NHTSA Complaint #11600334 — 2015 HYUNDAI TUCSON

Our 2015 Hyundai Tucson check engine light started flashing and went into "limp mode" while driving on the freeway. Limp mode means the car loses power to accelerate, struggles going up hills, and limits speed. Thankfully I was not pulling out. The vehicle was towed that day to a mechanic who found traces of metal in the oil (see documentation). The vehicle was then towed to the Hyundai dealer. The dealer explained there is a common problem with Hyundai engines failing due to rod bearing issues and PistonSlap. I later learned the dealership covers the rod bearing issues due to a court settlement from being sued for so many engine issues. The dealership said if they found it was an engine bearing rod issue (ring connecting to the piston) they would replace the engine since it was a safety issue. They claimed if it was a piston slap it would not be covered (even though the bearing rod is connected to the piston and could potentially cause PistonSlap). After checking that the car had been taken care of extremely well with oil changes around every 3 months and all safety procedures had been taken they performed a bearing clearance test. The test passed without error detection so they changed the existing knock sensor. We were directed to drive the car and if the sensor turned on again to bring the 2015 Tucson back. We did and a week later, the new Knock Sensor reported there was something wrong with the engine again. I also noticed when checking the oil that smoke came from the dipstick tube. We took the car to the Hyundai dealer again. They did the bearing clearance test again. It passed again but this time they detected a rattling noise coming from the engine block. According to the records the noise was loudest to cylinder 4. The dealer claimed we needed a new engine that would cost about $9,500. Clearly, this is a piston-manufactured defect. With metal floating in the oil and a limited piston warranty it encourages the owner to drive the car until it brakes.