2013 Hyundai Santa Fe Sport

The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles.  During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types.  The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement.  Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia.  The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio.  The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires.  In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines.  The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS.  It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension.  For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied.  Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates.  To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years.  In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires.  Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis.  Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023).  The agency reserves the right to take additional action if warranted by future circumstances.  To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Hyundai Sonata and Santa Fe vehicles equipped with Theta II and Lambda II engines (approximately 1.3 million vehicles). ODI also reviewed field data of other Hyundai vehicles equipped with Theta II, Gamma, Nu and Lambda engines (approximately 4.8 million). As a result of this PE, Hyundai has issued NHTSA Recalls 20V-746 and 21V-727 to address potential engine failures and fires in certain Hyundai vehicles equipped with various engine types. Additional information on these and other related recall actions is available in the downloadable version of this resume available at NHTSA.gov. In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure rewlated recalls mentioned above and conducted previously. See the EA21-003 Opening Resume available at NHTSA.gov for more information. Also available in the downloadable version of this resume is a list of the reference numbers for the 302 ODI reports, or Vehicle Owner Questionnaires (VOQs), cited above which ODI received through mid-November 2021. Note that the Manufacturer reports cited above are customer complaints received through March 2019.

Door latch closed indicator failure. Available for inspection (Yes) The Door may or may not be closed properly because the indicator shows always open. this is a safety risk because if the doors are opened while driving and the driver would not have the designed warning. Has the problem been reproduced or confirmed by a dealer or independent service center? (NO) Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? (No) Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? (yes) (I do not recall)

NHTSA ID

11776801

Incident

Jan 1, 2026

NHTSA SAFETY & CAMPAIGN NON-COMPLIANCE COMPLAINT (VIN: [XXX] | HYUNDAI CASE #XXX): On XXX, my 2013 Hyundai Santa Fe Sport 2.4L Theta II GDI (covered by Hyundai Warranty Extension TXXI Limited Lifetime Warranty under TSB 22-EM-001H-1 / NHTSA MC-10211673-0001 and Service Campaign T3G / NHTSA [XXX]) entered Engine Protection Mode (Limp Mode) with flashing Check Engine Light / DTC P1326 and a severe metallic connecting-rod bearing knock under 2,000 RPM. At 8:00 AM on XXX, I brought the vehicle to Huffines Hyundai Plano ([XXX]). Despite NHTSA ID [XXX] mandating an immediate Service Rental Car (SRC) or 3rd-party rental upon reception ("reimbursed regardless of PA's decision") and prohibiting diagnostic fees after Campaign 953/KSDS, the dealership refused a loaner, told me diagnosis would take a full week while I rent a car out of pocket, forced me to drive the unsafe vehicle in Limp Mode to take my disabled father to a medical appointment, and stranded us in the lobby for 7 hours (causing my father to miss scheduled prescriptions and failing to restore his disability placard). At 2:00 PM, the dealership claimed the vehicle "PASSED" the Bearing Clearance Test (BCT) without giving me the mandatory BCT printout or multi-point inspection sheet, cleared the P1326 code, performed a KSDS software update instead of inspecting the knocking engine, refused to record the mandatory STUI Engine Noise Video or submit a Warranty Prior Approval (PA), and tried to coerce me into signing a falsified Repair Order stating "CUSTOMER IS DECLINING DIAGNOSTICS." At 5:33 PM, HMA Executive Case Manager [XXX] ([XXX]) falsely stated in writing that TXXI is capped at 10 years/120,000 miles (confusing TXXC with TXXI), that T3G does not apply, and that passing BCT means "your rod bearings are in working order." CRITICAL HIGHWAY SAFETY FAILURE (RECORDED ON VIDEO): On the night of Wednesday, XXX — just hour INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11775842

Incident

Nov 4, 2026

While driving my engine seized up and my car completely stopped. I was luckily able to coast it to the side of the highway without getting into an accident. I had it towed to Go Hyundai in [XXX]. The did the diagnostic, found it was covered by the recall and allegedly ordered the engine. The engine is apparently on back order and has to come from [XXX]. They are dragging their feet in providing me with alternative transportation. Because I don't have a credit card I'm not able to use their loaner vehicles or rent a car myself from a car rental company. I am having to pay every day to go to and from work in Ubers. I can't continue to afford this and Go Hyundai is acting like it's MY problem the engine failed. Hyundai has been contacted directly but there doesn't seem to be much they can or will do either. I'm running out of money and without a vehicle I can't get to work. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11774944

