was no open recalls (based on your web site), and I counted on CarMax having an accurate knowledge about this when I purchased the vehicle. This is particularly disturbing because in 2022 CarMax settled out of court with 30+ states in part, for failure to disclose open recalls on vehicles they sold. True, I could have checked myself, but how did your entity report no open recalls on this VIN, and CarMax reported no open recalls on this VIN, but Hyundai was aware of the open recalls, and denied an engine warranty repair because the recall campaign had not been completed? There are two other open campaigns, # 933 and #P33 as well. The Hyundai dealer is going to perform these recalls after the repair. To summarize, I purchased this vehicle in good faith that the information provided on the NHTSA sheet, and the CarMax sheet were correct there were no open recalls. My bank financed the auto under the premise it was a safe reliable risk for them. Now, I'm going to be out $950 plus rental car expenses I've already paid. Please contact me if you have more questions.

NHTSA ID

11737757

Incident

Apr 30, 2026

Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. This bulletin provides instructions for updating the Engine Control Module (ECM) to address this condition.

Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. The California Air Resources Board has determined that these vehicles may be releasing air pollutants which exceed Federal and California standards.

Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.

Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.

Some Hyundai vehicles with exterior white paint may exhibit peeling or bubbling on metal body panels: hood, fender(s), roof, door(s), quarter panel(s), and tailgate/trunk. The paint warranty coverage for affected vehicles has been extended to 10 years/unlimited miles from the date of original retail delivery or date of first use and is valid for original and subsequent owners.

Certain Hyundai vehicles with exterior white paint may exhibit peeling or bubbling on metal body panels: hood, fender(s), roof, door(s), quarter panel(s), and tailgate/trunk. The paint warranty coverage for affected vehicles has been extended to 10 years/unlimited miles from the date of original retail delivery or date of first use and is valid for original and subsequent owners. The warranty extension does not apply to any vehicle that has ever been declared a total loss or sold for salvage by a financial institution or insurer or has a branded or similar title under any state’s law.