Hyundai Tucson Hybrid engine problems

ENGINE AND ENGINE COOLING

See attached document for complaint.

NHTSA complaint #11758141 — an unverified report by a vehicle owner.

ENGINE

System/Component Failed & Inspection: The vehicle suffers from recurring failures across the engine, powertrain, electronic throttle control, and exhaust gas recirculation (EGR) control systems (DTCs P0524, P0642, P2118, P022100). The vehicle is fully available for inspection upon request. Safety Risk: While driving, the vehicle suffered a complete, sudden loss of motive power on an active highway entrance ramp. The engine stalled in moving traffic with zero throttle response, creating an immediate collision hazard before requiring a tow. Confirmation by Dealer: Technicians formally confirmed these defect patterns. In May 2026, diagnostics logged major engine and emission/EGR control codes, but corporate refused goodwill repair. In August 2026, the highway stall recurred. Diagnostics confirmed active low oil pressure and throttle failure codes, which the dealer resolved by applying 4 factory ECU software updates under TSB 25-01-010H. Service personnel explicitly confirmed these engine control issues are manufacturing defects, not wear-and-tear or mileage-related. Inspections: Inspected, diagnosed, and serviced by authorized dealership service department technicians during both the May and August 2026 failure events. Warning Symptoms & History: Engine issues began at 341 miles when purchased new (settled). In May 2026, check engine lights returned with diagnostic codes for engine and EGR/emissions systems. In August 2026, total power loss occurred, preceded by check engine, forward collision camera, and radar sensor warnings.

NHTSA complaint #11758103 — an unverified report by a vehicle owner.

ENGINE

While driving my 2022 Hyundai Tucson Hybrid, the vehicle suddenly lost power, began shaking, and all warning lights illuminated at once. The car would not accelerate properly and became unsafe to operate in traffic. After pulling over and restarting the vehicle, the warnings cleared, but the issue has occurred more than once. It first occurred 3/25/26. The dealer was not able to reproduce the issue but found numerous faults and reset them. This is a serious safety concern because the vehicle can unexpectedly lose motor power while driving, creating a risk of collision. The problem is intermittent and unpredictable.

NHTSA complaint #11755202 — an unverified report by a vehicle owner.

ENGINE

I am reporting a critical Exhaust Gas Recirculation (EGR) valve and electrical circuit failure on my 2022 Hyundai Tucson Hybrid. The failure resulted in the check engine light illuminating, diagnostic codes identifying an EGR system malfunction, and visible corrosion found within the EGR connector and extension harness. This component breakdown causes severe performance risks, risk of sudden loss of engine power, and compromises vehicle safety. Diagnostic & Technical Details: Error Codes Captured: Diagnostic trouble codes in the P0400 series (EGR system flow/circuit malfunction) along with connector/wiring degradation were confirmed during inspection. Root Cause & Symptoms: The failure stems from degradation and electrical shorting risks in the EGR valve assembly and its immediate wiring harness connection. Manufacturer Response & Escalation Denial: When addressing this failure, I discovered that Hyundai has acknowledged widespread EGR valve assembly defects, electrical short risks, and solder flux contamination issues across multiple model years and production lines (such as NHTSA Campaign 24V-308 and subsequent service campaigns like 9B3). However, Hyundai restricts safety recall and warranty coverage strictly based on narrow VIN manufacturing parameters, leaving owners with identical, failing hardware to shoulder exorbitant out-of-pocket repair costs—in my case, quoted at over $2,013.  Because a compromised EGR system and corroded electrical harness can cause sudden engine performance failures while driving in traffic, and because Hyundai is limiting its accountability through arbitrary production windows, I am requesting that NHTSA investigate this systemic EGR and harness failure on 2022 Tucson Hybrid models and compel Hyundai to expand its safety coverage and reimburse affected owners for necessary repairs.

NHTSA complaint #11754790 — an unverified report by a vehicle owner.

