The 2013 Tucson's 2.4L Theta II engine is failing at 40,000 to 185,000 miles due to premature bearing degradation. Owners describe sudden, violent engine noise—loud knocking, ticking, or grinding—followed by complete power loss, often at highway speeds (65–75 mph) with no warning lights beforehand. Dealers diagnose metal shavings in the oil pan and hole in the engine block from thrown rods.
Hyundai issued Campaign 181 (oil pan seal defect) and Campaign 19V063000 (oil pan gasket/seal) but has not recalled all 2013 Tucsons; some owners are excluded from coverage based on VIN range or trim level, despite having the identical engine and identical failure modes as recalled Santa Fes and Sonatas. Owners report applying to Hyundai for goodwill assistance or reimbursement only to have claims denied or delayed indefinitely. A new software update (TSB 22-01-028H-1) designed to detect bearing failures caused stalls in at least one case, followed by engine failure days later.
Engine replacement costs $5,700–$12,000. Parts are frequently unavailable, leaving owners waiting three months to indefinitely. The oil pan gasket recall remedy of RTV application failed within a year in at least one case, yet dealerships refused to re-repair under the same recall. Owners who performed their own maintenance had warranty denied on faulty grounds (alleged lack of records despite maintenance being performed); one dealership later blamed the hole in the engine block—the defect itself—for the drained oil.
Failure modes owners describe
Rod/Main Bearing Failure
Catastrophic internal engine failure wherein the main rod bearing fails, typically ejecting the rod through the engine block or creating a hole. Metal shavings in the oil pan are a hallmark sign. Often produces loud knocking, ticking, or grinding noise immediately before complete power loss.
When: Typically 40,000–185,000 miles; one failure reported at 213,000 miles. Often occurs without miles-based pattern.
Symptoms owners cite: Loud knocking, ticking, or metallic grinding noise from engine; Loss of power or inability to accelerate; Engine stall without warning during highway driving; Loud noise escalating rapidly to complete shutdown; Metal shavings visible on dipstick or in oil pan; White or black smoke from engine compartment; Engine vibration or shaking; Check engine light may or may not illuminate
Codes mentioned: P0300 (Random/multiple cylinder misfire), Bearing failure confirmed on teardown
Repairs/costs cited: Engine replacement required; cost typically $5,700–$12,000. Parts often unavailable; owners report 3+ month delays or indefinite waits. Hyundai denial of warranty coverage common; goodwill assistance denied or partial (e.g., 75% coverage). One owner reported replacement engine installed has same defect.
Recalls/TSBs owners mention: Campaign 181 (oil pan seal/switch defect, announced but not launched at time of some complaints). Extended coverage under Campaign 966 (active campaign, mileage-limited to 150,000 miles). TSB 22-01-028H-1 (knock sensor software update). Hyundai denies coverage when vehicle out of warranty or not included in recall VIN range. Parts shortages cited repeatedly.
Oil Pan Seal/Gasket Leak
Defective oil pan gasket or seal that leaks oil, resulting in low oil levels and eventual engine damage. Recall 19V063000 (announced April 2019) called for oil pan removal, gasket replacement, and oil pressure sensor replacement. Multiple owners report the gasket seal was applied with RTV only and failed again within months to a year; dealership refused to re-repair under same recall.
When: Leak can appear months to years after recall repair. One owner reported failure approximately 1 year after recall work.
Symptoms owners cite: Oil dripping from underneath vehicle or oil pan area; Low oil level despite recent service; Engine power loss or stalling during operation; Warning lights (oil pressure, check engine) illuminating; Loss of power without warning, especially at highway speed
Codes mentioned: P0011, P0014 (Camshaft timing codes), Oil pressure codes
Repairs/costs cited: Recall remedy involved RTV application to oil pan gasket. Owners report this fix failed. Proper repair requires new gasket (thicker gasket recommended by some independent techs). Cost quoted at $396–$7,000+ for full engine rebuild if oil loss causes bearing failure.
Recalls/TSBs owners mention: Campaign 19V063000 (Engine and Engine Cooling) issued April 2019. Remedy involved oil pan removal, gasket replacement, oil pressure sensor replacement. Hyundai refused to re-cover the same area if RTV repair had already been performed, citing 'already serviced under recall.' Parts availability was a constraint; dealerships delayed work indefinitely.
Knock Sensor Failure / Defective Software Update
Engine knock sensor software update (TSB 22-01-028H-1) introduced to detect bearing failures caused engine stall. One owner's vehicle stalled one day after knock sensor update, then engine failed days later. Another owner received software update work without consent after bearing failure already occurred.
When: Stall occurred immediately after software update (1–4 days post-update); subsequent engine failure within days.
Symptoms owners cite: Engine stall without warning; Check engine light illumination; Subsequent engine failure shortly after software update
Codes mentioned: Knock sensor-related fault codes
Repairs/costs cited: Software update performed at dealership under TSB 22-01-028H-1. Engine replacement still required after update failure. Cost $12,000+. One dealership performed update without owner consent/signature.
Recalls/TSBs owners mention: TSB 22-01-028H-1 issued to reprogram knock sensor to detect bearing failures. Hyundai informed at least one owner the software update on older vehicles was causing engine failure. No warranty extension or goodwill offer documented.
CVVT/Timing Chain Failure
Failure of continuously variable valve timing (CVVT) gear and timing chain, rendering vehicle unable to start. One case diagnosed at 2018 with complications; repairs unsuccessful.
When: Approximately 2018; one reported case.
Symptoms owners cite: Vehicle unable to start; Complications with timing chain mechanism
Codes mentioned: CVVT system fault codes
Repairs/costs cited: Repair cost estimated over $5,000. Owner reported ongoing frustration with multiple different case representatives and lack of consistent support.
Recalls/TSBs owners mention: No consistent or helpful response documented; owner complained of different explanations from different customer service representatives.
Engine Fire / Overheating
Engine catching fire or producing excessive heat/smoke under the hood, sometimes accompanied by electrical shutdown or loss of function. Multiple owners reported flames and intense smoke.
When: Occurs during highway driving or while accelerating; reported at mileages 70,000–110,000.
Symptoms owners cite: Flames or smoke visible from engine compartment; Sparks coming from rear passenger side of vehicle; Check engine light and warning indicators; Burning wire smell; Black smoke from engine
Codes mentioned: Check engine light (code not always specified)
Repairs/costs cited: Vehicle deemed unserviceable; fire department called. One case investigated by insurance; no total loss declared initially. Engine replacement or complete vehicle loss typical outcome.
Recalls/TSBs owners mention: Not documented in fire cases; typically insurance-handled.
Synthesized from 144 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.