2013 Hyundai Santa Fe Sport
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Vehicles › Hyundai › Santa Fe Sport › 2013
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
These records cover every 2013 Hyundai Santa Fe Sport. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
6 recalls name the 2013 Hyundai Santa Fe Sport. Newest first.
Hyundai Motor America (Hyundai) is recalling certain 2011-2015 Elantra, Genesis Coupe, Sonata Hybrid, 2012-2015 Accent, Azera, Veloster, 2013-2015 Elantra Coupe, Santa Fe, 2014-2015 Equus, 2010-2012 Veracruz, 2010-2013 Tucson, 2015 Tucson Fuel Cell, and 2013 Santa Fe Sport vehicles. The Anti-Lock Brake System (ABS) module may leak brake fluid internally…
An engine compartment fire while parked or driving can increase the risk of injury.
Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will replace the ABS fuse, free of charge. Owner notification letters were mailed April 10, 2024 through October 11, 2024. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 251.
Hyundai Motor America (Hyundai) is recalling certain 2013-2015 Santa Fe Sport vehicles. Brake fluid may leak inside the Anti-lock Brake System (ABS) module, possibly resulting in an electrical short.
An electrical short in the ABS module can increase the risk of an engine compartment fire while parked or driving.
Owners are advised to park outside and away from structures as a precaution until the recall repair is complete. Dealers will replace the ABS multi-fuse, and inspect and replace the ABS module, as necessary, free of charge. Owner notification letters were mailed on August 25, 2021. Note: This recall includes all vehicles previously recalled under NHTSA recall number 20V-520. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 205.
Hyundai Motor America (Hyundai) is recalling certain 2013-2015 Santa Fe Sport vehicles. Brake fluid may leak inside the Anti-lock Brake System (ABS) module, possibly resulting in an electrical short.
If the ABS module short circuits, there is an increased risk of an engine compartment fire.
Hyundai will notify owners, and dealers will inspect the ABS module and replace it if necessary, free of charge. Owners are advised to park outside as a precaution until the recall repair is complete. The recall began December 22, 2020. Note: This recall has been superseded by NHTSA Recall 21V-303 and all affected vehicles will now be repaired under 21V-303. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's number for this recall is 194.
Hyundai Motor America (Hyundai) is recalling certain 2011-2014 Sonata and 2013-2014 Santa Fe Sport vehicles previously repaired under recall numbers 15V-568 and 17V-226. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned, or improperly torqued during the engine replacement procedure, allowing fuel to leak…
A fuel leak in the presence of an ignition source can increase the risk of a fire.
Hyundai will notify owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began March 1, 2019. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai's recall number for this recall is 180.
Hyundai Motor America (Hyundai) is recalling certain 2013-2017 Santa Fe and Santa Fe Sport vehicles. In the affected vehicles, the secondary hood latch actuating cable may corrode and bind, causing the secondary hood latch to remain in the unlatched position when the hood is closed.
If the hood is not securely closed or the primary latch is inadvertently released and the secondary latch is not engaged, the hood could unexpectedly open while driving, increasing the risk of a vehicle crash.
Hyundai will notify owners, and dealers will replace the secondary latch cable, free of charge. The recall began on August 4, 2017. Owner's may contact Hyundai customer service at 1-855-671-3059. Hyundai's number for the recall is 163.
Hyundai Motor America (Hyundai) is recalling certain 2013-2014 Sonata and Santa Fe Sport vehicles. Machining errors during the engine manufacturing process may cause premature bearing wear within the engine.
Bearing wear may result in the engine seizing, increasing the risk of a crash.
Hyundai will notify owners, and dealers will inspect the engine, replacing the engine short block, as necessary, free of charge. The recall began June 2017. Owners may contact Hyundai customer service at 1-800-633-5151. Hyundai's number for this recall is 162.