ENGINE

On XXX the vehicle lost motive power while my wife was accelerating to merge onto a highway with our two young children aboard. It would not accelerate and she was forced to pull over in an active merge area. Simultaneous warnings illuminated: Electronic Parking Brake, ESC, Forward Collision Avoidance, Blind Spot Detection, and hybrid system, with "Check Hybrid System" displayed. No crash or injury occurred, but loss of propulsion during a highway merge created serious collision risk. This is a recurring defect documented since early 2023: Hyundai's own Blue Link telematics auto-flagged an Engine Control System DTC on XXX; a jump-start was required XXX (dealer RO #XXX); check engine light and stored CAN-bus codes U100387, U100100, U004600, U010100 on 08/10/2023 (RO #XXX); and a September 2023 incident in which the center display shut off during reverse, disabling the backup camera. Hyundai performed Service Campaign 9B4 (BMS software update, DTC P1BB20, TSB 25-01-010H-1) on this VIN on XXX; the same failure category recurred 84 days later. The vehicle was towed to Safford Hyundai of [XXX] onXXX and has remained there 65+ consecutive days. The dealer replaced the 12V battery (defect persisted) and the Hybrid Power Control Unit (HPCU); per Hyundai Consumer Affairs' own written email ofXXX, the check engine light returned after the HPCU replacement and the cause "remains unidentified." The dealer states it cannot determine the root cause. The vehicle IS available for inspection at Safford Hyundai of Springfield, [XXX]. Five Hyundai Consumer Affairs cases exist on this VIN (current: #XXX). INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11753579 — an unverified report by a vehicle owner.

ENGINE

I am reporting a critical Exhaust Gas Recirculation (EGR) valve failure on my 2023 Hyundai Tucson Hybrid. The failure resulted in an immediate loss of engine power, reduced vehicle performance, reduced fuel efficiency, and the vehicle entering limp mode while driving, creating a significant safety hazard in traffic. Diagnostic & Technical Details: Error Codes Captured: Diagnostic trouble codes in the P0400 series (EGR system flow/circuit malfunction) were confirmed during diagnostic inspection. Root Cause: The component failure is directly linked to an internal short circuit in the EGR valve assembly, caused by solder flux contamination during manufacturing. Manufacturer Response & Escalation Denial: When contacting Hyundai regarding this failure, I was informed that my vehicle’s VIN is "not included in Safety Recall 260" (NHTSA Campaign 24V-308). I formally escalated this claim to Hyundai Corporate, but my request for reimbursement and coverage was explicitly denied on the grounds that my VIN falls outside the designated recall parameters. However, this exact failure mode, part assembly line, and manufacturing defect (solder flux contamination) are identical to the safety defect described in Recall 260 as well as Hyundai Service Campaign 9B3. Hyundai is restricting coverage based on narrow VIN manufacturing windows despite identical, defective parts being installed across non-recalled vehicles. Because a sudden EGR failure causes unexpected loss of power while traveling in traffic, and because Hyundai Corporate has refused to cover this out-of-pocket repair, I am requesting that NHTSA investigate this issue and compel Hyundai to expand the scope of Recall 260 to protect affected owners and mandate reimbursement for out-of-pocket repair costs.

NHTSA complaint #11753488 — an unverified report by a vehicle owner.

ENGINE

I purchased my vehicle from Ideal Hyundai on 04/23/26. On 06/22/26 (less than 2 months later), I was driving to work and the car started to lose power. The display said to check hybrid system and stop safely. After 10 minutes, I was able to drive the car 3 more miles to work. I took it to Ideal Hyundai the next day. I got the car back on 06/26/26 after they said they address the issue and the open recall. Two weeks later, on 07/23/26 I was driving home on a busy highway when the car began to lose power again. We were able to get to the side of the road but were still in a dangerous position. Within minutes, the car's power went out and fuel drained from the car. We used Hyundai Roadside Assistance and they towed it to the nearest Hyundai dealer (Antwerpen). They told me the next day that the car had serious issues and another recall. They said they'd repair it by the end of the week. I also had called the Hyundai corporate office on 07/13/26. They said someone would get back to me in 2-3 business days. They have not done so yet. When I called yesterday, they said someone will get back to me tomorrow (9 business days after my initial call). No one from Antwerpen is answering the phone. I just got a text from them on 07/17/26 saying the car would be ready on 07/20/26 (it's not ready). Because the car lost power in the middle of a busy highway and has lost power twice in less than a month, I am afraid to drive it and believe it has issues that make it unsafe.

