What 1,611 owners told NHTSA about the 2016 Hyundai Tucson Plug-in Hybrid

I am writing regarding the diagnosis provided for my vehicle [XXX] . I was informed today that the engine failure is being attributed to a "water hose failure" rather than the engine defects covered under the active safety recall/settlement regarding Connecting Rod Bearing failure. As there were no coolant leaks before or after the vehicle was towed to your dealership. I am formally requesting a re-evaluation and more detailed evidence. Given the known history of these engines seizing, I need to ensure this diagnosis is absolutely correct and not a symptom of the internal defect. I request the following information be provided immediately: 1. Evidence of Overheating: Did the vehicle store any specific "overheating" codes in the ECU prior to the engine shutting off? 2. Oil Pan Inspection: Has the oil pan been removed to inspect for metal shavings or debris? If the connecting rod bearings failed (the recall issue), there will likely be metallic debris in the oil, regardless of the condition of the water hose. 3. Bearing Clearance Test (BCT): Was the mandated Bearing Clearance Test performed? If not, I request that this be done, or that a teardown be performed to inspect the rod bearings specifically. 4. Causal Link: Can you provide evidence that the water hose failed causing the engine to seize, rather than the engine seizing causing a pressure spike that damaged the cooling system? I have no transportation to work and school. They would not honor a loaner. This has happened since Decemeber of 2025. I await your written response with the requested photos and technical data. My case # with Hyundai Consumer Affairs # XXX Please provide: All relevant photographs Freeze-frame and ECU data Technician diagnostic notes Results of oil pan inspection and/or BCT (if performed) Any physical evidence supporting the stated cause of failure I request this information be sent in writing at your earliest convenience. Thank you for your attention to INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11726365

Vehicle: 2016 Hyundai Tucson Issue Category: Engine / Powertrain / Vehicle Safety Complaint: I am reporting a serious safety issue involving my 2016 Hyundai Tucson equipped with a Theta II engine. My vehicle first displayed an engine oil warning light. I immediately took the vehicle to an authorized Hyundai dealership, where I was charged approximately $500 for an oil change and diagnostic testing. I was told there were no issues with the vehicle. Within approximately 20 miles of leaving the dealership, the vehicle suddenly entered limp mode while driving and displayed diagnostic code P1326. This created a dangerous situation as the vehicle lost power unexpectedly. I returned the vehicle to the dealership, where a software update was performed. However, within another 20–30 miles, the exact same issue occurred again, with the vehicle entering limp mode and triggering code P1326. Hyundai has now refused to repair the engine under warranty and is attempting to attribute the issue to a catalytic converter problem, despite the presence of code P1326, which is associated with engine rod bearing failure and is part of a known defect affecting these vehicles. This condition presents a significant safety risk, as the vehicle can lose power suddenly while driving, increasing the risk of a crash. I believe this issue is directly related to the known Hyundai Theta II engine defect, which has been the subject of recalls and a class action settlement. I am requesting that NHTSA investigate Hyundai’s handling of these failures and their refusal to repair vehicles experiencing known engine defects that pose a safety risk

NHTSA ODI 11725130

Three window regulators have failed, leaving the windows completely useless. The first occurring in heavy rain and making it impossible to close. This is an issue reported countless times online.

NHTSA ODI 11725249

The transmission began slipping and hesitating within days of purchase. The vehicle intermittently fails to accelerate when pressing the gas pedal, especially when pulling into traffic or crossing intersections. This creates a serious safety risk because the vehicle does not respond when needed, leaving me exposed to oncoming traffic. The issue is intermittent and does not always trigger warning lamps or fault codes. The problem has been reproduced multiple times by me while driving under normal conditions. The selling dealer performed only a brief test drive and stated they could not duplicate the issue, but the hesitation and failure‑to‑accelerate continue to occur. The vehicle has not yet been inspected by Hyundai, but the symptoms match known issues with the 2016 Tucson’s dual‑clutch transmission and TCM logic. There were no warning lights prior to the failure, and the symptoms first appeared within the first week of ownership. The vehicle is available for inspection upon request.

