2015 Hyundai Santa FE Sport engine problems

ENGINE AND ENGINE COOLING

See Attached Letter For Complaint

NHTSA complaint #11758550 — an unverified report by a vehicle owner.

ENGINE

The vehicle suffered a severe engine overheating failure that created an immediate fire risk and electrical safety signaling failure. A brand-new replacement engine was installed by an authorized dealership in April 2026 under a goodwill warranty and had only been driven ~ 3,100 miles since installation. While operating the vehicle, the air conditioning suddenly stopped functioning. Upon restarting, the check engine light illuminated; however, there was never any dashboard temperature warning indicator, notification, or chime to alert the driver to an active overheating situation. Shortly after, the engine completely disabled itself and died while in transit in a parking lot. AAA was contacted to tow the vehicle. Smoke was visible coming out of the engine's oil dipstick and oil intake spout before being towed. After being towed home, an overwhelming chemical burning odor was noted and continued to get worse. A physical check revealed that the oil level on the dipstick was critically overfilled a full inch above the maximum fill line. The local fire department responded to the scene to mitigate the thermal risk, ordered the battery disconnected due to safety hazards, and deemed the vehicle entirely unsafe to operate or connect to power. This represents a catastrophic failure of critical safety equipment and onboard driver warning networks on a newly installed engine assembly, presenting an active safety and fire hazard to passengers. An official corporate safety case has been opened with Hyundai Motor America under Case Number: 43112676.

NHTSA complaint #11756640 — an unverified report by a vehicle owner.

ENGINE

While I was driving my Theta engine got seized and Hyundai denied extended warranty of power train.

NHTSA complaint #11750711 — an unverified report by a vehicle owner.

ENGINE

Today while driving to church we started hearing a ping noise ever so often. This just started then . After leaving church to go home the pinging noise got louder than the engine stalled and wouldn't start again. I had to have my car towed to my house. That is where it is now. The tow truck driver said that it was a rod. He said that he was mostly sure that it was happened. He stated that he has towed similar ones like mine with the same problem.

NHTSA complaint #11749858 — an unverified report by a vehicle owner.

ENGINE

On 4/25/2026 I lost power on business freeway an orange light flash on along with whining noise I had to steer to right side shoulder for safety. Had it towed to dealership on 4/27/2026 they informed me 3 days later on 4/30/2026 that my car overheated. My car never overheated no smell of coolant nor no steam from the car when I exit to shoulder and turn car off. Retrieved manual from glove compartment it stated it had went into limp model. This has been a constantly nightmare my family could have been planning a funeral. These car manufacturers needs to be held accountable for their vehicle.

NHTSA complaint #11746986 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving approximately 65-70 MPH, the check engine warning light started flashing, and the vehicle stalled. The contact was able to pull over to the side of the road, where the vehicle failed to restart and was towed to a parking lot, where a mobile mechanic diagnosed the vehicle and determined that the engine had seized. The vehicle was towed to the residence and then towed to the dealer, where it was diagnosed. The dealer informed the contact that the engine had failed, and there was sludge in the engine oil. The dealer informed the contact that the engine replacement could not be covered due to missing oil change documentation prior to the ownership of the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 155,000.

NHTSA complaint #11730805 — an unverified report by a vehicle owner.

ENGINE

Engine failed while driving down the road, car was looked at by two mechanics with no known reason for engine failure so car was took to Hyundai of murfreesboro for diagnostic testing and was there for a total of 12 days for inspection, in which during that time i as asked to submit maintenance records for vehicle which i provided 18 pages of oil changes, other records. I was then told my claim was denied by Hyundai due to maintenance neglect as worded by the technician through a text message “is not proceeding with coverage on the engine due the cause of engine failure being maintenance neglect ” i received to other valid reason or cause, nor via email or in writing only a text message.

NHTSA complaint #11729381 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that the vehicle was taken to the local dealer, where it was diagnosed with a blown engine. The check engine warning light was illuminated. The vehicle was not repaired. The manufacturer was contacted, and the warranty service was declined because the oil maintenance records were not available. The failure mileage was approximately 114,080.

NHTSA complaint #11728707 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

The contact’s daughter owns a 2015 Hyundai Santa Fe Sport. While the owner was driving approximately 70 MPH, the engine started making a knocking sound. There were no warning lights illuminated. The driver called the contact and was advised to pull over to the side of the road and turn off the vehicle. Once the vehicle was turned off, it was towed to a certified mechanic who was unable to diagnose the vehicle. The vehicle was then towed to another mechanic, who diagnosed the vehicle with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The vehicle was then towed to a dealer, who confirmed the failure and that the engine needed to be repaired. The dealer informed the contact of a Class Action Lawsuit for the engine failure and that the engine could be repaired; however, because the vehicle had not received the software update for Hyundai Campaign: (Hyundai TXXM Warranty Extension Number: 966/953/TXXM); the vehicle was no longer eligible to receive the engine replacement. The vehicle was not repaired. The manufacturer was made aware of the issue. The manufacturer opened a case. The failure mileage was 86,204.