NHTSA complaint #11751767 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2022 Hyundai Tucson. The contact stated that while driving, after an hour, the vehicle was shaking and shuddering abnormally and the vehicle lost motive power. The driver was unable to maintain a steady speed while driving the vehicle. The vehicle was making an abnormal sound while driving at 60 MPH, and the vehicle was struggling to accelerate. There were no warning lights illuminated. The blue link indicated that the failure was associated with DTC: P03600. The vehicle was taken to the local dealer, who was unable to retrieve a diagnostic trouble code. The vehicle was diagnosed as needing the fluid, tires, and brakes to be changed, and the low jack to be removed. The vehicle was not repaired. Another local dealer, Napleton Hyundai (4333 W Ogden Ave, Aurora, IL 60504) was contacted, but there was no response. The manufacturer was contacted, and a case was opened. The failure mileage was approximately 48,000.

NHTSA complaint #11750241 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

See attached document for complaint.

NHTSA complaint #11740648 — an unverified report by a vehicle owner.

ENGINE

Car is a Gas Hybrid (not plugin). 3 occurrences over the last couple of months. Car emits a warning sound and a message on the dash says "Check Hybrid System. Stop Safely". Basically right after this message the car starts losing power and stops. Doesn't matter if on freeway or not. You need to find a place to pull over or you stop traffic wherever you are. Looks like Hybrid Battery is completely drained. Can not be re-created. Dealer has it now for the 3rd time. Dealer in the past have not been able to find cause/cure since this issue is not posting any errors to the onboard diagnostic system. Temporary 'fix' is to power off car, and power back on. Looks like this is a 'known' issue though as its being reported by quite a few people online.

NHTSA complaint #11728364 — an unverified report by a vehicle owner.

ENGINE

On [XXX], my 2025 Hyundai Tucson Hybrid displayed a red dashboard alert instructing me to “stop vehicle and check brake system.” The vehicle experienced brake system warnings and a loss of power steering, requiring me to pull over. I immediately contacted Hyundai through the Bluelink system, and the Bluelink operator confirmed that multiple fault codes were visible in Hyundai’s system. I scheduled a Hyundai service appointment at the next available date. On [XXX], before the scheduled service appointment could occur, the vehicle experienced a sudden and total electrical failure while traveling at highway speed (approximately 65 mph). The vehicle lost propulsion and displayed brake system warnings. After reaching the shoulder, the vehicle also lost hazard lights while disabled in heavy rain. The vehicle was towed via Hyundai Bluelink to a Hyundai dealership and removed from service. The occupants at the time of the incident included my wife and my minor child. The loss of propulsion, braking warnings, power steering, and hazard lights created a serious risk of a rear-end collision and injury. Due to repeated and escalating safety-related failures involving electrical, braking, and steering systems, I no longer consider the vehicle safe to operate. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11711220 — an unverified report by a vehicle owner.

ENGINE

I’ve experienced repeated electrical and mechanical issues with my 2022 Hyundai Tucson Hybrid. These include full battery drainage without engine activation (leaving me stranded), multiple warning lights, and recently a heater failure that remains unresolved. I’ve had over 8 service visits in two years, and Hyundai has not responded to my formal letter. A detailed timeline is available if needed.

NHTSA complaint #11700602 — an unverified report by a vehicle owner.

ENGINE

While driving the engine would not turn on and we were stuck EV MODE. Lost power , had to pull off to shoulder of road and had to turn vehicle off and back on in order for car to move.

NHTSA complaint #11696765 — an unverified report by a vehicle owner.

ENGINE

Vehicle propulsion system failed, as a result vehicle rolled down an inclined driveway in to the street and was stuck in the middle on the street in traffic. Vehicle had started normally, was able to shift into Drive, no obvious warning lights or error messages displayed. Vehicle would shift into Drive/Park/Reverse as required but would not move. Upon shutdown an restart two warning lights were display but Vehicle would still not move. Vehicle only had 168 miles on the odometer. Vehicle is a Hybrid, engine was running and Battery charged. Apparently the problem was a failed "Over the Air Software Update", this was corrected by Dealer (see attached file). Safety issue is that the Vehicle, 1 Failed to display any error regarding a Failed Update, 2 Failed to immobilize the Vehicle allowing to move in an unsafe state, 3 Failed to notify Owner that Updates had been done, 4 Proceeded with an over thew air Update that could potentially place the Vehicle in an unsafe state.

