2014 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.

There was a low noise when I got in the vehicle in the morning. I looked at the engine and it was coming from the abs system. I took it to the mechanic shop and the noise was even louder, the abs part on the passenger side of the firewall in the engine blew up and catch fire. Luckily they were able to put the fire down right away. I’m glad that didn’t happen while driving or while in the driveway of our house were there’s more vehicles parked. There was an Abs light on the dashboard due to an abs sensor for the rear right wheel.

NHTSA ID

11770765

Incident

Oct 13, 2026

1. 2014 Hyundai Santa Fe Theta 2 Engine Failure It was available for inspection upon request at local dealer and service After engine failedXXX abruptly while driving, it was towed to the service for inspection. 2. The Theta 2 engine in countless 2014 Hyundai Santa Fe models has been a safety risk for all citizens on the roads. This has been an unannounced recall failure due to manufacture shards of metal found within the engine, causing vehicle damage and failure. My car stopped abruptly on the road. I have maintained it through due oil changes and service. 3. The independent dealership that serviced my vehicle has verbally recognized that Theta 2 engines are a safety risk, after my family and I did research to expose underlying cause of engine failure. 4. It has been inspected by Allen Turner Hyundai in [XXX]. No known national manufacturers have been present or documented in case. 5. No, abrupt stop while driving along with burning smells and smoke coming from hood of vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11767435

Incident

Jul 24, 2026

I am reporting what I believe may be a safety-related defect involving the driver's door latch/lock actuator assembly in my 2014 Hyundai Santa Fe Sport, VIN [XXX]. The driver's door latch failed while the door was in the closed position. As a result of the failure, the driver's door could not be opened using either the interior door handle or the exterior door handle. The door remained mechanically stuck in the closed position. This was not simply a power door lock that failed to electronically lock or unlock. The failure prevented the driver's door itself from being opened from either side. Because the door was stuck closed, the inability to open the door normally substantially increased the difficulty and cost of the repair. SAFETY CONCERN My primary concern is occupant egress during an emergency. If this failure occurred during or immediately following a crash, vehicle fire, electrical failure, medical emergency, flooding event, or another situation requiring rapid evacuation, the driver or occupant could be unable to exit through the affected door. This presents an even greater concern for an elderly person, a person with a disability or limited mobility, or another occupant who may not be physically capable of climbing across the center console and exiting through another door. Depending upon the circumstances, an occupant could potentially remain trapped until another door could be accessed, a window could be broken, or emergency personnel could gain entry. The safety concern therefore is not merely that the door lock or actuator stops functioning. The concern is that failure of the latch/lock assembly can potentially eliminate a normal means of emergency egress from the vehicle. NHTSA has previously recognized in its investigations that an inability to open vehicle doors and circumstances involving potential occupant entrapment can create safety concerns, particularly when rapid access to or escape from a vehicle may be necessary. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U

NHTSA ID

11767395

Incident

May 29, 2026

The contact owns a 2014 Hyundai Santa Fe Sport. The contact stated that while driving approximately 30 MPH, there was smoke coming from the engine compartment with an abnormal burning odor entering the vehicle through the A/C vents. The vehicle was pulled over to the side of the road and turned off. The vehicle failed to restart and was towed to the residence. The vehicle was then towed to a dealer and was diagnosed and determined that the engine needed to be replaced. The contact stated that her father performed most of the maintenance on the vehicle and became aware that the Theta 2 engine had several failures. The manufacturer was notified of the failure, and a complaint was filed. The failure mileage was 157,596.

NHTSA ID

11765036

Incident

Jul 24, 2026

Mileage

157,596 mi

The contact owns a 2014 Hyundai Santa FE. The contact stated that while driving the vehicle at 60 mph the vehicle began to shake violently, and the engine experienced a complete loss of automotive power, the service vehicle soon, ABS and check engine warning lights were illuminated. The contact veered off an exit into the parking lot of an AutoZone where a diagnostic scanner displayed the code "P0302". The vehicle was towed to an independent mechanic where it was diagnosed, and the contact was advised that the exhaust valve on cylinder two had dissolved and needed to be replaced. The vehicle was towed to a local Hyundai dealer where it was diagnosed, and the contact was advised that the exhaust valve in cylinder two was faulty and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 89,687.

NHTSA ID

11757038

Incident

Aug 1, 2026

Mileage

89,687 mi

On June 20, 2026, while the 2014 Hyundai Santa Fe Sport was being driven on Richardson Highway near Mile 155 in Alaska, smoke and flames developed from the engine compartment without any collision. The driver stopped and both occupants exited before the vehicle became fully engulfed. The fire created an immediate risk of serious injury or death and blocked the northbound lane. There were no known prior drivability problems, warning lamps, or other symptoms before the incident. The exact failed component is UNKNOWN. Potential areas requiring investigation include the engine, electrical system, ABS/HECU brake module, multi-fuse, fuel system, and other engine-compartment components. Alaska Department of Public Safety responded. Its report states that there was no obvious cause, but that the fire appeared to have originated in the engine compartment. The vehicle was towed and preserved for the manufacturer. Hyundai inspected the vehicle and confirmed that the inspection was completed on July 11, 2026. Hyundai later stated orally that it did not find an engine defect, but it has not provided the complete inspection report, testing methods, photographs, technical findings, or a written origin-and-cause determination. Hyundai has not explained whether the ABS/HECU, electrical system, multi-fuse, fuel system, or other potential fire sources were separately examined. The vehicle sustained catastrophic damage and was a total loss. Both occupants escaped, but experienced severe ongoing psychological distress after the fire. I request that NHTSA evaluate whether the fire involved an engine, electrical, ABS/HECU, fuel-system, recall-remedy, or other safety defect. The vehicle was available for Hyundai's inspection. Its current availability for further inspection is UNKNOWN. The vehicle remains preserved and is currently available for further inspection upon request.

NHTSA ID

11753388

Incident

Jun 20, 2026

*"I am filing a complaint against Hallmark Hyundai in [XXX] regarding an active safety recall on my vehicle's ABS (Anti-lock Braking System) module.My vehicle was brought to the dealership on XXX. As of today, XXX, the dealership has held my car for 27 days without completing the safety remedy. The dealership continues to give me conflicting stories, refuses to provide an expected repair date, and is denying me manufacturer-funded alternative transportation while my vehicle is grounded for this safety defect.I am reporting this because the dealership is failing to provide a timely remedy for a critical braking safety hazard, leaving me without a safe vehicle." The warning lights came on on XXX every light on my dash is flashing. Hallmark Hyundai inspected my vehicle and said it was the abs module I have been without transportation for a whole month with no answers on when my car will be ready for pick. The advisor Devita keep telling me lie after lie I need my car immediately no way it takes a whole month to fix a recall repair I need my car I have lost my job due to this I’ve missed important dr appointments do to my car being held for a month with no answers INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11751694

Incident

Jun 23, 2026

Both front doors stopped opening cant get in the vehicle or out of the vehicle from the front doors. Both stopped working within two weeks. The locks unlock and lock but the doors will not open. Hyundai dealership wants 8,000 dollars to replace Both door panels. This is a safety issue. If I get stuck inside the car and cant get out

NHTSA ID

11751278

Incident

Jul 4, 2026

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.