Vehicle: 2013 Hyundai Santa Fe Sport 2.0T Limited, VIN [XXX]. Registered and titled in Georgia, USA since July 2022. Built in the USA (VIN begins with 5); originally retailed in Canada. The vehicle has an unremedied ABS module defect that can cause an engine-compartment fire even when parked and turned off. Hyundai Canada lists it as open safety recall R0246-1 (41D013, Transport Canada 2024-080), remedy available since 2024-05-27. The same defect and the same remedy (ABS fuse replacement) are covered in the US by NHTSA recall 23V651 / Hyundai Recall 251, which includes 2013 Santa Fe Sport vehicles produced 7/12/2012 to 6/15/2013. A second Canadian fire-risk recall is also open: R0212 (21DG01, TC 2022-659, rear park-assist sensors). The NHTSA recall lookup for my VIN shows 0 open recalls (checked 10/26/2026), apparently because the vehicle was first sold in Canada. Georgia Hyundai dealers refuse to perform the recalls, telling me they do not do recalls on Canadian vehicles. As a result, a US-registered vehicle with a known fire defect that Hyundai Motor America has recalled in the US cannot get the remedy anywhere in the US. I have asked Hyundai Auto Canada (10/26/2026) to authorize a US dealer. I ask NHTSA to ask Hyundai Motor America (1) why US-registered vehicles that are the same as those in recall 23V651 are excluded from the remedy because of their original market, and (2) to authorize its dealers to perform the remedy on my vehicle. I am parking outdoors away from structures in the meantime. My family, including three young children, rides in this vehicle. No fire, crash or injury has occurred. Documents available: Hyundai Canada recall lookup and NHTSA lookup for this VIN, both dated 10/26/2026. [XXX], [XXX], [XXX], [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
FORMAL VEHICLE SAFETY AND WARRANTY COMPLAINT Date: [XXX] From: [XXX] Vehicle: 2013 Hyundai Santa Fe Sport, 2.4L Theta II engine Mileage: Approximately 150,000 miles (exact current reading to be confirmed) Subject: Recurrent Check-Engine Warning Following Repeated Repairs; Request for Theta II Engine Investigation I am submitting this complaint to formally document recurring engine-related symptoms affecting my 2013 Hyundai Santa Fe Sport, and my repeated requests for investigation of a possible connection to the known Theta II engine defects and related warranty programs. On [XXX], the check-engine light illuminated again. Previously, on three separate occasions, the vehicle experienced a flashing check-engine light and a light ticking noise while idling. I was advised each time that the knock sensor was responsible, and the sensor was replaced. The vehicle returned to normal operation after those repairs, but similar symptoms subsequently recurred. While my vehicle was still below the 150,000-mile threshold, I repeatedly expressed concern that the symptoms could relate to the Theta II engine issue. During the most recent dealership visit, resulting in repairs on September 10, 2026, I emphasized that the recommended valve-cover gasket and spark-plug work might address a secondary issue without resolving the primary recurring problem. The check-engine light has now returned approximately five weeks after that repair. I am not claiming that a connecting-rod-bearing defect has been conclusively diagnosed. I am asking that the possibility be properly evaluated and that my earlier reports, repair attempts, and the mileage at which I first raised these concerns be preserved and considered when warranty eligibility is reviewed. I am sending this as a record of contact and communication.. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
The vehicle suddenly stopped and suddenly smoke appear in the front part of vehicle. Firemen appeared and when the front of the car was opened the flames of the fire were all over the engine of the car. The front glass broke and the hood has visible signs of the fire. Police were everywhere while firemen worked to stop the fire in the car. The car was towed to our home.
The contact owns a 2013 Hyundai Santa Fe Sport. The contact stated that the front driver’s side door failed to unlatch as intended using either the interior or exterior door handles or the locking mechanism. In addition, the contact exited the vehicle using the front passenger’s side door to exit the vehicle. An appointment was scheduled with the local dealer. Upon further investigation, the contact associated the failure with TSB: 14-01-004-1. The contact stated that it might be a potential safety risk for passengers in an emergency. The manufacturer was made aware of the failure by telephone. The failure mileage was approximately 142,622.
