2017 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 Office of Defects Investigation (ODI) received a petition on February 2, 2024, requesting a defect investigation into an alleged defect of the "engine" on the following vehicle model: 2017 Hyundai Santa Fe vehicles equipped with the 3.3L V-Shaped GDI Lambda-II engines. The petition cites allegations of a loss of motive power, often resulting in an engine seizure. The stall is preceded by a knocking sound, decreased performance and no warning lights. An analysis of the subject vehicle population was undertaken using complaints submitted to ODI along with manufacturer data.  It was determined that the frequency of events is low for the subject population, while those that specifically report a loss of motive power event have a high mileage at the time of incident.  The 2017 Santa Fe is equipped with a service interval reminder for the consumer that must be set by the consumer themselves or at a dealership.  A Technical Service Bulletin (19-EM-002H) instructs the dealership to set the maintenance reminder at the completion of routine maintenance service or anytime a repair is performed that requires new engine oil.  This maintenance reminder will help reinforce the need for proper oil maintenance intervals.  Additionally, the Santa Fe vehicles with 3.3L V-shaped Lambda-II engines will be added to Hyundai’s existing Technical Service Bulletin (23-EM-007H) related to combustion chamber cleaning.  These actions will help limit negative consumer incidents related to loss of motive power.  Lastly, Hyundai has extended the limited engine warranty for MY 2013-2019 Santa Fe vehicles equipped with 3.3L V-shaped Lambda-II engines included in the Petition.  The updated coverage is 15 years, or 150,000 miles and details are contained in Technical Service Bulletin 24-EM-003H. In view of the service interval reminder, combustion chamber cleaning, and extended warranty actions being taken by Hyundai, ODI is denying this Defect Petition.  The agency reserves the right to take additional action if warranted by future circumstances.  To review the report cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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 passenger restraint system in my vehicle has suffered a critical safety failure, and the manufacturer (Hyundai Motor America) is refusing to remedy the defect, leaving the front passenger airbag completely disabled. The Supplemental Restraint System (SRS) airbag warning light is permanently illuminated on the dashboard, accompanied by the "Passenger Airbag Off" indicator, even when an adult is seated in the front passenger seat. A diagnostic scan performed by an authorized Hyundai dealership confirmed a catastrophic failure of the Occupant Classification System (OCS) sensor mat located inside the front passenger seat cushion. The specific Diagnostic Trouble Code (DTC) retrieved was B1490 (OCS Sensor Mat Defect). The dealership confirmed that due to this hardware failure, the front passenger airbag is completely deactivated and will not deploy in the event of a collision, posing an immediate, severe injury risk to front-seat occupants. Hyundai previously recognized widespread safety defects with this exact component and issued an 18-Year OCS Sensor Warranty Extension (Campaign Z01) to replace the front passenger seat cushion/OCS sensor free of charge. However, Hyundai Corporate and the local dealership are refusing to honor the warranty extension on my vehicle based strictly on a technicality. They state that Campaign Z01 only covers the physical replacement of the OCS sensor if the computer outputs code B1764, whereas my vehicle is outputting code B1490. Both trouble codes identify an internal, unprovoked hardware failure of the exact same OCS sensor mat assembly, resulting in the exact same hazardous condition: a permanently disabled passenger airbag. By denying coverage based on a software code variation for an identical component failure, Hyundai is failing to remedy a known restraint system defect. I am filing this complaint to document this critical safety hazard.

NHTSA ID

11776322

Incident

Oct 1, 2026

I am submitting a complaint regarding engine oil consumption in my 2017 Hyundai Santa Fe Sport 2.4L 4-cylinder with approximately 117,000 miles. The vehicle consumes approximately one quart of engine oil every 5,000 miles during normal operation. There are no visible oil leaks or noticeable exhaust smoke. I am concerned that the engine may be consuming oil internally due to a possible defect involving the piston rings, valve seals, or another internal engine component. The exact cause has not been professionally diagnosed. Excessive oil consumption creates a safety concern because low engine oil levels can lead to inadequate lubrication, sudden engine failure, or loss of engine power while driving, potentially putting the driver and other motorists at risk. The condition has not yet been formally confirmed by a dealership or independent repair facility. The vehicle has not undergone a formal manufacturer or third-party inspection specifically for this issue. The engine is available for inspection upon request. There are currently no check-engine warning lights or diagnostic trouble codes. No visible smoke or external oil leaks have been observed. The primary symptom is the gradual loss of engine oil during normal driving. I am requesting that NHTSA document and investigate this condition to determine whether it may be related to an engine defect affecting Hyundai vehicles equipped with the 2.4L engine.

