2,633 of the
10,463 complaints filed about the Hyundai Santa FE
are about the engine —
100% of everything owners reported.
The worst model year for it is 2017.
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 complaint #11763606 — an unverified report by a vehicle owner.
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 complaint #11763336 — an unverified report by a vehicle owner.
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 complaint #11763180 — an unverified report by a vehicle owner.
The contact owned a 2021 Hyundai Santa Fe. The contact stated that while his wife was driving 50 MPH, the vehicle unexpectedly caught on fire. The contact's wife became aware that the radio was inoperable before the failure. Additionally, the contact’s wife’s eyes were irritated, and there was a hot, harsh odor which grew stronger very quickly. The odor was inside the vehicle. The contact stated that the smoke was black, and flames started shooting out from under the hood to consume the vehicle. The vehicle was a total loss. The fire was extinguished by the Murphysboro Fire Department. The Fire Department was unable to determine where the fire had started. There was a Police report filed. The vehicle was towed to an impound lot. The failure mileage was approximately 58,000.
NHTSA complaint #11763201 — an unverified report by a vehicle owner.
-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 complaint #11762822 — an unverified report by a vehicle owner.
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 complaint #11762696 — an unverified report by a vehicle owner.
1. Component/System Failure & Availability: The failed component is the engine's internal Camshaft Variable Valve Timing (CVVT) phaser backing bolt within the 3.3L V6 engine assembly. An internal factory bolt unthreaded, backed out, and physically pierced directly through the upper valve cover. The vehicle and intact failed engine are currently located at an authorized Hyundai dealership service center in [XXX], and remain fully available for immediate physical inspection by federal investigators upon request. 2. Safety Risk: An internal engine bolt unthreading and puncturing through the valve cover creates an extreme safety hazard. A high-velocity metal bolt piercing the engine casing causes immediate engine seizure, sudden loss of motive power at highway speeds, loss of power steering/braking assistance, and massive pressurized oil discharge directly onto red-hot exhaust manifolds, posing a severe risk of sudden catastrophic vehicle fire and multi-vehicle highway collisions. 3. Dealer/Independent Confirmation: Yes. The failure was formally inspected, reproduced, and confirmed by an authorized Hyundai dealership service department. Dealership technicians logged official diagnostic findings under Prior Authorization Case #XXX. 4. Inspection by Manufacturer/Others: Yes. The defect was inspected and escalated directly to Hyundai Motor America (HMA) Corporate Engineering. Corporate engineering officially verified the defect and issued Techline Case #XXX, confirming that an internal factory CVVT backing bolt unthreaded and pierced the valve cover, recommending a full engine replacement. 5. Warning Lights & Prior Symptoms: There were no prior warning lamps, check engine lights, unusual sounds, or advance warning symptoms prior to the failure. The internal hardware failure occurred suddenly and without warning while operating the vehicle at standard operating parameters. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11762257 — an unverified report by a vehicle owner.
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 complaint #11761955 — an unverified report by a vehicle owner.
The contact owns a 2026 Hyundai Santa Fe. The contact stated that while driving at an undisclosed speed, the vehicle hesitated while accelerating. The failure occurred mostly while making a left turn and while accelerating from a stop and continued for 10-seconds before self-correcting. There was no warning light illuminated. The contact stated that there was almost a crash during the failure. The failure was not self-corrected after one failure. The vehicle was turned off and restarted, and the failure was then self-corrected. The vehicle was taken to the local dealer, who was unable to determine the cause of the failures, and there was no DTC found. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was 5,100.
NHTSA complaint #11761943 — an unverified report by a vehicle owner.
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 complaint #11761505 — an unverified report by a vehicle owner.
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 complaint #11761774 — an unverified report by a vehicle owner.
My truck began emitting a strong oil odor on XXX. I took it to Amato in [XXX], where I was told the oil pan was leaking. They replaced the oil pan, and I paid for the inspection as well. About an hour after picking up my truck, the check‑engine light came on. I returned to the dealership, and they then said additional repairs were needed, even though I had already paid $2,211.57 for the work they claimed was necessary. At that time, my truck had 145,776 miles on it. Because the manager at [XXX] refused to address my concerns, I was told to go to another Amato location, and I was effectively blacklisted from the first dealership. I went to Amato Glendale, where I experienced the same issues. They fixed only one of the problems, and that was only after I contacted Hyundai corporate. My truck continued to have oil‑consumption issues. Amato required me to complete a three‑month, 1,000‑mile oil consumption test before they would consider providing assistance. I completed the test as instructed. Now, however, they are saying that due to the age and mileage of my truck, they will not cover the engine replacement — even though the problems began at 145,000 miles, not 156,000. Other drivers have reported that Hyundai delays necessary repairs until major engine damage occurs, and I believe that is exactly what has happened in my case. There was also a suspension recall that applied to the 2018 model but not the 2017. Amato Hyundai covered part of that repair only because I contacted corporate again. My current complaint is about the failing engine and Amato Hyundai’s lack of responsibility in properly diagnosing and repairing my truck. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11760878 — an unverified report by a vehicle owner.