NHTSA complaint #11692522 — an unverified report by a vehicle owner.

ENGINE

I purchased a brand-new Hyundai vehicle on [XXX] from Dublin Hyundai. Since purchase, the vehicle has exhibited repeated, serious defects that compromised the safety of my [XXX] baby and family. Timeline of Events: [XXX] – Vehicle purchased new. Safety concerns arose within weeks of ownership. July 16, 2025 – Vehicle dropped off for major issues: camera display failures, heads-up display malfunctions, and random security errors. Vehicle remained in service for over two weeks. August 2, 2025 – Returned with the check engine light on and a scratch on the deck. August 3–4, 2025 – Dropped off again; dealership instructed that the fuel level must remain between 50–70%. August 11, 2025 – Dropped off again; a loaner vehicle provided was unsafe — gear shift failure, body control system errors, infotainment failure, and inability to lock the vehicle. This put my baby’s safety at direct risk as the loaner could not be secured or reliably driven. August 19, 2025 – Vehicle returned with new scratches and multiple issues still unresolved. Late August 2025–Present – Vehicle was relocated to San Jose without my consent. I only know its location from the Hyundai app, which frequently alerts: “Battery level is below normal. Please check that vehicle lights and accessories are switched off to avoid battery drain.” I have not been provided proper updates from Hyundai or the dealership. Safety Risk: Repeated mechanical and electronic failures in both the new vehicle and the loaner. Vehicle is unreliable, unpredictable, and unsafe for transporting a young child. Manufacturer and dealer have failed to provide a safe, operable vehicle despite multiple repair attempts. I am filing this complaint because these issues pose a serious safety risk to me, my infant child, and other drivers on the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11684279 — an unverified report by a vehicle owner.

ENGINE

On June 30, 2025, I was driving at about 55 mph with the smart cruise on. A message appeared on the left side of the dash (in the left circular screen) that said “Conditions for smart cruise have not been met”. And the cruise turned off, Then a second message appeared that said the engine has been put on idle. At that time I tried to use the gas pedal and got no response. Fortunately I was near a parking lot on my left and had enough momentum to pull in and park. I turned the Tucson off and restarted it and was able to continue to drive. I took the Tucson to the dealer and they tried to duplicate the issue, but were unable to do so. Then the ran a diagnostic, but said it indicated everything came back as normal. I purchased this Tucson Limited hybrid on 1/23/2025 so the fact that the dealer couldn’t duplicate the incident didn’t surprise me. I believe that this was caused by a software problem even though the diagnosis by the dealer indicated everything was normal and in range. However, I believe that their equipment and/or their technical expertise was insufficient to identify the problem. You can imagine the danger if this occurs on an interstate or other highway where speeds are as high as 65 to 70 & higher by some drivers.

NHTSA complaint #11674337 — an unverified report by a vehicle owner.

ENGINE

I think when its hot like in illinois its been super hot the screen keeps going black!! I can't see the dashboard i called my hyundai dealership will get it looked at seems like I am not the only one dealing with this issue. Main screen on left goes black or it has problem logos on it randomly.

NHTSA complaint #11670347 — an unverified report by a vehicle owner.

ENGINE

Battery Management System failed Safety-Could not drive on interstate. Very unsafe. Dealer inspected problem afterwards. Warning lights appeared at time of problem. No warnings before. No signs of problem before it happened. SYNOPSIS: After driving through a torrential thunderstorm on the interstate (06-13-25) and as we were getting ready to slow down for our exit on the interstate, we hit the brakes and our SUV gave us a warning. The warning said, "Battery Management System Discharge". The SUV is a hybrid. At this point the SUV locked into E V mode. Our SUV would only go 10 mph which was very dangerous. It should be able to go up to 35 mph in E V mode and then past that, switch into gas mode. As stated, we could only go about 10 mph. We made it to our exit and found a spot to pull off the ramp. We let the SUV sit for a few moments and turned it off. We let it sit for a minute and then turned the car back on. The SUV when we turned it back on gave us a check engine light and still would not go over 10 mph. Luckily we were stopping for dinner. We were able to proceed to our destination. After dinner around an hour or so, when turned the vehicle back on, the SUV still gave us a check engine light. but was able to drive normally and switch between E V and gas modes. We made it home safely at the end of the weekend on 06-15-25. On 6-16-25 we took the SUV to be looked at by the dealer we purchased it from. Our phone app showed code DTC P0AA600. We gave the code to the staff. The staff inspected the SUV. The report stated, "customer states stopped driving and there code P0AA600 Battery Warning Light NPF Could not duplicate problem. Tech scanned for codes Code P0AA600 was found as a history code. Tech checked live data and everything came back within spec. Followed the flow chart procedure for the code. Check for BMS isolation faults none found. Check 12volt battery. Battery is good". We drove it home and filed this report.