NHTSA ODI 11723654

"On [XXX], my 2016 Hyundai Tucson (VIN [XXX] ) experienced severe engine power loss and mechanical noise under load while driving uphill, creating a dangerous safety situation. This occurred 2 days after a dealer visit (February 19, 2026) where an open KSDS Service Campaign (TSB HCE22-14-E600-TL, Issue 10D021) — directly related to engine monitoring — was left incomplete. The dealer subsequently denied an engine evaluation citing mileage over 150,000, despite the open campaign having no mileage restriction and despite a prior verbal commitment to cover repairs. Multiple follow-up attempts by phone, email, and WhatsApp have been ignored." INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11723436

No check engine lights came on! The entire car caught fire and was engulfed in flames!!! Driver could have been killed!

NHTSA ODI 11722495

My car had a KSDS knock sensor detection system campaign 966 installed in 2022 specifically to active if having rod bearing wear. Towed my car to Hyundai under the TXXM warranty and they said my bearing clearance was ok and i need new lifters and timing chain cost for repair $2900. I have asked for the full rod bearing wear test report and they will not provide it. They have had my vehicle for 20 days now and I am out of work on disability. Hyundai service center is generally expected to provide you with a report following a rod bearing wear test (often referred to as a Bearing Clearance Test or by a related service campaign, such as T6G or TSB 21-EM-004H). Here is what you can expect regarding reports and documentation: Documentation of Results: The dealership should provide a copy of the results, specifically noting if the bearing clearance passes or fails. Proof of Inspection: If the test is performed under a recall or Service Campaign (e.g., Campaign 966, 982, or T6G), they are required to document the inspection, which you can request for your records. Evidence of Damage: If the test results in a failed diagnosis, technicians often take photos of the engine internals, such as metal flakes in the oil pan or excessive wear, which are used to support the warranty claim. If the Test Passes: If your vehicle passes, ask the technician to print a copy of the results. If the Test Fails: A formal diagnosis of rod bearing failure, confirmed by this test, is required for engine replacement under the extended 15-year/150,000-mile warranty. Hyundai - Recalls +3 This is a safety issue without the full rod bearing report to consumer. Thank you for upstanding, [XXX] cell - [XXX] email - [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11721391

Excessive oil consumption caused engine failure on December 17, 2025. My truck stopped and I was stranded on Highway I55 South for 4 hours. Hyundai and the Extended warranty has denied fixing my truck. It is still at [XXX] Hyundai as of today. Hyundai’s failure to properly diagnose or repair this issue when it was first reported under warranty has caused financial burden, diminished vehicle value, loss of use and inconvenience, and emotional distress and stress. This is a legitimate safety concern. I am demanding resolution of an ongoing excessive oil consumption defect in my 2016 Hyundai vehicle. This defect began while the vehicle was under warranty and has continued despite proper maintenance and compliance with Hyundai’s service requirements. I expect Hyundai to honor its legal and contractual obligations without further delay. Please contact [XXX] [XXX] Hyundai) @ [XXX] for details regarding repairs, oil consumption tests, etc. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11718400

The engine, specifically cylinder # 3, has had a catastrophic failure at 114,000 miles. Engine repair shops and engine experts have determined the only fix is a complete engine replacement. Cost estimates are $8500 for a new engine + labor estimated at $2000. Scrap value is estimated at $1000 - $1500 The dealer from whom we bought the car in late 2015 said it is out of warranty. This is unacceptable. Please, please issue a recall on the engine of this vehicle. The vehicle is available for inspection if requested. Failure was catastrophic Problem has been confirmed by engine experts The car is not drivable to a manufacturing facility The engine has not been inspected by police nor our insurance company There we no warning lamps or messages Symptoms include shuddering at initial acceleration beginning at 75,000 miles Dealer said there was no problem and recommended and performed a transmission fluid change

NHTSA ODI 11717961

Window regulator and motor have failed due to plastic gears stripping out. I have replaced my two front windows in 2024 at $1063 a window. This week I had both rear windows fail allowing the windows to drop down unexpectedly. I was able to manually pull the windows up and tape them. I was supposed to receive a call from Hyundai twice this week about getting these covered under a recall since all four has failed, but they have failed to contact me.

