2015 Hyundai Veloster

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.

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.

2015 Hyundai Veloster Turbo (original owner). The vehicle has three severe safety defects: TRUNK/HATCH LATCH FAILURE: The hatchback lift support/latch fails, refusing to stay open. It unexpectedly fell, which has caused repeated, severe impacts to my head and neck, resulting in an injury requiring surgery. I must manually prop it open with a mini ball to load cargo. ENGINE & TURBO FAILURE / OIL CONSUMPTION: History of engine acceleration issues and turbo failures since 4,000 miles. At 44,000 miles, the turbo completely failed, the car started to whine, then rattle, and completely turned off. Dealer (Hyundai Escondido) forced a $2,200 out-of-pocket replacement despite being under warranty, citing a lack of at-home oil change receipts. The vehicle now has a documented, rapid oil leak and excessive consumption issue that the dealer refuses to repair, despite being reported prior to warranty expiration. SEAT BELTS: The front and rear seat belt latches are malfunctioning, intermittently releasing on their own, failing to release properly, or failing to latch securely, compromising the safety of a [XXX] passenger. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11748212

Incident

Dec 10, 2024

The contact owns a 2015 Hyundai Veloster. The contact stated that upon starting the vehicle and shifting into gear, the vehicle failed to respond and became inoperable. There was no warning light illuminated. The vehicle was taken to the dealer, and the rear axle was replaced, the transmission fluid was flushed and refilled, and a shift analyzer software update was performed; however, the failure recurred days later. The vehicle was taken back to the dealer, where it was determined that the wheel speed sensor had failed. Upon investigating the failure online, the contact advised the dealer to inspect the crankshaft position sensor; however, the dealer informed the contact that the failure was related to the transmission. The contact was informed that the failure could not be duplicated. The vehicle was not diagnosed or repaired, and the contact was advised to retrieve the vehicle. The manufacturer was notified of the failure and covered the cost of the rear axle replacement under a goodwill assistance program. Several cases were filed, and the contact sent a video of the failure to the manufacturer. The failure mileage was approximately 62,000.

NHTSA ID

11746142

Incident

Jan 15, 2026

Mileage

62,000 mi

The climate control fan knob suddenly stopped working. I smelled a burning smell on the interior of the car. I pulled the panel off and noticed that the plug to the climate control harness was burnt. I can no longer utilize the climate control system.

NHTSA ID

11743354

Incident

Apr 18, 2026

I am reporting a safety-related engine defect involving sudden internal engine failure, excessive oil consumption, persistent bearing knock, and overheating of the catalytic converter. The vehicle repeatedly triggered Bank 1&2O2 sensor fault codes due to oil blow-by and thermal overload. A certified mechanic documented the engine is failing internally and that the cat. converter has been damaged as a direct result of engine defect. The failure pattern is consistent with known Hyundai engine defect investigations involving bearing wear, oil consumption, stalling, and fire risk. The overheating cat. converter presents a significant safety hazard, including potential engine seizure. I purchased the vehicle used in March 2025. I am the third owner. Despite maintaining the vehicle responsibly (Regular oil changes), the engine failure progressed rapidly. Hyundai Motor America has denied a goodwill repair solely on the basis of mileage, even though the defect clearly originated long before my ownership and aligns with previously identified safety-related engine issues. Additionally, Hyundai's records show that this vehicle had an engine-related recall active during prior ownership period; the recall was never performed by the Hyundai dealership that sold the vehicle to the previous owner. This raises concerns about improper recall handling and whether the defect should have been corrected before the vehicle was resold. Given the safety implications, the documented defect pattern, and the unresolved recall history, I am requesting NHTSA's review of this matter. The engine failure poses a serious safety risk; Hyundai's refusal to address a known defect, the vehicle is unsafe to operate. Timeline: 2014 Hatchett Hyundai West, KS 17,665 mi.; 2017-H. West serviced vehicle, 58,918; 2019-Engine powertrain alert 83856mi; 2020- Edmund Hyundai, OK-engine power train 100179 mi; 2021- Edmund 145418mi.; Hy. Noblesville, IN 167,603mi.; 2024 - H.N. 171937; 2025 - denied repair 188890.