In October/November of 2023, while Hyundai was actively initiating Safety Recall 251 (NHTSA Campaign 23V-651), my vehicle's ABS Control Unit suffered an internal fluid leak that resulted in an electrical short-circuit. The failure caused major electronic communication errors, illuminated dashboard warning lights, and placed the vehicle into Limp Mode, rendering it unsafe to drive. Because the failure occurred prior to receiving a formal owner notification in the mail and the vehicle was un-drivable, I paid $1,300.54 out-of-pocket on November 17th 2023 to replace the failed ABS module. Hyundai Corporate has twice denied reimbursement, arguing that Recall 251 only covers a multi-fuse replacement and claiming internal fluid leaks are not covered. This contradicts NHTSA 23V-651 documentation, which explicitly identifies internal ABS module fluid leaks and electrical shorts as the core safety defect. Installing a fuse current-limiter cannot repair an already-ruined ABS circuit board or resolve a safety-mandated Limp Mode. I am reporting this to document on the official public record that Hyundai is actively denying reimbursement for the exact root-cause failure identified in NHTSA Campaign 23V-651. PLEASE NOTE: This report is submitted solely to document Hyundai Motor America's non-compliance and improper reimbursement denial for official record-keeping under Campaign 23V-651. I do not require follow-up contact from NHTSA regarding this submission.
I was driving down a highway and was slowing down as motorcycle in front of me was turning. I than proceeded to drive, I heard a loud noise which everyone in the vehicle thought it was the motorcycle (it wasn't) we pulled over into the nearest gas station and saw that my oil light was barely blinking (it was barely noticeable) was fading in and out) we got out checked the dipstick and it was low. Was not due for an oil change for another 1500miles. We put oil in and waited checked the dip stick it was then reading between the two lines of L and F. We waited another 5-10 minutes before leaving. We pulled out and the vehicle acted as if it had no power. I pushed on the gas to get up to speed and the car died out; I got pulled over to the side of the road. The car gave me no indication of anything. No oil light. I drove the days before with no issues I was 38miles from home.
The contact owns a 2013 Hyundai Santa Fe Sport. The contact stated that after a routine oil change, while driving back to the residence, the vehicle stalled. The vehicle was towed to the dealer to be diagnosed. The contact was informed that there were metal shavings inside the engine. The vehicle was diagnosed with engine failure. The vehicle was not repaired. The manufacturer was made aware of the failure and stated that the vehicle was not eligible for a recall repair because the engine software update was not performed. The failure mileage was approximately 136,434.
While driving a 2013 Hyundai Santa Fe Sport on a city street, the vehicle unexpectedly stalled and shut off while idling at a red light. The vehicle completely failed to restart. No dashboard warning lights, check engine lights, or fault messages illuminated prior to or during the stalling event. Immediately following the engine shutdown, a fire erupted under the engine hood. The fire rapidly escalated and completely engulfed the entire vehicle, resulting in a total loss. The local fire department responded to the scene to extinguish the blaze
My 2013 Hyundai Santa Fe Sport is subject to Hyundai Recall 162 / NHTSA Recall 17V-226, concerning premature connecting-rod-bearing wear that can cause engine knocking, engine failure, and loss of motive power. My vehicle developed engine knocking and a flashing check-engine light while I was driving. The vehicle is now at an authorized Hyundai dealership. Hyundai initially denied an engine replacement based on mileage. I escalated the matter to Hyundai Motor America Corporate Consumer Affairs. Hyundai has now confirmed in writing that, because my vehicle is more than eight years old and has more than 150,000 miles, Hyundai is applying the high-mileage provision of the Theta II settlement and will not replace the engine. Instead, Hyundai is offering either a repurchase or $2,000 in lieu of engine replacement. I understand that Hyundai is relying on the court-approved settlement. My concern is specifically whether Hyundai’s application of that settlement to my vehicle is consistent with the administration of Recall 162 and the federal safety-recall remedy, given that my vehicle is experiencing the engine failure that Recall 162 was designed to address. I am requesting NHTSA’s review of Hyundai’s handling of this safety-related recall matter.
Sunroof exploded while driving
The contact owns a 2013 Hyundai Santa Fe Sport. The contact stated that the subframe was rusted. The vehicle was taken to the dealer, who determined that the rear control arms and subframe were rusted and needed to be replaced. The contact was informed that the vehicle had previously been repaired under Service Campaign Number: 996 (Underbody Corrosion Preventive Service); however, the contact stated that the protective spray was only applied to the unibody and not the rear underbody. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 103,483.