NHTSA ODI 11715692

The contact owns a 2016 Hyundai Tucson. The contact stated that the check engine warning light was illuminated, and there was a ticking sound coming from the front of the vehicle. The vehicle was taken to Auto Zone, where a mechanic diagnosed the vehicle with a knock sensor failure. The knock sensor was replaced. The mechanic informed the contact that the vehicle was included in Manufacturer Campaign: CS966 for the transmission control module (TCM). The vehicle was taken to the dealer, who confirmed that the vehicle was included and the software update was performed. After the vehicle was repaired, the check engine warning light was no longer illuminated; however, approximately 30 minutes later, the vehicle failed to exceed 35 MPH, and the check engine warning light started flashing. The vehicle was returned to the dealer, and the contact was informed that the software update caused the vehicle to enter LIMP Mode to protect the engine. The dealer informed the contact to drive the vehicle for 30 days or a total of 500 -1000 miles, and if the vehicle continued to enter LIMP Mode or failed to operate as needed, to return the vehicle for the engine to be replaced. There were no additional repairs performed. The manufacturer was not informed of the failure. The failure mileage was approximately 125,000.

NHTSA ODI 11715203

I have diligently maintained the vehicle with all scheduled services performed at the Rick Case Hyundai dealership. My maintenance records show a documented history of proper oil changes and other essential services. These records confirm that the vehicle was regularly serviced according to the manufacturer's recommendations. The diagnostic report from the dealership indicates bad piston and heat marks, but there is no evidence to suggest this was caused by a lack of proper maintenance.

NHTSA ODI 11713678

I am filing this complaint regarding my 2016 Hyundai Tucson due to excessive oil consumption. The vehicle burns oil at an abnormal rate, requiring me to add approximately one quart of engine oil every one to two weeks, even though the vehicle is driven very infrequently. This condition poses a serious safety risk because the engine could run low or completely out of oil while the vehicle is in operation, potentially causing sudden engine failure. This vehicle is used to transport my family, including children, which puts their safety at risk. I have taken the vehicle to Hyundai dealerships multiple times for full ispection , but no defect, warning, or solution was ever identified or communicated to me. There have been no warning lights or messages on the dashboard to alert me of low oil levels or engine problems, increasing the risk of failure without warning. The problem is ongoing and repeatable, and the vehicle and engine are available for inspection upon request.

NHTSA ODI 11711941

The car has been diagnosed with internal engine failure by both an independent service center and a dealership service center. The issue was described as a rod timing issue causing knocking, leading to failure of the engine. A light was not on for a majority of the issue but did start flashing before car became completely undrivable. The car was sold to me with this issue and has been driven for nearly 3 years with a power loss issue that was dismissed as turbo lag or other issues. Driving a car with this issue that does not alert with a check engine light is a major threat to driver and passenger safety as it can result in engine seizure and vehicle fires. The engine issues began at the least before 58,000 miles, with total failure occuring at roughly 96,000 miles. Hyundai is known for this issue, particularly in turbo model engines. Only once during ownership of the car did the check engine light come on prior to engine failure. When checked, it was described as a catalytic converter issue. The service center also did an oil change on the car, and the light went off. The check engine light did not come on again for more than a year. The check engine light did not come on until after the issue was diagnosed by the independent service center it was taken to in January 2026.