NHTSA ID

11734516

Incident

Apr 10, 2026

I took my car to Gilroy Hyundai November 11, 2025 at 10:30 a.m. because my engine was not running normal, it shook lightly while driving at an incline and the engine light would not shut off. they charged me $284.99 to tell me what needed to be fixed, engine was not looked per Ernesto Garcia. Ernest told me they go by mileage, not actually checking the engine. He also stated that the mechanic drove it and it was fine. December 28, I was driving from Chico, CA back home to Morgan Hill, CA and the car shook and just died and left me on the side of Highway 505 Winters/San Francisco. I had it towed to Moorehead Automotive in Fairfield, CA and they said this car needs a new engine. I still owe 7,000.00 on this car and have had trouble with both Hyundai and Power (the additional insurance I purchased when i bought this car.)

NHTSA ID

11712779

Incident

Dec 28, 2025

The contact owns a 2015 Hyundai Veloster. The contact stated that while driving at an undisclosed speed, the vehicle hesitated. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic who performed a tune-up on the vehicle. The contact stated that several days after the tune-up, the failure reoccurred. The contact stated that while the vehicle was stopped at a traffic light, the vehicle hesitated and sounded as if the vehicle was going to stall. The vehicle was taken back to the independent mechanic, who diagnosed that the engine was losing pressure and needed to be replaced. The vehicle was not repaired due to the cost. The contact stated that before the vehicle had the tune-up, the engine was consuming an excessive amount of engine oil. The contact had not noticed any oil stains on the ground. The check engine light was occasionally illuminated. The manufacturer was not made aware of the failure. The failure mileage was approximately 72,000.

NHTSA ID

11699391

Incident

Sep 14, 2025

Mileage

72,000 mi

The contact owns a 2015 Hyundai Veloster. The contact reported that oil was leaking out of the exhaust. The vehicle was sputtering and running rough while driving at various speeds, and hesitated while accelerating. The check engine warning light was illuminated. The vehicle was taken to the dealer, who was unable to diagnose the failure. The dealer informed the contact that metal shavings were found in the oil pan during the oil change. The contact stated that the Oxygen sensors and catalytic converter were replaced; however, the failure persisted. The vehicle was contacted and advised the contact to return the vehicle to the dealer. The manufacturer was not informed of the failure. The failure mileage was unknown.

NHTSA ID

11695740

Incident

Oct 27, 2024

Excessive engine oil consumption causing fouled spark plugs engine stalling. Engine was replace due to defective rod bearings at 98 000 mile under warranty and recall. Engine now ha 130,000 miles piston rings have failed. Stalled on busy freeway almost causing mutual crash.I have an appointment at the Hyundai delership October 28th 2015. Hyundai replaced one defective engine with another.

NHTSA ID

11695652

Incident

Oct 14, 2025

Certain 2012 – 2017 model year Accent, 2012 – 2017 model year Azera, 2013 – 2018 model year Santa Fe Sport, 2013 – 2019 model year Santa Fe, and 2012 – 2017 model year Veloster vehicles may exhibit an intermittent airbag warning light and diagnostic trouble codes (DTCs) may be set. At Hyundai, we are committed to providing vehicles of outstanding quality and value. In an effort to meet this commitment, the warranty coverage for the Occupant Classification System (OCS)/Occupant Detection System (ODS) under these conditions has been extended to 18 years/unlimited mileage from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners.

Some vehicles listed below may exhibit an intermittent airbag warning light and DTC(s) B1763 (OCS ECU Defect), and/or B1764 (OCS Mat Defect) may be stored. Hyundai is extending the warranty coverage of the sensor for the Occupant Classification System (OCS) / Occupant Detection System (ODS) to 18 years/unlimited mileage from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners. Refer to the warranty and parts information outlined in this bulletin.

Some vehicles listed below may exhibit an intermittent airbag warning light and DTC(s) B1763 (OCS ECU Defect), and/or B1764 (OCS Mat Defect) may be stored. Hyundai is extending the warranty coverage of the sensor for the Occupant Classification System (OCS) / Occupant Detection System (ODS) to 18 years/unlimited mileage from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners. Refer to the warranty and parts information outlilned in this bulletin. This bulletin contains the procedure to inspect for the airbag warning light and DTC(s), replace the OCS (ODS) unit or wire harness, reset the OCS (ODS), and initialize the power seat module (if applicable). This TSB also contains the procedure to replace the OCS (ODS) mat if DTCs exist after replacement of the OCS (ODS) wire harness.

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.

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.

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.