2020 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.

Codes P0172 and P016B. Oil has fuel in it due to high pressure fuel pump leaking. Possible premature engine failure or fire. This is a 2020 santa fe limited 2.0T.

NHTSA ID

11766360

Incident

Sep 17, 2026

At times the engine will freeze up, stall the car while driving, or the car will altogether turn off when at a stop sign or light, while the car is still on. I've had the oil changed before the mileage indicated expired because the engine light came on and I was told the car had no oil at all when I know the oil was just changed within a 3 months time frame.

NHTSA ID

11766290

Incident

Feb 6, 2026

At approximately 42,000 miles, the AC system on my 2020 Hyundai Santa Fe suffered a potential immediate and premature failure, creating a severe driving safety hazard. The AC expansion valve began actively leaking refrigerant inside the dashboard, rendering the climate control system completely inoperable of normal operation. In Florida's high humidity and heavy rainstorms, this loss of proper AC function means the windshield defogging/defrosting mechanism fails to dehumidify cabin air. This results in sudden, severe window fogging while driving, heavily obstructing visibility and creating an imminent crash risk. Furthermore, as a senior managing multiple health conditions, a gradual, then total loss of cooling in extreme Florida heat poses a direct medical and physical safety hazard. The independent repair facility that fixed our vehicle noted an alarming pattern, servicing about 6 newer Hyundai models from our car's age group for similar AC failures and expansion valve leaks within a single month. Because an expansion valve is designed to last the life of a vehicle, this failure at 42,000 miles—combined with active industry investigations into internal Hyundai compressor degradation shedding debris downstream in the AC system—strongly indicates a systematic material defect. We have spent about $2,800 out-of-pocket to recharge the system, add dye, lose the charge again, and ultimately replace the valve inside the dashboard. Unfortunately, because Hyundai refuses to check our vehicle at their expense to find and remove potential Teflon or metal filings caused by this widespread compressor issue, and if needed, replace the compressor and other compromised components, this internal degradation can continue to cause recurring component leaks and damage at our unaffordable expense, while continuously releasing refrigerant into the air.

NHTSA ID

11766135

Incident

Jul 13, 2026

The contact owns a 2020 Hyundai Santa Fe. The contact stated that while driving approximately 55 MPH, the vehicle went into LIMP Mode and failed to properly accelerate, with the check engine warning light illuminated and flashing. The vehicle was later towed to the local mechanic, who was unable to determine the cause of the failure; however, engine oil was added to the engine. After retrieving the vehicle, the contact discovered that the engine oil level was low shortly after the engine oil was added. The contact stated that the vehicle was consuming an excessive amount of engine oil and the vehicle was taken back to the local mechanic. The mechanic confirmed that the engine oil level was low, and metal shavings were found in the engine oil. The vehicle was taken to the local dealer, and the contact was informed that an oil consumption test was needed. The cause of the failure was not yet determined. The failure mileage was 137,000.

NHTSA ID

11765014

Incident

Aug 17, 2026

Mileage

137,000 mi

I drove my car from for about an hour to my destination. I get to my destination and park and the car starts smoking lightly from under the hood and then increases. I was still sitting in the car when I was told my car was on fire. It went from a little smoke to a full blown fire in a couple of minutes. I got out the car and within minutes the front of the car caught fire and blew up. The car has been inspected by insurance. There were no warnings prior to this happening. I could have been serious injured or possibly killed. I am currently experiencing PTSD from this event. My son was just in my car previously. I am have this happened when I was there alone. I see that there are certain years that have been affected by fire, but the 2020 should be involved.