NHTSA complaint #11728772 — an unverified report by a vehicle owner.

ENGINE

Dealer failure to to remedy engine replacement under settlement. I am entitled under the March 1, 2022, Settlement Agreement (the “E2 Settlement”) due to recurring Theta II engine failures caused by the oil-starvation/connecting-rod bearing defect. Vehicle stalling on highways and heavy traffic, Repeated codes and failures of MAP sensors, VVT solenoids, camshaft position sensors, starters (×3), batteries (×2), turbo wastegate, fuel pump, EVAP canister, thermostats/housings, etc. — all downstream symptoms of oil starvation and bearing failure Hyundai dealers (Hyundai of Palm Springs and others) have continued to misdiagnose and charge me for unrelated repairs while refusing to acknowledge the covered defect in the replacement engine. Relief Demanded Under the E2 Settlement Pursuant to Settlement ¶¶ 4.1, 4.2, 5.1, 5.2, and 6, I demand the following within fourteen (14) days: Full replacement of the failed engine with a new or remanufactured long-block assembly at $0 out-of-pocket cost to me, including all related gaskets, hoses, sensors, turbocharger, and PCM reflash: Full reimbursement of all out-of-pocket repair expenses incurred since the 2022 replacement (approximately $8,178.50+ $150 for two maxed out Triple A cards, and a new rental car for this week at $1500.00 total to date $10,148.50— Reimbursement of all towing and rental-car expenses (receipts enclosed); Compensation for diminished value of the vehicle. Confirmation that the Lifetime Warranty remains in full force on any future engine. In the alternative, a cash buyback of $25,000 in full satisfaction of all claims. This vehicle has suffered two qualifying Theta II engine failures, the second occurring in a warranty replacement engine. Hyundai of Palm Springs continued refusal to properly honor the settlement has caused extreme hardship, safety risks (multiple freeway/intersection stalls), and thousands of dollars in unnecessary expense

NHTSA complaint #11706574 — an unverified report by a vehicle owner.

ENGINE

GDFI MODOR IS BURNING GAS AND OIL TOO QUICKLY Randomly shutting off Burning too much oil

NHTSA complaint #11696760 — an unverified report by a vehicle owner.

ENGINE

I am writing to express my concern regarding an ongoing and persistent issue with excessive engine oil consumption in my 2015 Hyundai Santa Fe, Subject: Severe Oil Consumption Issue - 2015 Hyundai Santa Fe - VIN: [XXX] The vehicle consumes an alarming amount of oil, approximately 1 quart every 300 miles. This rate of consumption is far beyond what is considered normal and strongly suggests a serious mechanical or manufacturing defect. I have already taken the vehicle to a mechanic to diagnose and attempt to resolve this problem. Based on their professional advice, the following parts were recently replaced: 1.Engine Valve Cover Gasket 2.Turbo Charger Oil Line 3.Spark Plugs Unfortunately, despite these repairs, the issue of excessive oil consumption remains unresolved. The rate of oil loss remains consistent and dangerously high. This was first informed by a service center when I took the car for a random check. Then, after traveling 1,000 miles, the engine oil level dropped again. After that, I am keeping an eye on that. This level of oil consumption poses a significant risk to the engine's long-term health and reliability, and it is a major inconvenience and expense for me as the owner. I am deeply concerned that a major engine component may be failing. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11689911 — an unverified report by a vehicle owner.

ENGINE

I bought the 2015 Hyundai Santa Fe yesterday evening. Upon leaving the dealership I promptly broke for a car in front of me. Immediately the vehicle turned off completely. I put the vehicle in the park and attempted to start the vehicle back up. The vehicle would not start up and begin leaking a prominent scent. Following this, white smoke with the same pungent smell was coming from the engine. I propped the hood and saw the smoke continue to release. I then motioned away from the vehicle and called for a tow truck. The car is now being inspected by the dealership I purchased it from the same day. I believe this is related to the NHTSA recall on 2010-2015 Hyundai Santa Fe, recall date 09/22/2023, recall number 21V303000, and Hyundai Safety Recall 251s Anti-Lock Braking System Fuse Replace. This issue is not listed under my vehicle VIN number but it’s apparent to be the case and issue and is being inspected further by the dealership.

NHTSA complaint #11676337 — an unverified report by a vehicle owner.

ENGINE

Despite regular oil changes and maintenance. Engine failed due to lack of oil at 122,000 miles. Complete oil change was done at 120,000 miles. Tune up completed at 118,000 miles

NHTSA complaint #11670871 — an unverified report by a vehicle owner.

ENGINE

During acceleration to pass car sputters and has no power. Merging into traffic is dangerous. The best shift is faulty as well . Mine is in park but it is showing it in drive and won't crank

NHTSA complaint #11667313 — an unverified report by a vehicle owner.

