2015 Hyundai Santa Fe Sport Engine Problems

While I was driving my Theta engine got seized and Hyundai denied extended warranty of power train.

NHTSA ID

11750711

Incident

Jun 22, 2026

Today while driving to church we started hearing a ping noise ever so often. This just started then . After leaving church to go home the pinging noise got louder than the engine stalled and wouldn't start again. I had to have my car towed to my house. That is where it is now. The tow truck driver said that it was a rod. He said that he was mostly sure that it was happened. He stated that he has towed similar ones like mine with the same problem.

NHTSA ID

11749858

Incident

Jul 12, 2026

On 4/25/2026 I lost power on business freeway an orange light flash on along with whining noise I had to steer to right side shoulder for safety. Had it towed to dealership on 4/27/2026 they informed me 3 days later on 4/30/2026 that my car overheated. My car never overheated no smell of coolant nor no steam from the car when I exit to shoulder and turn car off. Retrieved manual from glove compartment it stated it had went into limp model. This has been a constantly nightmare my family could have been planning a funeral. These car manufacturers needs to be held accountable for their vehicle.

NHTSA ID

11746986

Incident

Apr 25, 2026

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving approximately 65-70 MPH, the check engine warning light started flashing, and the vehicle stalled. The contact was able to pull over to the side of the road, where the vehicle failed to restart and was towed to a parking lot, where a mobile mechanic diagnosed the vehicle and determined that the engine had seized. The vehicle was towed to the residence and then towed to the dealer, where it was diagnosed. The dealer informed the contact that the engine had failed, and there was sludge in the engine oil. The dealer informed the contact that the engine replacement could not be covered due to missing oil change documentation prior to the ownership of the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 155,000.

NHTSA ID

11730805

Incident

Mar 6, 2026

Mileage

155,000 mi

Engine failed while driving down the road, car was looked at by two mechanics with no known reason for engine failure so car was took to Hyundai of murfreesboro for diagnostic testing and was there for a total of 12 days for inspection, in which during that time i as asked to submit maintenance records for vehicle which i provided 18 pages of oil changes, other records. I was then told my claim was denied by Hyundai due to maintenance neglect as worded by the technician through a text message “is not proceeding with coverage on the engine due the cause of engine failure being maintenance neglect ” i received to other valid reason or cause, nor via email or in writing only a text message.

NHTSA ID

11729381

Incident

Mar 14, 2026

The contact’s daughter owns a 2015 Hyundai Santa Fe Sport. While the owner was driving approximately 70 MPH, the engine started making a knocking sound. There were no warning lights illuminated. The driver called the contact and was advised to pull over to the side of the road and turn off the vehicle. Once the vehicle was turned off, it was towed to a certified mechanic who was unable to diagnose the vehicle. The vehicle was then towed to another mechanic, who diagnosed the vehicle with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The vehicle was then towed to a dealer, who confirmed the failure and that the engine needed to be repaired. The dealer informed the contact of a Class Action Lawsuit for the engine failure and that the engine could be repaired; however, because the vehicle had not received the software update for Hyundai Campaign: (Hyundai TXXM Warranty Extension Number: 966/953/TXXM); the vehicle was no longer eligible to receive the engine replacement. The vehicle was not repaired. The manufacturer was made aware of the issue. The manufacturer opened a case. The failure mileage was 86,204.

NHTSA ID

11728772

Incident

Mar 13, 2026

Mileage

86,204 mi

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that the vehicle was taken to the local dealer, where it was diagnosed with a blown engine. The check engine warning light was illuminated. The vehicle was not repaired. The manufacturer was contacted, and the warranty service was declined because the oil maintenance records were not available. The failure mileage was approximately 114,080.

