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.

The contact owns a 2013 Hyundai Santa Fe Sport. The contact stated that after a routine oil change, while driving back to the residence, the vehicle stalled. The vehicle was towed to the dealer to be diagnosed. The contact was informed that there were metal shavings inside the engine. The vehicle was diagnosed with engine failure. The vehicle was not repaired. The manufacturer was made aware of the failure and stated that the vehicle was not eligible for a recall repair because the engine software update was not performed. The failure mileage was approximately 136,434.

NHTSA ID

11756036

Incident

Jul 31, 2022

Mileage

136,434 mi

While driving a 2013 Hyundai Santa Fe Sport on a city street, the vehicle unexpectedly stalled and shut off while idling at a red light. The vehicle completely failed to restart. No dashboard warning lights, check engine lights, or fault messages illuminated prior to or during the stalling event. Immediately following the engine shutdown, a fire erupted under the engine hood. The fire rapidly escalated and completely engulfed the entire vehicle, resulting in a total loss. The local fire department responded to the scene to extinguish the blaze

NHTSA ID

11753884

Incident

Jul 30, 2026

My 2013 Hyundai Santa Fe Sport is subject to Hyundai Recall 162 / NHTSA Recall 17V-226, concerning premature connecting-rod-bearing wear that can cause engine knocking, engine failure, and loss of motive power. My vehicle developed engine knocking and a flashing check-engine light while I was driving. The vehicle is now at an authorized Hyundai dealership. Hyundai initially denied an engine replacement based on mileage. I escalated the matter to Hyundai Motor America Corporate Consumer Affairs. Hyundai has now confirmed in writing that, because my vehicle is more than eight years old and has more than 150,000 miles, Hyundai is applying the high-mileage provision of the Theta II settlement and will not replace the engine. Instead, Hyundai is offering either a repurchase or $2,000 in lieu of engine replacement. I understand that Hyundai is relying on the court-approved settlement. My concern is specifically whether Hyundai’s application of that settlement to my vehicle is consistent with the administration of Recall 162 and the federal safety-recall remedy, given that my vehicle is experiencing the engine failure that Recall 162 was designed to address. I am requesting NHTSA’s review of Hyundai’s handling of this safety-related recall matter.

NHTSA ID

11753820

Incident

Jun 30, 2026

Sunroof exploded while driving

NHTSA ID

11751898

Incident

Jul 21, 2026

The contact owns a 2013 Hyundai Santa Fe Sport. The contact stated that the subframe was rusted. The vehicle was taken to the dealer, who determined that the rear control arms and subframe were rusted and needed to be replaced. The contact was informed that the vehicle had previously been repaired under Service Campaign Number: 996 (Underbody Corrosion Preventive Service); however, the contact stated that the protective spray was only applied to the unibody and not the rear underbody. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 103,483.

NHTSA ID

11750907

Incident

Jul 16, 2026

Mileage

103,483 mi

Vehicle is a 2013 Hyundai Santa Fe Sport with the 2.4L Theta II GDI engine. A Hyundai dealer documented excessive oil consumption in December 2025 (3 quarts consumed over 1,703 miles during a dealer-administered oil consumption test; repair orders on file and available for inspection). On April 19, 2026, at 160,913 miles, following a highway drive, the engine developed a pronounced knock and vibration at low RPM and began stalling within seconds of idling in Park, with check engine and charging warning lamps illuminated. An engine that stalls at idle presents a safety hazard in traffic due to loss of power braking and steering assist. The vehicle was removed from service the same day, has not been driven since, and remains available for inspection. Knock Sensor Detection System software (Campaign 953) was installed and did not prevent the failure. Manufacturer has been notified in writing and consumer affairs cases are on file.

NHTSA ID

11750048

Incident

Apr 19, 2026

Issue was first identified in September 2024 when a rattling noise prompted inspection, and the engine was found to be significantly low on oil. Excessive engine oil consumption was confirmed with failure during manufacturer testing. Vehicle emits occasional burning oil smell when idling after 10 miles+ driving. Vehicle failed a 1,000-mile oil consumption test following a “Dynamic Engine Clean” performed by a certified independent mechanic, with documented oil loss of approximately 2 quarts. Vehicle subsequently failed a dealer-administered oil consumption test, with documented oil loss of approximately 2.3 quarts within 1,000 miles. Engine oil levels have dropped to critically low levels between checks despite active monitoring and maintenance. This condition presents a risk of engine seizure, sudden loss of power while driving, and potential engine compartment fire due to oil consumption or leakage. The issue has been reproduced and documented by both an independent mechanic and a Hyundai dealership. Despite confirmed excessive oil consumption, the manufacturer has delayed corrective action and has required repeated oil consumption testing and engine cleaning procedures rather than proceeding with repair. This condition appears consistent with known defects associated with Hyundai Theta II engines.

