2020 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 contact owns a 2020 Hyundai Tucson. The contact stated that upon starting the vehicle, the check engine, master general, and forward collision warning lights were illuminated. The vehicle was taken to the dealer, where it was diagnosed, and the contact was advised that the multifunction camera had failed and needed to be replaced. The manufacturer was notified of the failure. The failure mileage was 44,000.

NHTSA ID

11771466

Incident

Jun 11, 2021

Mileage

44,000 mi

On XXX, while driving at freeway speed in [XXX] with my [XXX] son in the back seat, the engine of my 2020 Hyundai Tucson (2.4L Theta II GDI, approx. 99,108 miles) seized suddenly and without warning. I lost all motive power in moving traffic and coasted to the shoulder, where my son and I sat stranded for 30 minutes with smoke and a burning smell coming from the engine while waiting for a tow. No warning lamps or messages appeared before the failure. COMPONENT FAILED: Engine. Tustin Hyundai ([XXX]) diagnosed the failure on RO XXX: engine seized; connecting rod pierced through the bottom of the engine block due to internal catastrophic failure at the crankshaft/bearings; starter had a burnt smell. The dealer recommends full long block replacement. The vehicle remains at Tustin Hyundai and is available for inspection upon request. CONFIRMED BY: Hyundai dealership technician (diagnosis on RO XXX) and an insurance adjuster (National General/Allstate claim XXX, Estimate of Record on file). A goodwill request was submitted to Hyundai Motor America and denied. RELEVANT DEFECT HISTORY: This is the same connecting rod bearing failure mode for which Hyundai extended a Limited Lifetime Warranty on 2018-2019 Tucson vehicles with the same Theta II 2.4L GDI engine (TSB 22-EM-001H-1/TXXI). Hyundai Service Campaign 9C2 (Theta II ECU software update, issued XXX) was open and incomplete on my VIN at the time of failure and was performed only at the post-failure service visit. Oil consumption without external leaks, a documented characteristic of this engine defect, was present before the failure. SAFETY RISK: Sudden total loss of motive power at highway speed in traffic with a child aboard created a serious risk of collision, and the 30-minute roadside wait exposed us to passing traffic. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11766998

Incident

Sep 13, 2026

Engine has defect that causes oil to heat at an unusual levels there for damaging other vehicle components such as The exhaust system parts clogging up and Triggering check engine warning lights for emissions.

NHTSA ID

11765249

Incident

Sep 3, 2026

The contact owns a 2020 Hyundai Tucson. The contact stated that while the vehicle was receiving a routine oil change, the contact was informed that the oil pan was empty. The contact was advised to take the vehicle to the dealer. The contact was informed about a possible oil consumption test. The contact was informed that there was carbon blowing out of the vehicle. The contact stated that three months later, the oil pan was empty. The vehicle was taken back to the dealer, and engine oil was added; however, the failure reoccurred. The vehicle was taken back to the dealer where the contact was informed that the engine needed to be replaced. The vehicle was repaired. The contact stated that while driving at an undisclosed speed, the contact heard an abnormally loud sound. The vehicle was taken to the dealer where the contact was informed that the bolts for the driveshaft were missing. The contact was informed that the bolts needed to be replaced. The vehicle was repaired. The contact stated that the dealer was negligent when the engine was replaced and the bolts to secure the driveshaft were not properly installed. The contact stated that the negligence needed to be reported. The contact was later advised by an associate to take the vehicle back to the dealer and requested an overall inspection of the driveshaft. The vehicle was taken back to the dealer, and the inspection was completed. The contact was informed that the vehicle had passed the inspection. The manufacturer was not made aware of the failure. The failure mileage was 80,000.

NHTSA ID

11758267

Incident

May 12, 2026

Mileage

80,000 mi

Dealer completed update 9C2 Theta 2 emissions update. After update, the car sputters slightly and increased noise is heard from the tailpipe. Customer returned to dealer after driving the car in different temps and noted the above complaint. Dealer verified the complaint but continues to take no responsibility for the fault on the repair receipt by writing condition is “normal” and recommending “customer to allow vehicle to properly warm up for one to three minutes prior to driving.” The last line of the service record indicates “no problem found at this time.” A template letter from Hyundai was attached to the repair record. Hyundai may be instructing dealers to not document problems in the service records assumably so they will not be liable for future litigation. It should be noted that owner was previously denied payment on their 2017 Hyundai Tucson due to lack of documentation by the dealer to prove the case with prior class action lawsuit despite years of verbal complaints to the service staff. Dealer may be intentionally not documenting or taking responsibility for systematic failures in the Tucson in service records. This may be on the direction of Hyundai corporate. 2020 Hyundai Tucson continues to sputter periodically during normal driving conditions. Car is parked in an attached garage making a 1 to 3 minute warm-up time-consuming and possibly unsafe. This required warm up should not be considered normal as indicated on the repair record. Hyundai should take responsibility for their shortcomings and allow proper documentation on service records rather than pushing the fault on the owners. As with previous Tucson complaints, the dealer continues to indicate the problems are the result of owner actions not internal failures.

NHTSA ID

11755723

Incident

Jul 8, 2026

The engine lost power while driving, and the vehicle entered a reduced-power mode. The check engine light began flashing, and the engine made a loud knocking noise during acceleration. A diagnostic scan showed code P1326 (Knock Sensor Signal Range/Performance). The knock sensor was replaced, and the engine oil was refilled after discovering an oil leak. The vehicle operated normally for a short time, but the same symptoms returned. The vehicle is available for inspection. The vehicle suddenly lost power while traveling approximately 70 mph on the highway, making it difficult to maintain speed and safely keep up with traffic. This created a risk of being struck by other vehicles or causing an accident. The problem has since recurred during normal driving. The problem has been reproduced multiple times. A diagnostic scanner consistently identified code P1326. The knock sensor was replaced and the engine oil was replenished, but the same symptoms returned after several trips. The vehicle has not yet been inspected by a Hyundai dealership. The vehicle has been inspected by the owner and a family mechanic who replaced the knock sensor and identified an engine oil leak. It has not yet been inspected by Hyundai, law enforcement, or an insurance representative. There were no warning lights or messages indicating low engine oil or an oil leak before the failure occurred. I had the engine oil changed approximately one month before the incident. While driving on the highway at approximately 70 mph, the vehicle suddenly lost power, the check engine light began flashing, and the engine started making a loud knocking noise. After inspecting the vehicle, we discovered it had an engine oil leak and the oil level was low. Before the loss of power, there were no warning signs that the engine was losing oil or that there was an oil leak.

NHTSA ID

11753365

Incident

Jul 20, 2026

High excessive oil consumption and premature piston ring failure leading to excessive oil consumption

NHTSA ID

11752334

Incident

Jul 22, 2026

Tried passing someone on the thruway, as I was about to the car jerked a bit then started decelerating. The check engine light started flashing and so did the oil light. Read the code as cylinder 3 misfire and a knock sensor. Changed the spark plugs and coil packs then checked the oil and saw there was no oil in the engine. Was told by my mechanic it’s a common problem with these Hyundai engines, it seems the rings are getting fried in the engine and that’s why it consumes oil so quickly.

NHTSA ID

11751269

Incident

Jul 4, 2026

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.