Incident

Oct 17, 2026

Vehicle: 2013 Hyundai Santa Fe Sport 2.0T Limited, VIN [XXX]. Registered and titled in Georgia, USA since July 2022. Built in the USA (VIN begins with 5); originally retailed in Canada. The vehicle has an unremedied ABS module defect that can cause an engine-compartment fire even when parked and turned off. Hyundai Canada lists it as open safety recall R0246-1 (41D013, Transport Canada 2024-080), remedy available since 2024-05-27. The same defect and the same remedy (ABS fuse replacement) are covered in the US by NHTSA recall 23V651 / Hyundai Recall 251, which includes 2013 Santa Fe Sport vehicles produced 7/12/2012 to 6/15/2013. A second Canadian fire-risk recall is also open: R0212 (21DG01, TC 2022-659, rear park-assist sensors). The NHTSA recall lookup for my VIN shows 0 open recalls (checked 10/26/2026), apparently because the vehicle was first sold in Canada. Georgia Hyundai dealers refuse to perform the recalls, telling me they do not do recalls on Canadian vehicles. As a result, a US-registered vehicle with a known fire defect that Hyundai Motor America has recalled in the US cannot get the remedy anywhere in the US. I have asked Hyundai Auto Canada (10/26/2026) to authorize a US dealer. I ask NHTSA to ask Hyundai Motor America (1) why US-registered vehicles that are the same as those in recall 23V651 are excluded from the remedy because of their original market, and (2) to authorize its dealers to perform the remedy on my vehicle. I am parking outdoors away from structures in the meantime. My family, including three young children, rides in this vehicle. No fire, crash or injury has occurred. Documents available: Hyundai Canada recall lookup and NHTSA lookup for this VIN, both dated 10/26/2026. [XXX], [XXX], [XXX], [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11773666

Incident

Oct 26, 2026

FORMAL VEHICLE SAFETY AND WARRANTY COMPLAINT Date: [XXX] From: [XXX] Vehicle: 2013 Hyundai Santa Fe Sport, 2.4L Theta II engine Mileage: Approximately 150,000 miles (exact current reading to be confirmed) Subject: Recurrent Check-Engine Warning Following Repeated Repairs; Request for Theta II Engine Investigation I am submitting this complaint to formally document recurring engine-related symptoms affecting my 2013 Hyundai Santa Fe Sport, and my repeated requests for investigation of a possible connection to the known Theta II engine defects and related warranty programs. On [XXX], the check-engine light illuminated again. Previously, on three separate occasions, the vehicle experienced a flashing check-engine light and a light ticking noise while idling. I was advised each time that the knock sensor was responsible, and the sensor was replaced. The vehicle returned to normal operation after those repairs, but similar symptoms subsequently recurred. While my vehicle was still below the 150,000-mile threshold, I repeatedly expressed concern that the symptoms could relate to the Theta II engine issue. During the most recent dealership visit, resulting in repairs on September 10, 2026, I emphasized that the recommended valve-cover gasket and spark-plug work might address a secondary issue without resolving the primary recurring problem. The check-engine light has now returned approximately five weeks after that repair. I am not claiming that a connecting-rod-bearing defect has been conclusively diagnosed. I am asking that the possibility be properly evaluated and that my earlier reports, repair attempts, and the mileage at which I first raised these concerns be preserved and considered when warranty eligibility is reviewed. I am sending this as a record of contact and communication.. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11771325

Incident

Oct 15, 2026

The vehicle suddenly stopped and suddenly smoke appear in the front part of vehicle. Firemen appeared and when the front of the car was opened the flames of the fire were all over the engine of the car. The front glass broke and the hood has visible signs of the fire. Police were everywhere while firemen worked to stop the fire in the car. The car was towed to our home.

