2016 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 XXXX, my 2016 Hyundai Santa Fe Sport AWD (VIN [XXX], ~89,151 miles) developed a flashing check-engine light while driving — an active misfire condition. An OBD-II scan pulled code P1326, Hyundai's knock-sensor detection code for connecting-rod bearing wear in the Theta II engine family, the same defect family covered by Hyundai's lifetime bearing-warranty extension under Service Campaign T6G (TSB 22-01-023H-1). The vehicle was towed to Grand Hyundai of Canton (repair order #XXX). The dealer performed the bearing clearance test (BCT, TSB 21-EM-004H-1) on XXX, and recorded only "PASS." The printed result from the dealer's own GDS diagnostic tablet shows PASS with no numerical clearance values, even though this is a measurement-based test. The knock sensor was NOT replaced, and a KSDS software update was performed. The final invoice was $0. I have asked, in writing and repeatedly, for the actual numerical clearance measurements from that test. I have not received them. What I have received instead is a contradiction: On XXX, at vehicle pickup, the dealership's service manager told my wife, [XXX], that the dealership does not have access to those results and that only Corporate has those measurement results. When she asked him to put that statement in the service notes, he refused — "we will not put that in the notes" / "she could not write it down." Service advisor [XXX] was present beside the manager, relayed the request to him, and relayed the refusal back; she witnessed both the statement and the refusal. The same manager had told me by phone that only Hyundai Corporate has the measurements. On XXX, Hyundai National Consumer Affairs Supervisor [XXX] wrote the opposite: that "diagnostic, testing and reporting results done by the dealerships are retained by the independent location" and only the servicing dealership can provide them. She refused to provide the numbers herself and said INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11775057

Incident

Oct 4, 2026

I was driving from Tampa to Wesley chapel Fl I was going about 70 and was pushing a bit then slowed down right away then I was speeding a little back up and my car was dropping to speed by itself I pulled over to the shoulder and it was leaking radiator fluid I was trying to crank it to see if I can make it work then it started smelling bad in the car so I turned it off right away and it was Smokey

NHTSA ID

11774924

Incident

Oct 31, 2026

While driving I smelled gasoline then it turned to a burnt smell, engine turned off. Got to side of the road and engine caught fire. Firetrucks and police arrived. Car is totaled entire engine bay was up in flames. Car has been towed.

NHTSA ID

11770488

Incident

Oct 11, 2026

Odometer Fraud. The contact purchased a 2016 Hyundai Santa Fe Sport. The contact stated that it was discovered that there was a mileage discrepancy. The vehicle was a private sale. At the time of purchase, the Facebook Marketplace advertisement and odometer reading were 114,841 miles. However, approximately one hour later, it was discovered that the title listed the mileage at 170,395.

NHTSA ID

11765865

Incident

Sep 20, 2026

Mileage

170,395 mi

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated that while the vehicle was parked, there was an abnormal knocking sound coming from the engine compartment. The vehicle was towed to a dealer where it was diagnosed that there was coolant in the engine and that the knock sensor detection system needed to be replaced. The dealer made the contact aware of Manufacturer Campaign Number: 953 and stated that the vehicle was not previously serviced under the campaign, so the vehicle could not be repaired. The manufacturer was notified of the failure. The failure mileage was approximately 111,000.

NHTSA ID

11762873

Incident

Aug 12, 2026

Mileage

111,000 mi

Was traveling along a city street with parked cars on the passenger side of my vehicle. Axle or wheel broke and veered into parked vehicle severing the engine wiring harness not allowing the airbag to deploy.

NHTSA ID

11761994

Incident

Aug 4, 2026

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated that while driving approximately 65 MPH and attempting to overtake another vehicle, the vehicle lost automotive power and decelerated with the check engine, battery, and oil warning lights illuminated. The vehicle was parked on the shoulder of the highway, and smoke was coming from under the hood of the vehicle. The contact stated that after parking on the shoulder, the brakes erroneously activated, and the vehicle failed to move forward. The contact stated that moments later there were flames and smoke was coming from under the hood. The contact exited the vehicle. The Fire Department was called to the scene, and the flames were extinguished by the firemen. The vehicle was destroyed in the fire. The vehicle was later towed to the residence. The cause of the failure was not yet determined. The manufacturer and local dealer were not contacted. The failure mileage was 105,225.

NHTSA ID

11755852

Incident

Aug 8, 2026

Mileage

105,225 mi

my BSD sensor would go on and off for the last several months when no one was around me. I work early and even when I was alone on the road the BSD would flash for 2-3 mins and go off.. then my fan for my air conditioner stopped. When I removed the glove compartment to see the wire connecting to the fan is "melted". When i called bob king hyundai, I was informed there was no recall. So, I attempted to fix the issue myself only to find the fuses (under the hood) are almost all bad. The tips of the fuses will not pull out. only the body of the fuse. With all this happening over the last several days and by the way, the vehicle passed inspection. I wanted to reach out as this is definitely a fire hazard and a huge concern.

NHTSA ID

11753163

Incident

Jul 27, 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.