2022 Hyundai Tucson Hybrid

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.

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.

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.

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)

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.

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.

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.

The contact owned a 2012 Kia Optima. The contact stated while driving 65 MPH, the vehicle lost motive power and was driving slowly. There was no warning light illuminated. The vehicle was taken to the dealer; however, no cause for the failure was found. The vehicle was not repaired. The contact stated that the failure persisted. The contact stated that recently, while driving 65 MPH, the vehicle lost motive power and stalled with an unknown message displayed. The contact was helped over to the side of the road. The vehicle was restarted. The manufacturer was made aware of the failure. The failure mileage was approximately 20,000.

1. What component or system failed or malfunctioned, and is it available for inspection upon request? The hybrid powertrain system, transmission, or engine appears to be malfunctioning. The vehicle hesitates or stalls when pressing the gas, losing power as if it doesn’t recognize when to transition between EV and gas mode. Yes, the vehicle is available for inspection upon request. 2. How was your safety or the safety of others put at risk? The issue caused the vehicle to lose power unexpectedly, particularly while driving at highway speeds, which forced me to pull over multiple times for safety reasons. This happened on [XXX] before the [XXX] Tunnel, creating a hazardous situation in heavy traffic. If the vehicle stalled at the wrong moment—such as in an intersection or while merging—it could significantly increase the risk of a crash. 3. Has the problem been reproduced or confirmed by a dealer or independent service center? No. I have taken the vehicle to a Hyundai dealership, but no official errors or diagnostic trouble codes (DTCs) have been detected. The dealership has not confirmed the issue unless I agree to high-cost diagnostics that may not guarantee a resolution. 4. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives, or others? The vehicle has been looked at by a Hyundai dealership, but no official findings or resolutions have been provided. The issue persists, and no recall or technical service bulletin (TSB) has been mentioned to me as a possible cause. 5. Were there any warning lamps, messages, or other symptoms of the problem prior to the failure, and when did they first appear? No warning lights, error messages, or dashboard alerts appeared before or during the power loss. The issue first started occurring at approximately 35,000–40,000 miles and has continued to around 50,000 miles. The first time I noticed the problem was during a long-distance drive from Los Angeles to CO INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5