2015 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.

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.

Driving on highway no warning lights appeared the car made a loud pop noise and heavy smoke appeared from under the hood. Immediately pulled over and noticed all of the oil poured out and was nasty looking. The car was up to date on oil change. My car was towed home and bone dry no oil and no coolant the engine now had loud knocking and needs to be replaced for failure. The car was looked at by independent mechanic. Miles on the car are 152010. I had no warnings and up until the issues the car was serviced and cared for.

NHTSA ID

11751822

Incident

Jul 12, 2026

I was driving down the road ( a busy Farm to market road) and my car lost power and died. Luckily i got off of the road. I tried to start the car again, but it kept dying. I had my son in law come help me move the car to a friends house so that I could get it to the dealership. It was after hours. I regularly get my oil changed and when my SIL checked the oil there was none on the dipstick. My SIL put oil in the car. My car was coming up on being due for a oil change. I am a single woman close to 50 yrs old and take my car in for maintenance. I then had my car towed to the local dealership to have an assessment done to find out what the issues is. The dealership reported that the timing was off and that bank 1 and 2 of the camshaft needs replaced. There is a known issue with the engine of this car doing the exact same thing my car did. There were no warning lights on to indicate a problem with the car. I inherited the car for my Mother In Law that passed away. She bought the car brand new and had it serviced regularly.

NHTSA ID

11743719

Incident

May 28, 2026

The engine failed due to complete and sudden oil loss. The vehicle is currently at Fremont Hyundai and available for inspection. Safety risk: the engine failed while driving on the highway with children in the vehicle. A check engine light appeared with no prior warning, the vehicle immediately lost power and stalled, requiring an emergency exit and tow. This is a direct collision risk at highway speed. The failure was confirmed by an independent mechanic who found zero oil in the engine and identified it as a known Hyundai defect. The vehicle was then towed to Fremont Hyundai, which is currently conducting diagnostics. The vehicle has been inspected by an independent mechanic and by Fremont Hyundai [XXX] ). No police or insurance involvement. There were NO warning lights, oil pressure alerts, or symptoms of any kind prior to failure. I purchased the vehicle in 2024 and maintained regular oil changes and checkups with receipts. The last oil change was performed a few months before the failure. No mechanic ever flagged low oil. The only warning was a check engine light that appeared seconds before the engine stalled. I have incurred $900 in towing costs as a direct result of this failure. Fremont Hyundai is now requiring me to pay $280 for a diagnostic, followed by $890 for a two-week oil consumption test. They have also stated that if the engine does not pass the initial diagnostic, they cannot help me at all. Given that the engine ran completely dry of oil, it is highly unlikely to pass. This means I am being asked to pay fees for a process the dealership already expects to fail, leaving me with no path to resolution and a car I cannot drive. The 2015 Hyundai Santa Fe is included in a class action lawsuit (Cho et al. v. Hyundai Motor Company) over this exact defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11738413

Incident

May 8, 2026

2015 Hyundai Santa Fe Limited, 3.3L Lambda II GDI V6, ~102,000 miles. In December 2022, an authorized Hyundai dealer replaced three specific parts under a Hyundai recall/campaign (records requested). On Sunday [DATE] at approximately [TIME] PM, I was driving on [FREEWAY], [STATE], at 55–70 mph at night. With NO prior warning — no warning lights, no chimes, no loss of power buildup, no knocking, no engine protection mode — the engine suddenly and completely died. The failure was instantaneous. There was no limp-home mode and no opportunity to reach the shoulder under engine power. The vehicle lost forward momentum and rolled backward in a live highway travel lane, where it remained stranded until a tow truck recovered it. No injuries. The 12V battery and electrical system remained fully active throughout. The instrument cluster was operational and capable of displaying warnings before the failure. None were displayed. Dashboard warning lights illuminated only seconds AFTER the engine had already died — a post-failure consequence of engine shutdown, not a pre-failure warning. An independent mechanic diagnosed a seized engine due to loss of oil flow. No oil pressure or low-oil light had ever illuminated. The vehicle was then transported to the Hyundai dealer that performed the 2022 service; they promised a diagnostic call and have not provided one or any written diagnostic. This failure mode matches Hyundai TSB 24-EM-003H (15yr/150k extended warranty for 3.3L Lambda II engines in 2013–2019 Santa Fe), NHTSA Recall 21V-727 (acknowledging stall risk at highway speed), and the active class action Burns v. Hyundai Motor Company (C.D. Cal. 2025). Hyundai's KSDS is documented to trigger a blinking MIL, audible chime, and reduced-power Engine Protection Mode upon bearing wear. None of these protective behaviors occurred.

NHTSA ID

11736814

Incident

May 3, 2026

Vehicle engine started knocking heavily while driving down the road. Had vehicle inspected for issue and was told vehicle had burned all the oil down to one quart and the engine was destroyed. Vehicle recently serviced with oil change within roughly 3,000 miles.

NHTSA ID

11733051

Incident

Jul 29, 2025

I purchased this vehicle one year ago from a used car dealership with 148,000 miles on it. Within a few months it was throwing crankshaft position, sensor codes, camshaft codes, and burning oil. I cannot bring my RPMs above two without my check engine light coming on and blinking. My car will go into limp mode. Hyundai does not have my car included in the engine recall they only have the sport Santa Fe included. They released an extended warranty for 150,000 miles but by the time that was put into place my car was at 151,000 miles so it was not eligible.

NHTSA ID

11719329

Incident

Jun 1, 2025

Passenger airbag dash is cracked risking unpredictable deployment of air bag

NHTSA ID

11718270

Incident

Jan 1, 2026

On 08/15/2025 I started the vehicle and heard a ticking noise that lasted for 3 seconds and stopped. The same noise happened when I would start the car in the mornings. It never lasted more than 3 seconds and I wasn't too sure what the noise was. There was no engine lights that came on so I wasnt too worried about it. On 8/21/2025 my husband went to the store and when he came back the car shut off while backing into the driveway. He said it made a weird noise and just shut off. We tested the battery but it was still charged. We brought it to our mechanic and he called us 15 mins later saying he found metal shavings on the oil filter and the engine had seized. He recommended going to the dealer, which is 90 miles away. Around the 15th we had received the warranty extension for 15 years/150,000 miles from Hyundai talking about a knocking sound that can lead to engine seizure. So I called the dealer and they said to bring it in. We got the car towed to the dealer on 8/26/2025. On 09/04/2025 they called to let us know that they ran the test on the engine but Hyundai was not going to help due to the car having 176,000 miles. They agreed the engine seized due to rod failure but wasn't going to offer Goodwill assistance, even with the service history we submitted from our carfax that showed regular scheduled maintenance recorda. We bought the car on 03/08/2025 when it was at 170,000 miles. I knew about the other open recalls and had them fixed on 06/12/2025 ( after being delayed from the dealer for 2 months because they couldn't get the parts for the auxiliary canister). Luckily the car died in the driveway and not in the middle of traffic. Hyundai has known about their Lambda engines having this issue and the KDSS recall was not available for this car which could have triggered a lifetime warranty on the engine. I barely had the car for 5 months.

NHTSA ID

11698430

Incident

Aug 21, 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.