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 complaint #11760934 — an unverified report by a vehicle owner.
My car is consuming an immense amount of oil, the manufacturer recommends oil changes every 7,500 miles, I get an oil change less than 3,000 miles and on my last oil change i was told that there are oil shavings in my oil filter. I just got the SC9C2 update and now my engine is knocking. Car drives super rough and has signs of rod bearing failure. My engine is the Theta II 2.4GDI, a class action lawsuit was filed against Hyundai but my car wasn't included. I don't understand how Hyundai can know about this issue with this engine and not cover replacement. A car should at the very least last for the life of the loan, I am going to end up with no car and still making payments.
NHTSA complaint #11760974 — an unverified report by a vehicle owner.
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 complaint #11760439 — an unverified report by a vehicle owner.
2020 HYUNDAI SANTA FE SEL WITH 2.4L THETA II ENGINE EXPERIENCES SEVERE OIL CONSUMPTION AND REPEATED ENGINE STALLING DURING NORMAL OPERATION. THE VEHICLE HAS A DOCUMENTED HISTORY OF REPEATED LOW-OIL CONDITIONS DESPITE REGULAR OIL SERVICE. THE PROBLEM PROGRESSED TO THE ENGINE REPEATEDLY STALLING WHEN RETURNING TO IDLE. WHEN BRAKING TO A STOP OR WHILE STOPPED AT A TRAFFIC LIGHT OR STOP SIGN, THE ENGINE MAY STALL UNLESS THE DRIVER MAINTAINS ADDITIONAL THROTTLE. THIS CREATES A SAFETY CONCERN BECAUSE THE ENGINE CAN SHUT OFF DURING NORMAL TRAFFIC OPERATION. THE VEHICLE WAS PRESENTED TO CENTEREACH HYUNDAI FOR DIAGNOSIS. ACCORDING TO THE HYUNDAI SERVICE ADVISOR, THE DEALERSHIP FOUND THE ENGINE WITH VERY LITTLE/NEARLY NO ENGINE OIL DESPITE THE VEHICLE HAVING TRAVELED LESS THAN APPROXIMATELY 500 MILES SINCE ITS MOST RECENT OIL SERVICE/TOP-OFF. THE HYUNDAI TECHNICIAN REPORTEDLY SUSPECTS THAT THE ENGINE TIMING MAY HAVE JUMPED AND THAT THIS CONDITION MAY BE RELATED TO THE LOW-OIL CONDITION AND MAY EXPLAIN THE ENGINE STALLING. HYUNDAI HAS DIRECTED THAT AN OIL-CONSUMPTION TEST BE PERFORMED. THE INITIAL OIL SERVICE/ENGINE-FLUSH PROCEDURE HAS BEEN AUTHORIZED BY THE OWNER AT APPROXIMATELY $400. THE PROCEDURE THEN CONTEMPLATES APPROXIMATELY 1,000 MILES OF ADDITIONAL VEHICLE OPERATION TO MEASURE OIL CONSUMPTION. THIS CREATES AN ADDITIONAL SAFETY CONCERN BECAUSE THE VEHICLE BEING REQUIRED TO ACCUMULATE APPROXIMATELY 1,000 MILES IS THE SAME VEHICLE THAT HAS BEEN REPORTED TO REPEATEDLY STALL AT IDLE AND FOR WHICH THE HYUNDAI TECHNICIAN REPORTEDLY SUSPECTS A TIMING PROBLEM. THE OWNER HAS REQUESTED THAT HYUNDAI DOCUMENT WHETHER THE VEHICLE HAS BEEN EVALUATED FOR THE STALLING CONDITION AND WHETHER HYUNDAI CONSIDERS IT APPROPRIATE TO OPERATE FOR THE REQUIRED MILEAGE-ACCUMULATION TEST. HYUNDAI MOTOR AMERICA CASE NUMBER: 43164946. VIN: 5NMS3CAD4LH173916.
