2014 Hyundai Santa Fe

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.

The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.

I request that NHTSA review what I believe is a misleading Hyundai warranty extension involving the Occupant Classification System (OCS/ODS), part of the air bag system. Around Mid May 2026, my air bag warning light began illuminating intermittently. I waited because I needed to save up the cash. Around June 2026, Hyundai mailed me a Warranty Extension Notice stating that if the air bag warning light came on, I should take the vehicle and the letter to a Hyundai dealer. The notice contains no exclusions or limitations. I was excited because my local repair shop said it would cost $800 to $2000 depending on the issue. Relying on Hyundai's written instructions, I took my vehicle to the dealer. I was told my repair not covered under the scope of the warranty and was charged over $900. I paid under protest because I felt it was a safety risk to continue driving with an air bag warning. Although my initial goal was to receive a full refund, my main concern is that owners may rely on Hyundai's notice, only to discover the repair is denied. Some may delay repairing an air bag system because of the unexpected cost, creating a potential safety risk. I have written Hyundai July 2026 requesting a full explanation as to why my repair was excluded or a full refund but to date I have not received a response. I ask NHTSA to review whether Hyundai's warranty notice adequately discloses its actual coverage and limitations. I have attached the warranty letter, which contains no exclusions, and my repair invoice. Thank you for your attention to this matter [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11755191

Incident

Jul 7, 2026

We are the original owner of a 2014 Hyundai Santa Fe. The vehicle is experiencing issues from internal engine oil consumption caused by a manufacturing defect in the GDI powertrain. In 2023, while driving under normal operating conditions, the vehicle began severely jerking, shuddering and hesitating during acceleration. This hesitation and sudden drop in power creates a severe and immediate traffic hazard, as the vehicle loses acceleration capabilities unpredictably while driving, merging, entering a highway or crossing intersections. I have since experience low oil volume due to this systemic oil consumption. On April 7, 2023 while I was under the 100,000 mile factory warranty (at 99,644), the issues were reported to the dealership but they found no issues. Since then the engine light come up regularly and we must add or change oil soon. On June 15, 2026 we took it back with the same issue and we have been told after checking it and filling it up we must repeat the process from 2023, drive it for 1000 miles without changing or adding oil, even if it dries up. This will create a safety hazard not only for the public but for my family. Now we are told the engine needs to be replaced but since we're out of warranty, we must pay $21,000. We were under warranty when we reported the issue and they purposedly led us out knowing the issues were happening to other Sonata and Santa Fe models. Now we are left with a dangerous vehicle which we cannot in good faith sell to any other family.

NHTSA ID

11744914

Incident

Feb 6, 2023

My car was in shop for Smog inspection and failed. Mechanic told me that the most likely reason was that the engine has issues related to failing crankshaft position sensor which triggered the check engine light. He further explained that the engine with this condition will have abnormal oil consumption. My experience is that is exactly what I wondered. No smoke in the exhaust, no oil leaks under the hood and no oil on the parking space at home nor work. Mechanic recommended I take the car to Hyundai dealer in Folsom. The service department there diagnosed my car and did not find fault with crankshaft position sensor but did find that there is a problem with timing mechanisms. They also said that the engine has difficulty starting, which I never experienced in over 50,000 I have driven it, save the time of battery replacement about 2 years ago. I decided to take my car back to my mechanic where he diagnosed it with timing issues. The abnormal engine noise was accounted for as a link to timing. In the interim I drive a rental at the rate of about $65.00 /day. I m in a quandary; if my mechanic repairs the timing issues, which may not be under warranty, does that invalidate the existing engine warranty? If I can get the warranty to cover the ongoing issues, we can save ourselves wasting time and money. If safety concerns are a priority, which is not, then we cannot sacrifice safety in the interest of celerity. In the meantime, my family are in the crossroads and I cannot accept that.