NHTSA ODI 11711041

There is a major problem with certain year Hyundai vehicles from 2016-2021 with the engine burning oil and clogging up the exhaust. My moms vehicle has been at dealership for evaluation and combustion cleaning multiple times and the problem still continues. There has been times where she is driving car and it starts to bog down and loose power which is a safety issue especially if on highway. The vehicle is burning oil, occasionally have to add oil. The engine light does come on at times. The car has been at dealership for recommended oil consumption test at every 1000 miles and has not passed. Combustion cleaning done each time and sent on way. Called and made complaint with Hyundai corporate and and got no where. The tech department at Hyundai factory gave dealership recommendations to do which were completed and still having same issue. The factory was only willing to cover 70% off the cost of new catalytic convertor and my mom to be responsible for remaining balance. Hyundai claimed that the convertor was out of warranty 8 years/80,000 miles even though this has been going on for past 2 years. This is not a problem caused by consumer but an issue with factory. Hyundai not living up to there 10 year/100,000 mile warranty as they advertise. There are facebook groups with people having same problems as we are with dealership not really doing anything other than combustion cleaning as advised by factory and corporate not doing anything either. I believe this is a major safety/defect issue with engines in these Hyundai Vehicles . What happens when someone is on the highway and the vehicle bogs down and another vehicle comes from behind and slams into you?

NHTSA ODI 11711157

On my husband's way home from work he explained to me that the car had a "hiccup" and then an engine light blinked on, then it died at an intersection. He was pretty close to home so he got it started again and drove it home. He replaced spark plugs and coil packs and it still had a misfire. We took it to an auto repair shop where they did a scan and told us it had a dead hole in cylinder 2 and that it needs a full engine replacement. The car also had an oil change just before Thanksgiving. My husband checks oil regularly and added a quart a month before the oil change and it seems to consume more oil then it should.

NHTSA ODI 11710952

Numerous issues with this vehicle. Now, when having oil change, told by the hyundai service center that it is using excessive oil and may need a new engine. In researching this problem, have discovered hyundai has had several problems with excessive oil consumption in their many of their hyundai vehicles, including the 2016 Tuscan

NHTSA ODI 11710436

My 2016 Hyundai Tucson experienced engine failure consistent with known Hyundai engine defects. After reporting multiple battery outages, rapid oil consumption, and limited acceleration ability, outstanding warranties were checked and updated. However, the issues persisted, and the engine failed suddenly while I was driving. Hyundai denied warranty coverage without proof of the issues being unrelated to the warranty. This presents a serious safety hazard due to unexpected engine failure.

NHTSA ODI 11710087

The contact owns a 2016 Hyundai Tucson. The contact stated that after coming to a complete stop, the vehicle failed to accelerate as intended while depressing the accelerator pedal. The vehicle went into LIMP Mode. In addition, the vehicle failed to accelerate above 30 MPH. No warning light was illuminated. The vehicle was taken to several dealers. The contact was informed that the unknown hoses and the dipstick melted inside due to the engine overheating. The contact stated that the catalytic converter was replaced; however, the failure persisted. The contact stated that the catalytic converter had been replaced three times since the first failure. The contact stated that on a separate occasion, the engine was consuming an excessive amount of engine oil. The contact was adding engine oil every two weeks. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The failure was a recurring failure, and the contact drove the vehicle intermittently due to the safety concerns. The manufacturer was not made aware of the failure. The failure mileage was approximately 90,000.