NHTSA ID

11767319

Incident

Sep 23, 2026

The contact owns a 2013 Hyundai Santa Fe Sport. The contact stated that the front driver’s side door failed to unlatch as intended using either the interior or exterior door handles or the locking mechanism. In addition, the contact exited the vehicle using the front passenger’s side door to exit the vehicle. An appointment was scheduled with the local dealer. Upon further investigation, the contact associated the failure with TSB: 14-01-004-1. The contact stated that it might be a potential safety risk for passengers in an emergency. The manufacturer was made aware of the failure by telephone. The failure mileage was approximately 142,622.

NHTSA ID

11764127

Incident

Sep 5, 2026

Mileage

142,622 mi

In October/November of 2023, while Hyundai was actively initiating Safety Recall 251 (NHTSA Campaign 23V-651), my vehicle's ABS Control Unit suffered an internal fluid leak that resulted in an electrical short-circuit. The failure caused major electronic communication errors, illuminated dashboard warning lights, and placed the vehicle into Limp Mode, rendering it unsafe to drive. Because the failure occurred prior to receiving a formal owner notification in the mail and the vehicle was un-drivable, I paid $1,300.54 out-of-pocket on November 17th 2023 to replace the failed ABS module. Hyundai Corporate has twice denied reimbursement, arguing that Recall 251 only covers a multi-fuse replacement and claiming internal fluid leaks are not covered. This contradicts NHTSA 23V-651 documentation, which explicitly identifies internal ABS module fluid leaks and electrical shorts as the core safety defect. Installing a fuse current-limiter cannot repair an already-ruined ABS circuit board or resolve a safety-mandated Limp Mode. I am reporting this to document on the official public record that Hyundai is actively denying reimbursement for the exact root-cause failure identified in NHTSA Campaign 23V-651. PLEASE NOTE: This report is submitted solely to document Hyundai Motor America's non-compliance and improper reimbursement denial for official record-keeping under Campaign 23V-651. I do not require follow-up contact from NHTSA regarding this submission.

NHTSA ID

11757483

Incident

Oct 30, 2023

In certain areas, a vehicle’s underbody may exhibit corrosion due to road salt usage. As a preventative measure, cavity wax coating is applied to the internal surfaces of underbody components, and an undercoating spray is applied to exterior surfaces of specified underbody components. This service campaign describes the procedure to perform this preventative service on certain Santa Fe Sport (AN) vehicles.

Certain Santa Fe Sport (AN) vehicles may exhibit underbody corrosion due to road salt usage. As a preventative measure, this bulletin provides the procedure to apply a cavity wax coating to internal surfaces of underbody components, and an undercoating spray to exterior surfaces of specified underbody components.

Some Hyundai vehicles may be equipped with a parking distance warning (PDW) sensor(s) that may trigger various DTCs and display warning messages on the instrument cluster, resulting in the PDW sensor(s) failing to detect nearby objects or triggering multiple false alarms. This condition may be a result of external damage to the PDW sensor membrane or sensor cover from rock chips or road debris, a collision, or previous vehicle repairs or modifications.

Some vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin outlines the combustion chamber cleaning procedure for vehicles diagnosed with this condition. All internal combustion engines consume some engine oil during normal operation, depending on driving conditions and mileage, and this procedure should only be performed when deemed necessary based on inspection and diagnosis of the vehicle as outlined in TSB 26-EM-015H, Engine Oil Consumption – Inspection & Repair Guidelines, or the latest revision.

Certain vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin provides the inspection and repair procedures for vehicles exhibiting this condition. All internal combustion engines consume engine oil as part of normal engine operation. Oil consumption rates may vary based on mileage, operating conditions, driving habits, and maintenance history. Hyundai recommends following the prescribed maintenance schedule and periodically checking the engine oil level using the dipstick to maintain proper engine oil level.

Certain 2012 – 2017 model year Accent, 2012 – 2017 model year Azera, 2013 – 2018 model year Santa Fe Sport, 2013 – 2019 model year Santa Fe, and 2012 – 2017 model year Veloster vehicles may exhibit an intermittent airbag warning light and diagnostic trouble codes (DTCs) may be set. At Hyundai, we are committed to providing vehicles of outstanding quality and value. In an effort to meet this commitment, the warranty coverage for the Occupant Classification System (OCS)/Occupant Detection System (ODS) under these conditions has been extended to 18 years/unlimited mileage from the date of original retail delivery or date of first use (whichever occurs first) and is valid for original and subsequent owners.