NHTSA ID

11742287

Incident

May 9, 2026

Driving to work at 0730 on 20 may, i put my foot down to accelerate from 40mph and nothing happened, i tried again thinking foot placement and the engine died. All ligjts went out, engine turned off and i free coasted for 100 -150yards. Once stopped i mangaed to get the hazard lights on, and get out the vehicle. I was 30yards from traffic lights on a 3 lane road. Once pushed from the road, the car showed lights and internal radio etc, but no noise on the push start. There was no noise from the engine prior to this, there was no dash lights showing issues and no warning. I was then towed 4hrs later to a garage where the diaognostics show engine failure and new engine required. A service 4000k miles ago and the car had used 5.5quarts of oil. All eveidence ive mainated the vehicle is online. 1st garage advices not driveable due to 10ks of miles of damage.

NHTSA ID

11739568

Incident

May 20, 2026

My insurance company said I have an urgent Recall on my vehicle. Recall # 251 ABS fuse replacement. NHTSA# 23V651000. I would like this replaced.

NHTSA ID

11727699

Incident

Mar 4, 2024

My engine failed and was diagnosed as needing to rebuilt or replaced by the dealership. During the pandemic it was hard to get parts so they rebuilt it. At first it was missed diagnosed because it was a 3.3l V6 and only the 4 cylinder engines were on recall. I had check engine lights on all the time. I paid for repairs that only masked the problem for a short time. It was such a problem I had to get a waiver to register my vehicle. After having more problems with my engine. Hyundai of Kennesaw confirmed my engine needed to be replaced they actually requested Corporate to approve an engine replacement for my vehicle in 2021. It was denied. So I paid for the rebuild. In August of 2025 i sent a letter extending the warranty which covered my vehicle engine rebuild. Hyundai denied that claim Jan 2026.

NHTSA ID

11711112

Incident

Jun 15, 2021

The engine has been running rough for awhile and emissions light came on. My car was having problems accelerating, 2 years ago the light came on but didn’t stay on so the dealer couldn’t diagnose problem.

NHTSA ID

11688912

Incident

Sep 11, 2025

My daughter owns a 2014 Hyundai Santa Fe GLS, which is currently experiencing internal engine failure and abnormal engine noise. These issues directly align with Hyundai’s notification regarding the extended warranty coverage for vehicles equipped with the 3.3L Lambda II GDI engine, which may experience abnormal engine noise or damage. Hyundai has acknowledged these concerns and extended warranty protection for engine repairs or replacement. The Hyundai Holler dealership in winter park Florida. recently inspected the vehicle and reported a critical failure requiring immediate attention. The recommended service included: Timing job (all CVVTs, intake, camshaft, chains, guides, tensioners) Both valve cover gaskets and RTV replacement ( This is the internal parts of the engine) The estimated repair cost was $6,723.92. This recommendation reflects the exact type of engine-related failure covered under Hyundai’s extended warranty for this VIN. It is both unreasonable and disappointing that my daughter was presented with such a significant repair estimate for a condition Hyundai has already committed to covering. For context, my husband is a certified technician, and we have carefully reviewed the inspection details. The diagnosis provided by Holler Hyundais service department is consistent with the warranty-covered issue. Therefore, this repair should rightfully be processed under Hyundai’s extended warranty program.I must also share that my daughter a single disabled mother of three with limited resources and income. The dealership’s approach in presenting her with an astronomical repair bill—without recognizing the warranty coverage—causes unnecessary stress and financial hardship Mr Jesse Cappiello Service consultant. Refuses to accept this as warranty, by stating the warranty is only for Rod bearing failure. When the warranty clearly states engine failure I have attached the warranty info for your review.

NHTSA ID

11687469

Incident

Sep 15, 2025

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.

Certain Santa Fe / Santa Fe XL (NC) vehicles equipped with 3.3L Lambda II GDI engines may exhibit abnormal engine noise or damage. This bulletin describes the procedure to inspect the engine and perform the proper repair based on the results of the inspection. Utilize the flowcharts as a guide to ensure the proper procedure and repair is performed. The warranty coverage for engine repair or replacement related to engine noise or damage has been extended to 15 years or 150,000 miles from the date of original retail delivery or date of first use, whichever occurs first. Warranty coverage is valid for original and subsequent owners.