NHTSA ODI 11709514

While driving under normal conditions, my engine experienced a sudden and catastrophic failure. The check-engine light illuminated, the vehicle began shaking violently, and I was forced to pull over immediately due to safety concerns. There was no prior warning and no oil pressure or oil warning light activated at any time before or during the failure. After stopping safely, I checked the oil level and found it lower than expected. I added oil as a precaution, but the condition did not improve and the vehicle became inoperable and required towing. The engine assembly remains intact and available for inspection upon request. This failure posed a serious safety risk, as the loss of engine function occurred without warning while the vehicle was in motion, creating the risk of stalling or loss of control. The vehicle was inspected by an authorized Hyundai dealership. Hyundai Motor America denied warranty and goodwill assistance, citing mileage and alleged insufficient maintenance documentation, despite the vehicle being within the 10-year powertrain period and despite the nature of the failure. Routine maintenance was performed throughout ownership; however, some historical service records are unavailable due to the age of the vehicle and changes in service locations over time. Multiple facilities no longer retain records from that period. Notably, no oil warning indicators never activated, which raises concern regarding the failure mechanism. Hyundai has acknowledged widespread engine issues in this engine family involving oil consumption, bearing failure, and sudden engine seizure. The symptoms and progression of this failure closely align with those known defect patterns. This complaint is submitted to document a sudden engine failure presenting a clear safety concern and to assist in identifying potential defect trends. This car has undergone previous engine repair, AC condenser and entire turbo by their service department previously 2022 & 2024 respectively.

NHTSA ODI 11708990

Car died/lost power while driving in traffic 11/28/25. Good Samaritan was kind enough to push me off the road out of traffic. Car was towed to Hyundai dealer that day, then 12/1 told engine failure, required engine replacement. Class action lawsuit settlement for engine replacement, but denied by Hyundai because of "neglect", since I am not able to locate all of the service records that they request. Known faulty rotating assembly, and Hyundai has implemented concerted practice of denying warranty coverage for failed engine. Now having to pay almost $8K to replace with new engine, but concern that new engine will have same issue. (multiple posts about this). There was high potential for significant traffic collision, injury due to sudden, catastrophic engine failure. Traumatic experience.

NHTSA ODI 11708402

While driving on the highway at normal speed, the vehicle suddenly lost power and shut off without warning. There were no warning lights or messages prior to the loss of power. I was able to safely pull over, but the engine would not restart at that time and the vehicle required towing. The sudden engine shutdown occurred in active traffic and created a safety risk due to loss of propulsion. The vehicle later restarted, but I brought it to an authorized Hyundai dealership for inspection. The dealership diagnosed internal engine damage, including piston ring failure and cylinder wall scoring, and advised that the engine would need to be replaced. Since the incident, the vehicle has shown intermittent oil pressure warning lights and reduced performance. The issue has been confirmed by a dealer inspection. The vehicle is currently not considered reliable or safe for regular driving.

NHTSA ODI 11705564

Drove into a parking space, with the foot pressing on the brake pedal, the car suddenly and without warning rapidly accelerated uncontrolled causing the vehicle to accelerate past the end of the parking space causing property damage.

NHTSA ODI 11705267

My motor has a knocking/tapping noise that is obnoxiously loud. My oil level is always changed on time every 3k miles. I have 146,257 miles on my vehicle. I was informed from my mechanic shop that many of the 1.6L motors have issues. I have never had an engine noise then boom its knocking. I was informed not to drive my car to further damage the vehicle. I do not drive it but now am stuck in a loan for a vehicle I cannot drive. I had zero warning for this matter.

NHTSA ODI 11704984

Vehicle is showing KSDS-related engine warning behavior and the Hyundai dealership performed a diagnostic scan. The service manager told me, “I don’t recommend you driving it,” due to a potential engine safety issue. However, Hyundai Motor America’s National Consumer Affairs team is refusing to authorize towing or a loaner/rental until after a full diagnosis is completed. The dealership cannot complete the diagnosis unless the vehicle stays on-site, but I am unable to safely leave it because Hyundai is refusing transportation assistance and I was told not to drive it. This forces me to drive a vehicle they identified as unsafe in order to complete the required inspection. This involves KSDS/engine failure risk, which has been associated with stalling, loss of power, and possible fire hazards. Being advised not to drive while being denied towing or transportation creates a serious safety concern for myself and my children. I am requesting NHTSA document this incident because Hyundai is creating a safety hazard by refusing support for a vehicle they identified as unsafe to operate.

NHTSA ODI 11703404