NHTSA ID

11728707

Incident

Jan 30, 2026

Mileage

114,080 mi

Dealer failure to to remedy engine replacement under settlement. I am entitled under the March 1, 2022, Settlement Agreement (the “E2 Settlement”) due to recurring Theta II engine failures caused by the oil-starvation/connecting-rod bearing defect. Vehicle stalling on highways and heavy traffic, Repeated codes and failures of MAP sensors, VVT solenoids, camshaft position sensors, starters (×3), batteries (×2), turbo wastegate, fuel pump, EVAP canister, thermostats/housings, etc. — all downstream symptoms of oil starvation and bearing failure Hyundai dealers (Hyundai of Palm Springs and others) have continued to misdiagnose and charge me for unrelated repairs while refusing to acknowledge the covered defect in the replacement engine. Relief Demanded Under the E2 Settlement Pursuant to Settlement ¶¶ 4.1, 4.2, 5.1, 5.2, and 6, I demand the following within fourteen (14) days: Full replacement of the failed engine with a new or remanufactured long-block assembly at $0 out-of-pocket cost to me, including all related gaskets, hoses, sensors, turbocharger, and PCM reflash: Full reimbursement of all out-of-pocket repair expenses incurred since the 2022 replacement (approximately $8,178.50+ $150 for two maxed out Triple A cards, and a new rental car for this week at $1500.00 total to date $10,148.50— Reimbursement of all towing and rental-car expenses (receipts enclosed); Compensation for diminished value of the vehicle. Confirmation that the Lifetime Warranty remains in full force on any future engine. In the alternative, a cash buyback of $25,000 in full satisfaction of all claims. This vehicle has suffered two qualifying Theta II engine failures, the second occurring in a warranty replacement engine. Hyundai of Palm Springs continued refusal to properly honor the settlement has caused extreme hardship, safety risks (multiple freeway/intersection stalls), and thousands of dollars in unnecessary expense

NHTSA ID

11706574

Incident

Sep 22, 2025

GDFI MODOR IS BURNING GAS AND OIL TOO QUICKLY Randomly shutting off Burning too much oil

NHTSA ID

11696760

Incident

Sep 1, 2025

I am writing to express my concern regarding an ongoing and persistent issue with excessive engine oil consumption in my 2015 Hyundai Santa Fe, Subject: Severe Oil Consumption Issue - 2015 Hyundai Santa Fe - VIN: [XXX] The vehicle consumes an alarming amount of oil, approximately 1 quart every 300 miles. This rate of consumption is far beyond what is considered normal and strongly suggests a serious mechanical or manufacturing defect. I have already taken the vehicle to a mechanic to diagnose and attempt to resolve this problem. Based on their professional advice, the following parts were recently replaced: 1.Engine Valve Cover Gasket 2.Turbo Charger Oil Line 3.Spark Plugs Unfortunately, despite these repairs, the issue of excessive oil consumption remains unresolved. The rate of oil loss remains consistent and dangerously high. This was first informed by a service center when I took the car for a random check. Then, after traveling 1,000 miles, the engine oil level dropped again. After that, I am keeping an eye on that. This level of oil consumption poses a significant risk to the engine's long-term health and reliability, and it is a major inconvenience and expense for me as the owner. I am deeply concerned that a major engine component may be failing. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11689911

Incident

Apr 29, 2025

Driving on freeway and noticed smoke. Realized I needed to pull over and brakes weren’t working. Off ramp was at an incline so car came to a stop just in time to get toddler and myself out of vehicle. Car was on fire.

NHTSA ID

11678091

Incident

Jul 31, 2025

I bought the 2015 Hyundai Santa Fe yesterday evening. Upon leaving the dealership I promptly broke for a car in front of me. Immediately the vehicle turned off completely. I put the vehicle in the park and attempted to start the vehicle back up. The vehicle would not start up and begin leaking a prominent scent. Following this, white smoke with the same pungent smell was coming from the engine. I propped the hood and saw the smoke continue to release. I then motioned away from the vehicle and called for a tow truck. The car is now being inspected by the dealership I purchased it from the same day. I believe this is related to the NHTSA recall on 2010-2015 Hyundai Santa Fe, recall date 09/22/2023, recall number 21V303000, and Hyundai Safety Recall 251s Anti-Lock Braking System Fuse Replace. This issue is not listed under my vehicle VIN number but it’s apparent to be the case and issue and is being inspected further by the dealership.

NHTSA ID

11676337

Incident

Jul 25, 2025

Despite regular oil changes and maintenance. Engine failed due to lack of oil at 122,000 miles. Complete oil change was done at 120,000 miles. Tune up completed at 118,000 miles

NHTSA ID

11670871

Incident

Jun 27, 2025

During acceleration to pass car sputters and has no power. Merging into traffic is dangerous. The best shift is faulty as well . Mine is in park but it is showing it in drive and won't crank

NHTSA ID

11667313

Incident

May 16, 2025

See attached document for complaint.

