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.

My husband was driving the car to work and all of a sudden a bunch of dash warning lights came on. It was lit up like a Christmas tree. Then the car went into limp mode. The vehicle has been at the dealership 4 weeks. And they refuse to do a 20 min test on the ABS module. It is a part of the HECU Settlement. You can find the settlement at [XXX] My husband is an electronic engineer. He knows why all the lights are on simultaneously. The ABS needs to be replaced. It's causing all the communication to go down that's on that can bus system. That's why all the parts dont make sense to each other. It all boils down to the ABS improperly working causing communication issues. The recall fix did fix the fires. It won't catch fire now but the ABS is still malfunctioning. There's a lawsuit. All vehicles involved in the recall are required a free ABS inspection and a replacement if they are malfunctioning  but the dealership refuses to diagnose the ABS. That is the loophole Hyundai has found to not uphold the law. They are not standing by the settlement. They are skirting around from checking the ABS module so they won't find the malfunction. They want us to replace parts that are brand new that my husband just replaced. They want to charge us $700 for some other part and refuse to check the ABS system per the lawsuit. My husband needs that vehicle to work. So he's been out of work for 4 weeks. It's ridiculous! I can't hire a lawyer at this time and it's ridiculous that I may have to. This corporation should uphold their part of a lawsuit! There was already a settlement. My vehicle is included without even submitting a claim. It's ABS warranty is also extended per the lawsuit. I've read it backwards and forwards. I'm so at a loss! I need help. They also refuse to help us with a loaner and that will force us to drive an unsafe car in limp mode off the property when they are responsible for fixing this faulty part per the settlement INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11776890

Incident

Oct 15, 2026

NHTSA Safety Complaint – 2019 Hyundai Tucson Engine Failure I am reporting a serious engine safety concern involving my 2019 Hyundai Tucson AWD 2.0L (VIN: [XXX]). On XXX, the red engine oil-pressure warning light suddenly illuminated while I was preparing to drive home. Concerned about possible engine failure, I stopped using the vehicle and had it towed to Pohanka Hyundai in [XXX]. On XXX, the dealership provided a diagnostic video indicating that the engine was defective and needed replacement. A written estimate dated XXX quoted $7,823.58 for an engine replacement. Despite this diagnosis, the dealership later declared the vehicle drivable and returned it after adding oil, without providing a satisfactory explanation for reversing its original findings. The engine problems continued, and the vehicle had to be returned to the dealership. This presents a serious potential safety hazard. An unresolved engine or oil-pressure problem could cause sudden engine failure, loss of propulsion, or a breakdown while driving on a highway or in heavy traffic, increasing the risk of a collision and injuries to occupants and other motorists. I am particularly concerned that a vehicle initially diagnosed as needing engine replacement was subsequently declared safe to drive without documented evidence that the underlying problem had been corrected. I request that NHTSA investigate whether this engine failure represents a broader safety defect affecting 2019 Hyundai Tucson vehicles and whether additional safety measures, including a recall investigation, are warranted. Vehicle: 2019 Hyundai Tucson AWD 2.0L VIN: [XXX] Mileage at diagnosis: Approximately 87,656 miles Incident Date: XXX INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11771618

Incident

May 19, 2026

While driving on the highway 65 mph in our 2019 Hyundai Tucson AWD, the vehicle suddenly experienced a severe power loss, loud engine knocking, engine light flashing, and the car in limp mode. This caused a terrifying hazard. We exited to safety, the car was towed and is at a Hyundai dealership. It pulled a diagnostic engine trouble code P1326 (Knock Sensor Detection System). The dealership confirmed the code, but is refusing to replace the engine under the Hyundai Engine II Class Action Settlement without an out-of-pocket 'combustion cleaning' fee, which, as seniors, we cannot afford on a fixed income. The dealership service manager told us that he requested Goodwill from Hyundai Corporate for the combustion engine cleaning. And because of a past denial, corporate denied it a 2nd time. So, we contacted our Hyundai Corporate case manager, who said our request for “the engine replacement” was still pending and in review by their team. She saw no denials, except for a loaner, which would be approved, upon repair approval. We added the dealership service manager on this call to discuss confusion about goodwill be denied by Corporate for the “combustion cleaning”. He said this case manager would not see the combustion cleaning requirement, because it was instructed by another department. His then pivoted the topic & said we received an estimate for combustion cleaning. My response “we never received an estimate & have no estimate in my email”. His response “I hate to use this word, but you’re a liar”. My husband then took the call saying “we did not receive an estimate in writing, although we had asked the tech for an estimate but nothing was final.” The service manager cut him off and said “we are done come pick up your car” & hung up. This dealership phone interaction needed to be included in this incident because now we are being put in grave danger as he is expecting us to pick up our un-drivable, unsafe & hazardous car with no concern for safety.

