NHTSA complaint #11692096

Owner complaint summary

The vehicle is experiencing excessive oil consumption and increasingly severe engine performance symptoms. The oil level drops rapidly between changes, but the loss is not due to external leaks. The engine burns oil internally, causing residue buildup and damage to other components — specifically the intake manifold and catalytic converter, which the dealer has now recommended replacing. These issues align with the symptoms addressed in Hyundai Campaign 966 (Engine Monitoring / Knock Sensor Detection System), which is intended to detect early bearing wear and related oil consumption defects. However, the dealership refused to perform the required campaign diagnostics (bearing inspection, KSDS verification, and oil-consumption test) without charging a diagnostic fee. Even though the engine has not yet fully failed or entered limp mode, the excessive oil consumption is already causing secondary damage to emissions and intake components. If left unresolved, this can escalate to engine seizure, catalytic converter overheating, or exhaust-related fires due to unburned oil entering the converter. These are clear safety hazards that can result in loss of power, smoke, or fire while driving. Multiple Hyundai owners have reported identical problems — excessive oil loss, residue damage to emission systems, and dealer refusals to perform Campaign 966 inspections. These patterns indicate a systemic engine defect that leads to downstream component failures, not isolated wear. Replacing the manifold or converter does not correct the root cause, as oil consumption continues after replacement and will likely damage new parts. The dealer’s refusal to perform the manufacturer’s required diagnostics and their attempt to charge for unrelated repairs prevent proper defect identification. This is a serious and ongoing safety issue affecting Hyundai Tucson and other models with the same engine family.