NHTSA ID

11763784

Incident

Sep 6, 2026

At approximately 122,000 miles, my 2020 Hyundai Santa Fe experienced a serious engine malfunction while I was driving on the highway. The check engine light suddenly illuminated and the vehicle began thrusting/jerking forward unexpectedly. We immediately took action to exit the highway and were able to get off the highway, but the engine died before we could fully stop the vehicle. This created a serious safety risk because the unexpected jerking and subsequent loss of engine power occurred while traveling at highway speeds and could have resulted in loss of control or a collision. The vehicle was towed to a local independent mechanic. After inspecting it, the mechanic stated that the engine needed to be replaced and recommended taking it to a Hyundai dealership because of the continuing issues associated with the Theta II engine. The vehicle was then towed to the Hyundai dealership. The Hyundai dealership inspected the vehicle and determined that cylinders 2 and 4 were not firing and recommended replacing the valve shaft. We requested a complete engine replacement. Hyundai initially offered a 50/50 split of the repair cost, but after we requested an engine replacement, Hyundai declined and instead offered a 70/30 cost split. There was also a previous documented concern regarding increased oil consumption, as noted in an earlier oil-consumption report. The vehicle has been inspected by both an independent mechanic and a Hyundai dealership. The vehicle and engine components are available for inspection upon request. No police or insurance inspection was performed, to my knowledge.

NHTSA ID

11763336

Incident

Aug 15, 2026

My car has the 2.0 T GDI theta 2 motor and it went into limp mode and after scanning the codes it’s the p1326 code. The vin doesn’t show to be apart of the class action lawsuit but it’s the same motor

NHTSA ID

11762696

Incident

Sep 7, 2026

Hyundai Motor America & Wallace Hyundai of StuartVEHICLE: 2020 Hyundai Santa Fe (2.4L Theta II GDI Engine)VIN: 5NMS23AD5LH181669INCIDENT MILEAGE: 181,000 MiHYUNDAI CASE NUMBER: 42981944SECTION 1: CATASTROPHIC INTERSTATE SAFETY INCIDENTOn July 16, 2026, while navigating heavy, high-speed traffic on Interstate 95 (I-95) at approximately 80 to 85 MPH, my vehicle suffered an un-commanded, catastrophic mechanical engine seizure. The vehicle instantly dropped from highway speeds down to a 21 MPH "limp mode," creating an immediate multi-car pile-up hazard on a major interstate. Physical inspection immediately after the failure proved that the engine oil level was completely full. The internal components catastrophically failed due to a documented, systemic factory defect involving premature rod bearing failure and oil starvation mechanisms, entirely unrelated to consumer maintenance.SECTION 2: PRIOR SAFETY COMPLAINTS & DOCUMENTED TIMELINEHyundai Motor America has intentionally forced me to operate a known, life-threatening safety hazard for 17 months, during which I drove an additional 31,000 miles under extreme duress. I filed formal oil consumption complaints with Hyundai Corporate every three to four months. I was forced to manually replenish the engine oil every 1,000 miles due to excessive oil loss.Specific safety reports detailing hazardous engine behavior were formally logged with Hyundai on November 25, 2025, and again in April 2026. Rather than remediating the vehicle, Hyundai corporate claims adjusters and dealership supervisors ignored these warning tracks, effectively throwing a consumer out into active traffic in an unsafe, defective vehicle.SECTION 3: AUTOMATIC SHUTDOWN TRAUMA & ACCIDENT RISKThe manufacturing defects caused an intermittent, un-commanded automatic The manufacturing defects caused an intermittent, un-commanded automatic engine shutdown condition. On 5 to 10 separate occasions while stationary at active traffic lights, the vehicle stalled10times

NHTSA ID

11761774

Incident

Jul 16, 2026

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.

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.

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 2019 – 2020 model year Santa Fe, 2017 – 2018 model year Santa Fe Sport, 2015 – 2019 model year Sonata, and 2018 – 2021 model year Tucson vehicles may exhibit elevated engine-out emissions. Hyundai is conducting a service campaign to update the Engine Control Module (ECM) Software for vehicles equipped with the (2.4 GDI) Theta II engine to improve engine combustion and fuel trim adaptations.

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.