NHTSA ID

11771149

Incident

Oct 5, 2026

While driving at highway speeds, my 2019 Hyundai Tucson SE suddenly loses acceleration and drops into a 30 mph 'limp mode' while the engine overheats. This creates an immediate highway safety hazard with an imminent risk of a rear-end collision. The vehicle also suffers from excessive oil consumption, requiring manual top-offs twice a week. The servicing dealership diagnosed a fuel system failure, quoting $5,847 to replace the fuel pump, fuel injectors, and oil gasket. Hyundai Corporate (Case #43358088) officially denied warranty coverage on October 12, 2026, falsely claiming wear and tear despite active TXXM 150,000-mile extended warranty framework protections. Furthermore, there is a data discrepancy: the dealership pulled diagnostic trouble code P0172, but corporate claims the vehicle threw code P0173 and is withholding the physical diagnostic printout behind a fee paywall.

NHTSA ID

11770781

Incident

Sep 28, 2026

The new 2019 Hyundai Tucson equipped with the Nu2.0L GDI engine, I purchased in 1/2020 as the original owner to this day has been diagnosed with a burnt exhaust valve due to heavy oil consumption that has been an uncorrected documented manufacturer’s defect within Hyundai motor corporation. The excessive engine oil consumption has poisoned and destroyed the first catalytic converter, has fouled the combustion chamber which has consequently choked and burnt the exhaust valve with the excess oil ash and carbon buildup. The car was approved for a second catalytic converter install last week which my car currently sits at 125,000 miles and the dealership through the authority of approval with Hyundai motor America has replaced under warranty however subsequently running the excess consumption test, the car now has a burnt exhaust valve which Hyundai motor America is extending a “good faith” proposal which they are willing to replace 60% of the burnt valve and I’m responsible for the 40% even though I have complied fully with the dealership’s recommended preventive maintenance schedule which has been solely performed at the same dealership since the day I bought the car and drove off the lot up until the 100K mile warranty. And now discovering my particular motor has been extended to the 15/150,000 warranty due to the lawsuit settlement. I have continued with my diligence with keeping up with the oil, instead of ignoring the issue that the car burns excessive oil to potentially has the engine fail while driving to be fully covered on the rod bearing failure settlement. Help in my concerns would be greatly appreciated through NHTSA.

NHTSA ID

11769517

Incident

Sep 19, 2026

I have had 2 catalytic converters the original and a 2nd one. Now I need a 3rd due to excessive oil consumption. Corporate did a good will for a combustion cleaning and that did nothing. The dealership checked my oil and said there was excessive oil consumption and submitted for an engine replacement and it was rejected. Absolutely ridiculous.

NHTSA ID

11769509

Incident

Oct 6, 2026

The contact owns a 2019 Hyundai Tucson. The contact stated that while driving 50 MPH, there was a burning odor coming from the vents, with the battery warning light illuminated. The vehicle was taken to the service center, where it was diagnosed with alternator failure. The contact was informed that the alternator needed to be replaced. The vehicle was repaired; however, the failure reoccurred. The contact stated that the alternator had been replaced three times with aftermarket parts and a fourth time with an OEM part. After inspecting the alternators, the contact noticed that the copper wires inside each alternator were black due to the failure. The contact was concerned that a previous recall associated with the failure did not properly fix the vehicle. The manufacturer was made aware of the failure by telephone, and a case was opened. The contact also requested a buyback of the vehicle. The failure mileage was approximately 61,000.

NHTSA ID

11767493

Incident

Aug 12, 2026

Mileage

61,000 mi

The contact owns a 2019 Hyundai Tucson. The contact stated that while driving 40 MPH, the vehicle lost motive power. A Forward Collision Avoidance message was displayed. The vehicle was able to restart. The vehicle was taken to the dealer, where the contact was informed that the failure could not be duplicated. The failure mileage was approximately 135,700.

NHTSA ID

11764716

Incident

Sep 14, 2026

Mileage

135,700 mi

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 Tucson (TL) vehicles equipped with a 2.0L engine may exhibit a continued DTC P132600 after an ECM logic update has been performed per TSB 24-01-068H, Engine Monitoring Logic (Service Campaign 966). This bulletin provides instructions to inspect and resolve other engine mechanical issues and if DTC P132600 remains, then a procedure and manual mode passwords are given to perform the update again in manual mode to resolve this condition.

Certain vehicles may exhibit excessive paint peeling or bubbling of the primer/paint film on the exterior metal body panels: hood, fender(s), roof, door(s), quarter panel(s), and tailgate/trunk. This warranty extension only applies to factory-applied paint and does not cover collision-related paint repairs or vehicles with a salvaged title. Hyundai is extending the warranty coverage for certain white paint colors under these conditions from 3 years and 36,000 miles, to 10 years with unlimited miles from the date of original retail delivery or date of first use, and is valid for original and subsequent owners.

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.