ENGINE

Oil consumption issues, can cause engine failure while driving. Car burns 2-3 quarts every 1,000 miles car takes just over 5qt to fill. Issues stated at around 70,000 now at 82,000. This is a long standing issue that needs to be addressed on hundreds of thousands of vehicles with the GDI engines

NHTSA complaint #11654023 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving home at approximately 25 MPH, the engine seized with several unknown warning lights illuminated. The contact was able to park the vehicle on the side of the road safely. The contact attempted to restart the vehicle however, the vehicle failed to restart. The vehicle was towed to an independent mechanic for diagnosis. The contact was informed that the engine had seized and needed to be replaced. The vehicle was next towed to the dealer to be diagnosed. The dealer confirmed that the engine had seized and needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The approximate failure mileage was 128,000.

NHTSA complaint #11624003 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving at an undisclosed speed and attempting to accelerate, the vehicle lost motive power and was unable to exceed 15 MPH. The contact was able to arrive to the intended destination, where the failure persisted. After restarting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed a failure with the knock sensor. The vehicle was not repaired. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was unknown.

NHTSA complaint #11605436 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated while driving approximately 35 MPH, the vehicle started losing motive power. The contact depressed the accelerator pedal; however, the vehicle continued to lose motive power and then stalled. The contact stated no warning light was illuminated. The contact had the vehicle towed to a local dealer, where it was diagnosed and determined that the engine needed to be replaced. The contact was informed that the engine control software update was not performed, and the vehicle did not qualify for an engine replacement. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was unknown.

NHTSA complaint #11590298 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated while driving at approximately 60 MPH, the vehicle stalled. The vehicle was not able to be restarted. Additionally, the contact observed white smoke coming from the engine and an abnormal oil burning odor. The check engine and oil warning lights were illuminated. The vehicle was taken to an independent mechanic where it was diagnosed and determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 148,000.

NHTSA complaint #11585211 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated while her husband was driving at an undisclosed speed, the vehicle inadvertently lost motive power however, the driver was able to coast to the shoulder of the roadway. After restarting the vehicle, the vehicle seemed to return to normal functionality, but the failure recurred. The check engine warning light was illuminated. The vehicle was taken to the dealer however, the dealer was unable to determine the cause of the failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 94,000.

NHTSA complaint #11535511 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while driving approximately 45 MPH, the vehicle lost motive power. While making a right turn, the vehicle stalled. The contact noticed smoke coming from the engine compartment. There were no warning lights illuminated. The vehicle was towed to an independent mechanic and the contact was informed that the engine needed to be replaced. The contact called the local dealer who referred her to the manufacturer for assistance. The manufacturer was contacted but provided no additional assistance. The failure mileage was approximately 121,000.

NHTSA complaint #11529327 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated that while operating the vehicle, the vehicle lost motive power and stalled without warning. After replacing the battery and starter, the vehicle remained inoperable and would not start. The vehicle was towed to the local dealer who diagnosed that the engine was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 115,000.

NHTSA complaint #11482159 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2015 Hyundai Santa Fe Sport. The contact stated he took the vehicle to the dealer to be serviced under NHTSA Campaign Number: 21V303000 (Service Brakes, Hydraulic). The contact stated that while his daughter was driving 45 MPH, the vehicle failed to accelerate with the check engine warning light illuminated. The vehicle was towed to the dealer and the contact was informed that the knock sensor detected a failure and shifted the vehicle into SAFE mode. The manufacturer was contacted by the dealer. The dealer was asked to continue performing tests on the vehicle. The vehicle was not repaired. The failure mileage was 71,000.

NHTSA complaint #11479954 — an unverified report by a vehicle owner.

ENGINE

The contact's mother owns a 2015 Hyundai Santa Fe Sport. The contact stated that while her mother was driving at an undisclosed speed, the vehicle made an abnormal sound. The contact's mother was able to drive to her residence; however, the vehicle was not able to restart. The vehicle was towed to the dealer and diagnosed with engine failure. The contact was informed that the engine needed to be replaced and that there was a Service Campaign Number: 953 (ECM & Cluster Update - Engine Monitoring Logic Product Improvement) associated with the VIN that was unrepaired. The contact's mother did not receive notification of the Service Campaign. The vehicle was not repaired and remained at the dealer. The manufacturer was made aware of the failure but informed the contact that the vehicle was out of warranty. The failure mileage was 90,088.

NHTSA complaint #11452470 — an unverified report by a vehicle owner.

ENGINE

The contact's sister owns a 2015 Hyundai Santa Fe Sport. The contact stated that while his sister was driving and following him on the highway at 60 MPH, the vehicle shut off without warning. His sister managed to pull the vehicle off to the side of the road and had the vehicle towed to the residence. Prior to the failure, the contact had taken the vehicle to a dealer where she had the vehicle serviced under an unknown recall. The manufacturer had yet to be notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 71,000.

NHTSA complaint #11437546 — an unverified report by a vehicle owner.