2019 Hyundai Santa Fe

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 03/26/2026, my 2019 Hyundai Santa Fe received Hyundai Service Campaign 9C2 (TSB 26-01-013H-1), which included an Engine Control Module (ECM) software update for Theta II emissions improvement. The vehicle did not have the following drivability problem before this software update. Immediately after the 9C2 update, the vehicle began jerking/bucking slightly at low speeds, most noticeably around 10-20 mph when coasting with no accelerator input or when applying very light throttle. Acceleration response also feels slower than before the update, with noticeable hesitation when the accelerator is pressed. The problem is most noticeable during the beginning of a drive when the vehicle is cold. After driving for some time and the vehicle warms up, the symptoms improve, although the change in drivability remains noticeable compared with operation before the update. There have been no warning lights or warning messages associated with the problem. The issue began immediately following the ECM software update. The vehicle has not yet been returned to the dealer for diagnosis or confirmation and is available for inspection. I am concerned about the safety implications of delayed or unpredictable acceleration response, particularly when entering traffic, crossing an intersection, or merging when timely acceleration may be necessary. I am reporting this because the condition began only after Hyundai Service Campaign 9C2 was performed and I believe NHTSA should evaluate whether this ECM software update is causing similar drivability and acceleration problems in affected vehicles.

NHTSA ID

11766397

Incident

Mar 26, 2026

The vehicle experienced a sudden, intermittent engine stall while driving, specifically when slowing down or coasting to a stop in live traffic. When the engine dies, the vehicle immediately loses engine power, power steering, and power braking assist, creating an extreme safety hazard. After stalling, the vehicle refuses to restart for several minutes. An authorized Hyundai dealership previously replaced the high-pressure fuel pump under warranty to address this issue, but the dangerous stalling has persisted over the last 2,000 miles. The vehicle continues to randomly shut off without throwing a permanent check engine light or diagnostic trouble code, and the manufacturer has failed to correct this critical safety defect.

NHTSA ID

11765740

Incident

Apr 9, 2026

The car started having problems immediately after replacement with a new battery. The issue with the ISG (Idle Stop and GO System) started appearing. When the Auto Stop Indicator turns green, the car stalls which puts my life at risk. I have spoken to a number of mechanics and I am not getting a satisfactory answer on how to fix this problem.. One mechanic told me it was the starter which turned out not to be true. I have also spoken with a number of other mechanics and they are clueless on how this problem can be remedied. And the Hyundai dealter wanted $275 just to look at it but with no guarentee. The whole issue is putting my life and other motorists at risk.

NHTSA ID

11764874

Incident

Apr 15, 2025

2019 Santa Fe with 80,000 miles showed signs of excessive oil consumption. Service was scheduled with licensed Hyundai franchise service center. Known oil consumption issues on Theta II engines for that year. Testing requires 3 steps. First step is to change the oil and document levels. Engine is tested for 1000 miles then returned to service center. After 1000 miles, service center reports 2.5 qts of oil per 1000 miles. Hyundai corporate was contacted where they approved warranty work for the vehicle. Step two requires Combustion Chamber Cleaning. During this portion of the work, service center calls about fire that took place immediately after a test drive. Dealership states engine and components destroyed.

NHTSA ID

11763606

Incident

Sep 8, 2026

My vehicle had a very strong gas smell inside and outside of the car. I found a gas puddle under the car coming from the back of the vehicle. Car was hesitating when I stepped on the gas. I was afraid it may stall. I drove the vehicle to my regular service station. Vehicle has an active fuel leak and this is a fire hazard. I was very concerned whether the vehicle would stall and cause an accident. Warranty coverage was denied.

NHTSA ID

11762546

Incident

Aug 28, 2026

Update Re: ODI Complaint Number: 11759237 Subsequent Actions and Manufacturer Refusal to Remediate Safety Defect: ​Following the [XXX], acute safety incident—where the vehicle lost motive power and entered severe limp mode on [XXX] immediately upon release from Sheehy Hyundai of Chantilly—the vehicle remained in dealer custody for 11 days (August 20–August 31, 2026). ​Failure to Diagnose Core Defect: Despite recurring total power loss, active diagnostic trouble code P00AF00 (Turbocharger Boost Control Module Performance), and four consecutive turbocharger destructions within 20,000 miles, the authorized dealership refused to conduct internal engine diagnostics, drop the oil pan, inspect the oil filter, or perform borescope checks. ​Physical Contamination Documented: On August 29, 2026, an on-site physical inspection confirmed sparkling metallic particulate suspended in the engine oil on the dipstick and substantial oil blow-by/intrusion into the turbocharger air intake line. ​Formal Denial of Safety/Warranty Coverage: On August 31, 2026, dealership management and Hyundai Motor America (Consumer Affairs Case #[XXX]) formally denied warranty assistance and refused engine teardown under the Theta II Lifetime Engine Warranty Settlement. Coverage was declined citing "outside influence" due to an aftermarket turbocharger assembly, while Hyundai refused to investigate the underlying engine failure contaminating and destroying the forced-induction system. ​Evidence Preservation: On August 31, 2026, the vehicle was towed to an independent facility to mitigate road hazards, conduct teardown diagnostics, and preserve the engine oil/filter for ISO-accredited spectrographic laboratory analysis. ​The manufacturer released an unsafe vehicle into traffic on August 20, 2026, and subsequently refused to investigate or remedy a documented internal engine failure that creates sudden, recurring loss of motive power. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11761505

Incident

Aug 20, 2026

My vehicle recently received the Hyundai 9c2 emissions upgrade they required and since then the vehicle has had predictable acceleration issues for the first several minutes after the vehicle. While trying to slowly accelerate the vehicle with unpredictably lurch forward. Many people have been reporting this.

NHTSA ID

11760439

Incident

Aug 27, 2026

The vehicle suffers from recurring, sudden loss of motive power and transitions into engine "limp mode" while driving in active, heavy traffic. This severe drivability defect has occurred on four separate occasions under Diagnostic Trouble Code (DTC) P00AF00 (Turbocharger/Supercharger Boost Control "A" Module Performance) and related boost/MAP faults (P0234). During these episodes, the vehicle abruptly loses acceleration capability without warning, creating an acute collision risk when navigating highway traffic and intersections. The turbocharger assembly has required replacement three separate times due to recurring oil contamination from the engine crankcase. Despite meticulous maintenance (documented synthetic oil changes every 3,000–5,000 miles since new), the manufacturer and dealership have repeatedly blamed peripheral turbo components rather than diagnosing or repairing the root cause (I suspect excessive engine crankcase pressure/piston ring blow-by based on the significant oil deposition on the turbo, map sensor, and pooling in the intake line).

NHTSA ID

11759237

Incident

Aug 20, 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.

Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. This bulletin provides instructions for updating the Engine Control Module (ECM) to address this condition.

Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. The California Air Resources Board has determined that these vehicles may be releasing air pollutants which exceed Federal and California standards.

Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.

Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.

Certain Hyundai vehicles with exterior white paint may exhibit peeling or bubbling on metal body panels: hood, fender(s), roof, door(s), quarter panel(s), and tailgate/trunk. The paint warranty coverage for affected vehicles has been extended to 10 years/unlimited miles from the date of original retail delivery or date of first use and is valid for original and subsequent owners. The warranty extension does not apply to any vehicle that has ever been declared a total loss or sold for salvage by a financial institution or insurer or has a branded or similar title under any state’s law.