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.

Component/System Failed: Engine assembly (Theta II 2.4L GDI) and Exhaust/Catalytic Converter. Description: The vehicle suffered a failure associated with the known Theta II engine defects. Engine oil consumption and internal engine wear directly led to unburned fuel and debris entering the exhaust stream, resulting in severe catalytic converter restriction/failure. Safety Risk: The combined failure caused sudden loss of power while driving, engine stalling, and significant driveability hazards, creating an immediate risk of a rear-end collision on public roads. Confirmation & Inspection: The failure was confirmed and diagnosed by a certified service facility. Replaced components and diagnostic documentation remain available for inspection upon request.

NHTSA ID

11765645

Incident

Sep 2, 2026

My son was driving the vehicle normally. There were no issues, warning lights, abnormal feel to the drive, and no odd noises. Suddenly, all of the warning lights on the dashboard lit up, acceleration dropped and he could no longer accelerate. He pulled off the main road and there was a burning smell and the vehicle was inoperable.

NHTSA ID

11765544

Incident

Sep 11, 2026

Service update 9C2. Car hesitates or slightly bucks on a cold start. No remedy to fix yet.

NHTSA ID

11765542

Incident

May 6, 2026

Hyundai performed recall #9C2, on 7/2/26. Since that time, the engine has a full time miss. When it is cold, it will hesitate, kick and buck. Hyundai is aware of this. Their solution is to warm the car for 3 to 5 minuets before moving. What happens if there is an emergency and you can't wait? Possible accident with injuries trying to pull into, or cross traffic! I have filed a case with Hyundai, and they just update that they are aware and working on a solution with no expected date for the software fix. This is a serious problem, and they need to fix SOON! Also, when an engine runs like this, over a period of time it will destroy the catalytic converter. Who's going to pay for that??

NHTSA ID

11765456

Incident

Jul 2, 2026

Vehicle was brought to an authorized dealership for service, and while there Campaign 9C2 (ECU Software Update for Theta II Emissions Improvement) was performed. Immediately following this software update, the vehicle developed drivability degradation, specifically engine stutter/hesitation and rough transmission shifting during cold starts. When attempting to accelerate in the first few minutes of driving, the vehicle delays engagement and then suddenly surges or lurches forward unpredictably. This creates a safety hazard, as the unpredictable power delivery and lag prevent the vehicle from accelerating safely when merging into traffic or turning across oncoming lanes, placing occupants at an immediate risk of a collision. The software logic error is fully reproducible every time the vehicle has sat long enough to cool down. The dealership confirmed the update was applied. There were no warning lamps or symptoms prior to the 9C2 update; the failure was caused directly by the manufacturer's campaign software modification to the Engine Control Unit (ECU). The vehicle and its ECU are available for inspection upon request.

NHTSA ID

11763180

Incident

Aug 18, 2026

-The primary mechanical failure is a burned exhaust valve in Cylinder 2, which has resulted in 0 PSI compression and a persistent engine misfire. This severe top-end valve degradation occurred as a direct consequential result of a chronic, underlying defect in the engine's internal oil-delivery and consumption systems. The vehicle is currently fully assembled, intact, and available for immediate inspection upon request at Brown-Daub Hyundai. -The vehicle suffered a sudden, severe loss of motive power while operating in traffic due to the cylinder drop, triggering a sudden transition into a dangerous operating state. The extreme oil consumption rate (burning 5 to 6 quarts of motor oil every 3,000 miles) created an ongoing, severe risk of sudden highway stalling, catastrophic moving component seizure, and potential engine bay fire due to extreme internal operating friction and chronic oil starvation. -Failure has been confirmed by two independent automotive facilities: Independent Confirmation: On XXX, [XXX]’s Service Center performed a diagnostic scan and an engine compression test, formally documenting diagnostic trouble code P030200 (Cylinder 2 Misfire) and verifying 0 PSI compression in Cylinder 2.Dealership Confirmation: On XXX, the service manager at Brown-Daub Hyundai executed a formal electronic and mechanical inspection under Repair Order #XXX, duplicating the failure and logging active trouble codes P0301, P0302, and P0128. -Symptoms first appeared progressively through an accelerating, severe oil consumption defect, which was documented during multiple routine maintenance: XXX oil consumption (115,865 mi): XXX (119,601 mi) no external leaks: XXX (125,502 mi) excessive oil consumption:XXX (135,116 mi) excessive oil consumption:XXX (133,022 mi) P0420 Cat Code: XXX (approx. 137,000 mi)engine rough-riding, shaking, & violent misfires began, preceding the mechanical breakdown INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11762822

Incident

Jun 4, 2026

On May 26.2026, Southern States Hyundai performed mandated Service Campaign 9C2 (Theta II Emissions Improvement). The software immediately caused drivability degradation and a catalytic converter failure, mirroring the defects Hyundai acknowledged to the NHTSA on May 18, 2026. Corporate customer care is using an unrelated oil consumption testing protocol to deflect liability and charge me $1,400 for the testing and/or $4002 for the catalytic converter out of pocket for damage caused by their own recall software. This hesitation is a severe safety risk when accelerating into traffic.

NHTSA ID

11761955

Incident

May 26, 2026

Cold-Start Hesitation & Rough Shifting: Following the 9C2 ECU update, my vehicle is experiencing a brief period of throttle hesitation, rough shifting, or jerky transmission behavior specifically during cold-start operations.

NHTSA ID

11760934

Incident

Aug 21, 2026

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 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.

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.

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.

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.

Certain Santa Fe / Santa Fe XL (NC) vehicles equipped with 3.3L Lambda II GDI engines may exhibit abnormal engine noise or damage. Technical Service Bulletin (TSB) 26-EM-002H 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.