2016 Hyundai Veloster

On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles.  During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types.  The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement.  Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia.  The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio.  The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires.  In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines.  The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS.  It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension.  For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied.  Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates.  To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years.  In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires.  Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis.  Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023).  The agency reserves the right to take additional action if warranted by future circumstances.  To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

Formal complaint against Hyundai Motor America for failure to provide safety recall remedies on a U.S.-conforming vehicle. Vehicle History: This 2016 Hyundai Veloster was purchased in the U.S. territory of [XXX], manufactured to meet U.S. Federal Motor Vehicle Safety Standards (FMVSS). Years later, it was legally relocated to the U.S. mainland and is currently registered and driven in [XXX]. The Database Issue: Official factory documents from Hyundai Puerto Rico confirm this VIN has critical, active safety recalls (chassis and engine/fire campaigns). However, due to regional database fragmentation between internal networks, these active recalls do not populate on domestic U.S. systems. The MyHyundai USA portal accepts the VIN, but the recall dashboard displays as completely blank (0 open/0 closed), hiding these safety risks from local U.S. dealerships. Corporate Refusal: I opened corporate Case #XXX with Hyundai Motor America to request a manual database sync so a local MA dealer could perform the repairs. On XXX, Hyundai Customer Care issued a formal written refusal via email, stating textually: "Hyundai Motor America only maintains records for US vehicles. We suggest working with your local dealer and Hyundai Worldwide." Because [XXX] is a U.S. territory, denying a safety recall remedy by treating this as a foreign vehicle violates federal safety mandates. Local dealers cannot perform repairs because corporate refuses to push the data entry through. Uploaded Attachments: - Hyundai PR safety recall log showing active campaigns for this VIN. - Email from Hyundai Motor America (Case XXX) refusing service. I request NHTSA compel Hyundai Motor America to update this VIN's regional status so my local dealer can execute the safety repairs free of charge. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11751038

Incident

Jun 13, 2026

The contact owns a 2016 Hyundai Veloster. The contact stated that gas fumes were entering inside the vehicle and exhaust fumes were present while driving the vehicle and while the vehicle was parked. The vehicle was taken to an independent mechanic on several occasions and to several dealers; however, the cause of the failure was not yet determined. The master cylinder was replaced, and the high-pressure fuel pump was replaced due to a reported internal fuel leak, but the failure persisted. The contact stated that while refueling the vehicle at a gas station, fuel leaked from the vehicle with a strong fuel odor. The manufacturer was notified of the failure. The approximate failure mileage was 19,000.

NHTSA ID

11746173

Incident

Sep 27, 2022

Mileage

19,000 mi

Complaint regarding 2016 Hyundai Veloster engine oil consumption and warranty denial. In late 2023, at approximately 70,000–80,000 miles, my vehicle began experiencing excessive oil consumption. I reported this issue to Hyundai and authorized dealerships while the vehicle was still under warranty. Since then, I have completed multiple oil consumption tests, inspections, combustion cleanings, and repeated service visits, none of which resulted in a permanent repair or resolution. The oil consumption has continued and worsened over time. I am required to frequently add oil between services, raising serious concerns about engine reliability, safety, and potential engine failure. Despite ongoing documentation and repeated attempts to resolve the issue, Hyundai has not identified or corrected the root cause and has instead relied on temporary measures that have not fixed the problem. Throughout this process, my concerns have often been dismissed or minimized. Customer service has been inconsistent and at times unhelpful, despite a clear and documented history of complaints and repair attempts. Communication has been lacking and I have repeatedly had to advocate for proper attention to my case. These issues were first reported while the vehicle was under warranty, and Hyundai has had multiple opportunities to properly diagnose and repair the defect. Based on the documented history of ongoing oil consumption and repeated unsuccessful repair attempts, I believe Hyundai should honor its warranty obligations. I am requesting a full review of my case, acknowledgement of all warranty-period complaints, and approval of an engine replacement or other permanent repair at no cost to me. I am seeking accountability, fair treatment, and a lasting resolution to an ongoing engine defect.