NHTSA ID

11662712

Incident

Jan 11, 2025

Oil consumption issues, can cause engine failure while driving. Car burns 2-3 quarts every 1,000 miles car takes just over 5qt to fill. Issues stated at around 70,000 now at 82,000. This is a long standing issue that needs to be addressed on hundreds of thousands of vehicles with the GDI engines

NHTSA ID

11654023

Incident

Jul 1, 2023

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving home at approximately 25 MPH, the engine seized with several unknown warning lights illuminated. The contact was able to park the vehicle on the side of the road safely. The contact attempted to restart the vehicle however, the vehicle failed to restart. The vehicle was towed to an independent mechanic for diagnosis. The contact was informed that the engine had seized and needed to be replaced. The vehicle was next towed to the dealer to be diagnosed. The dealer confirmed that the engine had seized and needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The approximate failure mileage was 128,000.

NHTSA ID

11624003

Incident

Aug 26, 2024

Mileage

128,000 mi

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving at an undisclosed speed and attempting to accelerate, the vehicle lost motive power and was unable to exceed 15 MPH. The contact was able to arrive to the intended destination, where the failure persisted. After restarting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed a failure with the knock sensor. The vehicle was not repaired. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was unknown.

NHTSA ID

11605436

Incident

Feb 15, 2024

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated while driving approximately 35 MPH, the vehicle started losing motive power. The contact depressed the accelerator pedal; however, the vehicle continued to lose motive power and then stalled. The contact stated no warning light was illuminated. The contact had the vehicle towed to a local dealer, where it was diagnosed and determined that the engine needed to be replaced. The contact was informed that the engine control software update was not performed, and the vehicle did not qualify for an engine replacement. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

NHTSA ID

11590298

Incident

May 11, 2024

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated while driving at approximately 60 MPH, the vehicle stalled. The vehicle was not able to be restarted. Additionally, the contact observed white smoke coming from the engine and an abnormal oil burning odor. The check engine and oil warning lights were illuminated. The vehicle was taken to an independent mechanic where it was diagnosed and determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 148,000.

NHTSA ID

11585211

Incident

Apr 20, 2024

Mileage

148,000 mi

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated while her husband was driving at an undisclosed speed, the vehicle inadvertently lost motive power however, the driver was able to coast to the shoulder of the roadway. After restarting the vehicle, the vehicle seemed to return to normal functionality, but the failure recurred. The check engine warning light was illuminated. The vehicle was taken to the dealer however, the dealer was unable to determine the cause of the failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 94,000.

NHTSA ID

11535511

Incident

Jul 26, 2023

Mileage

94,000 mi

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving approximately 45 MPH, the vehicle lost motive power. While making a right turn, the vehicle stalled. The contact noticed smoke coming from the engine compartment. There were no warning lights illuminated. The vehicle was towed to an independent mechanic and the contact was informed that the engine needed to be replaced. The contact called the local dealer who referred her to the manufacturer for assistance. The manufacturer was contacted but provided no additional assistance. The failure mileage was approximately 121,000.

NHTSA ID

11529327

Incident

Jun 14, 2023

Mileage

121,000 mi

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving approximately 75 MPH, the vehicle lost motive power and stalled. The vehicle was towed to the local dealer who diagnosed that the engine was faulty and needed to be replaced. After replacing the engine, each time the vehicle was in for routine service the mechanic noted that the engine coolant was low. Later while driving there was a loud popping noise coming from the engine compartment before the engine was engulfed in flames. During the failure, the vehicle and camping equipment were destroyed. A police report was taken at the scene and the vehicle was towed away. The cause of the failure was not yet determined. The manufacturer was notified of the failure. The failure mileage was 104,000.

NHTSA ID

11509664

Incident

Jul 15, 2022

Mileage

104,000 mi

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while operating the vehicle, the vehicle lost motive power and stalled without warning. After replacing the battery and starter, the vehicle remained inoperable and would not start. The vehicle was towed to the local dealer who diagnosed that the engine was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 115,000.

NHTSA ID

11482159

Incident

Aug 3, 2022

Mileage

115,000 mi

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated he took the vehicle to the dealer to be serviced under NHTSA Campaign Number: 21V303000 (Service Brakes, Hydraulic). The contact stated that while his daughter was driving 45 MPH, the vehicle failed to accelerate with the check engine warning light illuminated. The vehicle was towed to the dealer and the contact was informed that the knock sensor detected a failure and shifted the vehicle into SAFE mode. The manufacturer was contacted by the dealer. The dealer was asked to continue performing tests on the vehicle. The vehicle was not repaired. The failure mileage was 71,000.

NHTSA ID

11479954

Incident

Jul 30, 2022

Mileage

71,000 mi