NHTSA complaint #11760193 — an unverified report by a vehicle owner.
While operating the vehicle, the vehicle suddenly began severely hesitating and stalling. During the incident, engine RPM surged to approximately 6,000 RPM and accelerator pedal response became abnormal. The vehicle was not responding normally to accelerator input, which significantly affected the ability to operate the vehicle safely. The vehicle subsequently recorded diagnostic trouble code P0304 – Cylinder 4 Misfire Detected. The abnormal operation of the vehicle during the incident was also captured on video. The vehicle was taken to an authorized Hyundai dealership for diagnosis. The dealership has advised that because the condition is not currently occurring and they have been unable to duplicate the problem, they may be unable to diagnose or repair the vehicle. The safety concern is not simply an illuminated check-engine light or a stored P0304 code. The concern is the combination of severe hesitation/stalling, abnormal accelerator response, and the engine surging to approximately 6,000 RPM while the vehicle was being driven. The cause of the condition has not been identified and, at the time of this complaint, the vehicle has not been repaired for the underlying problem. I am concerned that this condition could recur without warning while accelerating, entering or crossing traffic, or traveling at highway speeds. A recurrence could result in an inability to accelerate normally, unexpected vehicle behavior, loss of normal vehicle operation, or a collision. Hyundai has been notified of the issue and I have requested further technical investigation of the engine misfire as well as the transmission/TCU and electronic throttle/accelerator systems due to the high-RPM event and abnormal accelerator response. I am submitting this complaint because this appears to be a potentially serious safety-related defect and I want NHTSA to have a record of the incident and determine whether similar stalling, high-RPM, acceleration, transmission, or engine-misfire.
NHTSA complaint #11760466 — an unverified report by a vehicle owner.
2024 Hyundai Santa Fe gasoline model. My VIN was included in Hyundai Safety Recall 263 / NHTSA Recall 24V-529 involving the Transmission Control Unit and potential damage to the dual-clutch transmission. On September 25, 2024, at fewer than 5,000 miles, the transmission failed and the vehicle was taken to a Hyundai dealership. The transmission repair/replacement was approved and the vehicle remained out of service until October 21, 2024. On June 5, 2026, the vehicle would not start and required towing to an authorized Hyundai dealership. The vehicle has remained at the dealership continuously since June 5 and has not been returned to me. The dealer has undertaken multiple unsuccessful repair/diagnostic efforts during the current visit. I am currently being told that the condition involves the engine/powertrain. Hyundai is now sending an engineer to the dealership because the condition remains unresolved. I am reporting this history because this vehicle experienced a transmission failure shortly after being subject to a federal transmission-related safety recall and has now developed another major engine/powertrain condition while still relatively new.
NHTSA complaint #11759564 — an unverified report by a vehicle owner.
My 2017 Hyundai Santa Fe, purchased new from Lynnes Hyundai in February 2017, has approximately 93,000 miles. The vehicle previously developed a significant oil-consumption/engine problem that was diagnosed by Hyundai, and Hyundai replaced the engine with a remanufactured engine. Approximately two weeks after the engine replacement, the check-engine light illuminated and DTC P1326 was identified. The dealership replaced the knock sensor. Approximately two weeks later, the check-engine light illuminated again with a recurring P1326 condition. The vehicle is currently at Lynnes Hyundai and has been there approximately three weeks while they attempt to determine the cause. Hyundai Techline is involved. Prior to the current repair visit, while traveling approximately 60 mph, the vehicle experienced a very forceful hesitation that jerked the vehicle. I immediately slowed down and pulled onto the shoulder. The vehicle continued to hesitate intermittently while I drove slowly to safety. I was concerned that the vehicle could lose power or shut down while I was driving at highway speed, creating a risk of a crash. The recurring P1326 condition has been confirmed by the Hyundai dealership. The vehicle and engine have been inspected by Hyundai/Lynnes Hyundai multiple times, including after the engine replacement. The current recurring condition has not been resolved. The check-engine light is the warning lamp associated with the current condition. I do not know the underlying cause of the recurring P1326 condition; Hyundai is currently attempting to diagnose it. The vehicle is currently available for inspection at Lynnes Hyundai.
NHTSA complaint #11759120 — an unverified report by a vehicle owner.
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 complaint #11759237 — an unverified report by a vehicle owner.