NHTSA ID

11743640

Incident

Jul 31, 2023

2016 Hyundai Veloster with 1.6L Gamma engine experienced repeat catastrophic engine failure consistent with NHTSA Recall 20V746000 / Hyundai Recall 198 for connecting rod bearing failure. Failure #1: At 124,036 miles, engine developed loud knocking noise increasing with RPM, check engine light, and DTCs P0300 (random misfire) + P0303 (cylinder 3 misfire). Dealer repair order documented "broken intake valve on cylinder 3." Engine was replaced at my expense because Hyundai stated VIN was not covered under Recall 198, despite failure mode matching the recall. Failure #2: Hyundai replacement engine failed at 164,410 miles (40,374 miles on replacement engine). Identical symptoms returned: loud metallic knock that increases with RPM, same DTCs P0300/P0303, misfire cylinder 3. Vehicle is currently inoperable. Safety Concern: NHTSA Recall 20V746 states connecting rod bearings "may wear prematurely, which over time can result in engine damage" and "can increase the risk of a fire." Both of my engines suffered catastrophic internal damage at ∼40k-50k mile intervals with identical codes and cylinder 3 failure. A broken intake valve is engine damage directly caused by bearing wear allowing piston-to-valve contact. This is a pattern defect. My VIN was excluded from the recall, yet suffered the exact failure twice. The replacement engine supplied by Hyundai had the same defect. This presents a safety risk of sudden engine stall, loss of power, or fire while driving. Requested Action: Investigation into why VINs experiencing the exact failure mode are excluded from Recall 20V746, and assistance obtaining remedy from Hyundai.

NHTSA ID

11742811

Incident

Jun 8, 2026

I was driving down the highway when I lost all power to my engine and had to coast off and exit. Prior to the incident there was no indication of a problem. White smoke began coming out of my exhaust. I brought the car to a dealership and they told me that I would need a timing job and a new turbo. They said that my car was starved for oil, regular maintenance had been kept up with on the vehicle.

NHTSA ID

11737073

Incident

Apr 28, 2026

I was driving on the highway when suddenly the car lost power and the engine light started flashing. I was able to coast into a gas station. The car would no longer start and I was stranded. The next day, we drove back to where the car was stranded and attempted to get it started again, but we were unsuccessful. We had the car towed to a mechanic shop where we were told that the entire engine was blown and needed to be replaced. We had the car towed to the local Hyundai service center so they could inspect the engine. We discovered that the make, model, and year of our Veloster had been subject to an engine recall and these cars were given an extended warranty to 15 years/150,000 miles. Hyundai inspected the engine and refused to provide assistance under the extended warranty/recall. Replacement of the engine is going to cost close to $10,000.

NHTSA ID

11734400

Incident

Mar 20, 2026

The contact owns a 2016 Hyundai Veloster. The contact stated that while driving at 35 MPH, the vehicle shuddered and stalled. The vehicle was restarted. The contact shifted to reverse and pulled into a parking lot. The message that the transmission had overheated was displayed. The contact used a scanner and diagnosed the vehicle with clutch actuator failure. The local dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 86,494.

NHTSA ID

11731458

Incident

Apr 12, 2026

Mileage

86,494 mi

Incident Description: I purchased a 2016 Hyundai Veloster (VIN: KMHTC6ADXGU255844) in May 2025. Shortly after purchase, the vehicle began exhibiting serious mechanical issues, including engine knocking, excessive oil consumption, stalling, misfiring, and loss of power. Despite these ongoing issues, the vehicle is listed as having Recall 198 completed. However, the symptoms associated with that recall continued and progressively worsened. The vehicle ultimately stalled in traffic while I was making a turn, resulting in an accident. In a separate incident, after exiting the vehicle and believing it to be in PARK, the vehicle moved unexpectedly and ran over me, causing serious physical injuries including fractures. Prior to these incidents, the vehicle had ongoing mechanical issues that were not properly resolved. The vehicle also required repeated jump-starts and became unreliable to operate. Additionally, there are discrepancies in the service records. The vehicle was towed to a dealership on or about June 8, 2025 and remained there until approximately July 15, 2025. However, the documentation provided reflects only a limited number of service days and consolidates multiple visits into a single summary. Due to these inconsistencies and the continued presence of failure symptoms, I am unable to verify that recall-related repairs were properly performed. These incidents raise serious concerns about engine failure and possible unintended vehicle movement, both of which present significant safety risks.

NHTSA ID

11730509

Incident

Dec 31, 1969

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.

This TSB references the Op codes to use for claim submission and the Parts required based on the vehicle’s inspection results from TSB 22-01-023H (DTC P1326 – Engine Bearing Inspection/Engine Replacement) or the latest version.