NHTSA complaint #11667104 — an unverified report by a vehicle owner.

ENGINE

On June 3, 2025, I experienced a terrifying and dangerous incident while driving my 2023 Hyundai Tucson Hybrid on a three-lane road at approximately 50 mph. Without any warning, the gas pedal became completely unresponsive, and the car abruptly decelerated from 50 to 20 mph. This sudden loss of acceleration was incredibly frightening, especially with vehicles close behind me that nearly collided with mine. There were no warning lights or check engine alerts. Fortunately, I was able to safely cross all lanes and pull over before having the vehicle towed to a local Hyundai dealership. I shudder to think what might have happened if this had occurred on a highway at higher speeds. This is not the first time I’ve experienced serious issues with this vehicle. In February 2024, at about 17,000 miles, I received an urgent alert recommending a system check. At that time, the car was revving while idle and would occasionally lurch at low speeds. The dealership had difficulty diagnosing and resolving the issue, and my vehicle remained in the shop for over a month before they ultimately replaced the oxygen sensor. Since then, the car has continued to lurch intermittently — for example, when backing out of a parking space or in stop-and-go traffic. In fact, approximately 10 minutes before the June 3 incident, the vehicle lurched several times while moving slowly in traffic. When the car began to lose speed during the most recent incident, I pressed the gas pedal all the way down, but it failed to respond at all. I believe the current issue may be related to the unresolved problems from last year and represents a significant and recurring safety concern. I’ve also read in Tucson owner forums that other drivers have experienced similar issues, suggesting this may be part of a broader, systemic defect. At this point, I do not feel safe driving this vehicle. I truly believe this car is a lemon. This vehicle is still at the dealership, but they have not given me any updates yet.

NHTSA complaint #11665014 — an unverified report by a vehicle owner.

ENGINE

📌 NHTSA Complaint Description (Modify as Needed) 🚨 Safety Issue: I purchased a brand-new 2025 Hyundai Tucson Hybrid on March 3, 2025, and within 5 minutes of driving and less than 20 miles, the vehicle stalled three times on a busy highway without warning. 🚨 Component/System Failure: The vehicle suffered a complete power loss, rendering it undrivable in the middle of the highway. The gas pedal became unresponsive, and I had no control over the vehicle’s movement. 🚨 Immediate Safety Risk: The sudden stalling on a highway put my family and other drivers at serious risk of a collision. We were left stranded for over 3 hours while waiting for assistance. The vehicle was inspected by Hyundai’s roadside assistance and later towed to the dealership. 🚨 Inspection & Confirmation of the Issue: The dealership and Hyundai’s technical team later diagnosed the issue as a failure in the electric oil pump and the oil pump control unit. Hyundai has not provided a clear resolution and is pushing for repairs, despite the vehicle failing immediately after purchase. The manufacturer and dealership have not provided a pre-delivery inspection report confirming whether the vehicle was defective before delivery. 🚨 No Prior Warning Signs: There were no warning lamps, error messages, or any prior symptoms before the failure. The issue occurred suddenly and repeatedly within minutes of taking delivery of the vehicle. 🚨 Request for Investigation: Given the severity of this mechanical failure and its potential to cause serious accidents, I am reporting this to the NHTSA for further investigation. This issue needs to be addressed immediately before it leads to a fatal accident for another Hyundai Tucson Hybrid owner.

NHTSA complaint #11648012 — an unverified report by a vehicle owner.