NHTSA ID

11775876

Incident

Nov 5, 2026

On October 14, the vehicle experienced a sudden and catastrophic loss of motive power ("limp mode") while driving at highway speeds, creating an immediate and severe risk of a high-speed rear-end collision. Notably, no Check Engine Light or dashboard warning illuminated prior to or during this sudden deceleration to warn of the failure. On October 16, the vehicle was transferred to an authorized manufacturer dealership (ABC Hyundai in Las Vegas, Dealer Code NV031), where it is currently located and available for inspection. The vehicle has now been in the dealership's custody for 17 consecutive days. Despite telematics data proving the vehicle is being actively started and driven around the dealership lot across multiple shifts, the service department has refused to formally document the diagnostic trouble codes (DTCs) or submit the mandatory engine failure diagnostic paperwork to the manufacturer. The manufacturer's corporate customer care department confirmed on day 17 that the dealership has submitted zero diagnostic data to them regarding this failure. Furthermore, the vehicle had three open safety recalls when surrendered. Records indicate the dealership has performed two of these recall repairs during this 17-day hold without providing any notification, status updates, or documentation to me. Yet, they have deliberately left the most critical mandate—an "URGENT: FIRE RISK WHEN PARKED" safety recall (NHTSA Recall 22V056000)—unrepaired. The dealership is actively holding, starting, and driving the vehicle without mitigating this urgent fire risk, while simultaneously refusing to process the engine failure diagnostics or provide a safe alternative vehicle. The dealer's deliberate refusal to process the catastrophic engine failure while selectively performing other recall work in secret presents an ongoing safety hazard and a gross lack of transparency.

NHTSA ID

11775175

Incident

Oct 13, 2026

The engine light came on. Upon driving it on the highway it would lost acceleration but was able to drive under 50 miles per hour about 5 miles. When opened the hood there was fluid splattered on the engine. There is a hole in the upper left quadrant beneath the engine cover.

NHTSA ID

11774378

Incident

Oct 25, 2026

Odometer Fraud. The contact purchased a 2017 Hyundai Santa Fe. It was discovered that there was a mileage discrepancy. The vehicle was a dealer sale. At the time of the purchase, the mileage was 45,000. However, when the vehicle was taken to a dealer for a trade-in, it was discovered via a Carfax report that the mileage was over 109,000.

NHTSA ID

11772926

Incident

Aug 22, 2026

Mileage

109,000 mi

On [XXX], Laguna Niguel Hyundai performed Service Campaign 9C2 (ECU software update for Theta II emissions improvement, Hyundai TSB 26-01-013H) on my 2017 Hyundai Santa Fe Sport. Immediately after the update, the vehicle developed drivability problems that did not exist before: rough/harsh shifting, hesitation, and loss of power during cold-start operation (the first 1-3 minutes after engine start), plus intermittent infotainment and navigation system failures. Hyundai's own dealer notice dated 05/18/2026 acknowledges vehicles may exhibit 'hesitation or rough shifting' after the 9C2 update and states the matter is 'currently under review' — no permanent fix has been released. The dealership that performed the recall has since refused to service my vehicle again. I opened case #[XXX] with Hyundai corporate; my inquiries on 09/03/2026, 09/11/2026, and 09/17/2026 asking for a corrective action have gone unanswered. The hesitation and power loss are a safety hazard when merging into traffic or crossing intersections. I request NHTSA investigate this pattern. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11771344

Incident

May 28, 2026

On XXX, [XXX] Hyundai performed Service Campaign 9C2 (ECU software update for Theta II emissions improvement, Hyundai TSB 26-01-013H) on my 2017 Hyundai Santa Fe Sport. Immediately after the update, the vehicle developed drivability problems that did not exist before: rough/harsh shifting, hesitation, and loss of power during cold-start operation (the first 1-3 minutes after engine start), plus intermittent infotainment and navigation system failures. Hyundai's own dealer notice dated XXX acknowledges vehicles may exhibit 'hesitation or rough shifting' after the 9C2 update and states the matter is 'currently under review' — no permanent fix has been released. The dealership that performed the recall has since refused to service my vehicle again. I opened case #XXX with Hyundai corporate; my inquiries on XXX asking for a corrective action have gone unanswered. The hesitation and power loss are a safety hazard when merging into traffic or crossing intersections. I request NHTSA investigate this pattern. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11770978

Incident

May 28, 2026

Was driving down road car went into limp mode about caused a big wreck, check engine was flashing and heard a loud noise as I was trying to get to safety. Had the car scanned and was for code p1326 and looking at all the recalls nothing is for the 2.4l but y'all have been having a lot of issues with these theta 2 engines.

NHTSA ID

11767901

Incident

Sep 27, 2026

n 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 (NC) and Santa Fe XL (NC) vehicles.

Certain Santa Fe and Santa Fe XL (NC) 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.

Certain Palisade (LX2) and Santa Fe (NC) vehicles equipped with Lambda II 6-cylinder 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.