NHTSA ID

11747266

Incident

Sep 19, 2024

I have great concern that certain vehicles of Hyundai are getting a little bit of extended warranty occupant classification system forward slash occupant detection system known issues. OCS/ODS I will try to attach a picture of the letter. As a nurse manager I find this once again appalling on Hyundai behalf, after these years pass we won't know if our air big warning lights or trouble codes or even a a passenger is detected when driving. They offered to pay if you had issues with this problem or in my case in the next four and a half years they would cover it but after that do I feel that this is my problem because they're having defect sensors and warning lights or maybe lack thereof altogether after speaking to them when I called and made a case number XXX with Hyundai Motor America. I strongly believe this should be a recall. I would never trust anybody sitting in my passenger seat, and I don't think you would either. They always try and find some way to get around doing the right thing and obviously they have problems with intermittent airbags warning lights trouble codes and this needs to be looked into if there are any risk/issues detecting or possibly never detecting a grandchild sitting in that front seat! After 5 years I will worry if anybody sits in the front seat now. I have started the process and will wait for your reply, of communicating with [XXX] our Minnesota State Attorney General's office on this matter. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11742849

Incident

Jun 5, 2026

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.

Some vehicles listed below may exhibit an intermittent airbag warning light and DTC(s) B1763 (OCS ECU Defect), and/or B1764 (OCS Mat Defect) may be stored. Hyundai is extending the warranty coverage of the sensor for the Occupant Classification System (OCS) / Occupant Detection System (ODS) 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. Refer to the warranty and parts information outlined in this bulletin.

Some vehicles listed below may exhibit an intermittent airbag warning light and DTC(s) B1763 (OCS ECU Defect), and/or B1764 (OCS Mat Defect) may be stored. Hyundai is extending the warranty coverage of the sensor for the Occupant Classification System (OCS) / Occupant Detection System (ODS) 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. Refer to the warranty and parts information outlilned in this bulletin. This bulletin contains the procedure to inspect for the airbag warning light and DTC(s), replace the OCS (ODS) unit or wire harness, reset the OCS (ODS), and initialize the power seat module (if applicable). This TSB also contains the procedure to replace the OCS (ODS) mat if DTCs exist after replacement of the OCS (ODS) wire harness.

The National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous driver’s-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN). These inflators were not supplied, approved, or authorized by the vehicle manufacturers and have primarily been found in vehicles that previously experienced a crash and underwent airbag replacement using non-genuine parts. These dangerous inflators have ruptured during deployment, posing a serious risk of injury or death due to metal fragments entering the vehicle cabin. To date, Hyundai is aware of three people who have died while driving a Hyundai vehicle with one of these substandard replacement airbag inflators that deployed in what likely would have been a survivable crash. NHTSA has issued a public advisory urging vehicle owners and service professionals to have vehicles inspected if there is reason to believe that a non-genuine replacement airbag may have been installed. Vehicles with salvage or rebuilt titles, prior airbag deployments, or unknown repair histories may present a higher risk. NHTSA strongly cautions against self-inspection by vehicle owners and recommends inspection by trained technicians.

The National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driver‑side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN), that have been identified in U.S. vehicles following prior crashes, theft, or non‑certified airbag replacements. These inflators are not approved for use, may rupture during deployment, and have caused serious injuries and fatalities. Please see attached announcement, provided by NHTSA, for more details.

In response to this trend, we engineered a software upgrade that addresses the social media theft method and made it available to owners of eligible models free of charge at authorized Hyundai dealers since early 2023. In addition to the anti-theft software, we’ve developed a new zinc-reinforced ignition cylinder protector hardware upgrade that can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Because your Hyundai vehicle with the VIN listed above (“Subject Vehicle”) was not factory-equipped with an engine immobilizer and was previously eligible for the software upgrade, you are now eligible until March 31, 2027 to have the ignition cylinder protector installed — if you request it — at no cost to you through an authorized Hyundai dealership.