Vehicle is a 2013 Hyundai Santa Fe Sport with the 2.4L Theta II GDI engine. A Hyundai dealer documented excessive oil consumption in December 2025 (3 quarts consumed over 1,703 miles during a dealer-administered oil consumption test; repair orders on file and available for inspection). On April 19, 2026, at 160,913 miles, following a highway drive, the engine developed a pronounced knock and vibration at low RPM and began stalling within seconds of idling in Park, with check engine and charging warning lamps illuminated. An engine that stalls at idle presents a safety hazard in traffic due to loss of power braking and steering assist. The vehicle was removed from service the same day, has not been driven since, and remains available for inspection. Knock Sensor Detection System software (Campaign 953) was installed and did not prevent the failure. Manufacturer has been notified in writing and consumer affairs cases are on file.
Issue was first identified in September 2024 when a rattling noise prompted inspection, and the engine was found to be significantly low on oil. Excessive engine oil consumption was confirmed with failure during manufacturer testing. Vehicle emits occasional burning oil smell when idling after 10 miles+ driving. Vehicle failed a 1,000-mile oil consumption test following a “Dynamic Engine Clean” performed by a certified independent mechanic, with documented oil loss of approximately 2 quarts. Vehicle subsequently failed a dealer-administered oil consumption test, with documented oil loss of approximately 2.3 quarts within 1,000 miles. Engine oil levels have dropped to critically low levels between checks despite active monitoring and maintenance. This condition presents a risk of engine seizure, sudden loss of power while driving, and potential engine compartment fire due to oil consumption or leakage. The issue has been reproduced and documented by both an independent mechanic and a Hyundai dealership. Despite confirmed excessive oil consumption, the manufacturer has delayed corrective action and has required repeated oil consumption testing and engine cleaning procedures rather than proceeding with repair. This condition appears consistent with known defects associated with Hyundai Theta II engines.
I have great concern that certain vehicles of Hyundai are getting a little bit of extended warranty occupant classification system forward slash occupant detection system known issues. OCS/ODS I will try to attach a picture of the letter. As a nurse manager I find this once again appalling on Hyundai behalf, after these years pass we won't know if our air big warning lights or trouble codes or even a a passenger is detected when driving. They offered to pay if you had issues with this problem or in my case in the next four and a half years they would cover it but after that do I feel that this is my problem because they're having defect sensors and warning lights or maybe lack thereof altogether after speaking to them when I called and made a case number XXX with Hyundai Motor America. I strongly believe this should be a recall. I would never trust anybody sitting in my passenger seat, and I don't think you would either. They always try and find some way to get around doing the right thing and obviously they have problems with intermittent airbags warning lights trouble codes and this needs to be looked into if there are any risk/issues detecting or possibly never detecting a grandchild sitting in that front seat! After 5 years I will worry if anybody sits in the front seat now. I have started the process and will wait for your reply, of communicating with [XXX] our Minnesota State Attorney General's office on this matter. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
I noticed a Check Engine Light flashing on my dashboard while driving on May 27, 2026. The vehicle suddenly losing power is extremely unsafe for me and my family, and also others on the road. This is a repeated P1326 code which happened before in 2021 and 2024. Based on the receipts I have from the previous inspections from the dealer, the Bearing Clearance Test (BCT) was not done in 2024, but was performed in 2021. The knock sensor was replaced in 2024 and I was denied engine replacement. This is a repeat failure of the same condition under Hyundai Motors TSB T3G Theta II. Once again, my safety was at extreme risk as the engine lost its power suddenly. It could have easily lead to a crash. In 2024, Hyundai and the dealer declined an engine replacement despite me showing the safety concerns and my possible eligibility for an engine replacement for the underlying condition.
The contact owns a 2013 Hyundai Santa Fe Sport. The contact stated that occasionally, while driving at various speeds, an abnormal knocking sound was heard coming from under the hood while the accelerator pedal was depressed, and the steering wheel would shudder. The Check engine oil warning light illuminated. Upon further investigation, the contact related the failure to NHSTA Campaign: 17V226000 (Engine and Engine Cooling). The vehicle was taken to a local dealer, where it remains for further investigation; however, the vehicle was not diagnosed or repaired due to a lack of maintenance records, and the recall repairs were rejected. The manufacturer was made aware of the failure and determined that the recall repairs were performed under previous ownership; however, the recall repairs were not completed. The failure mileage was approximately 147,000.
Passengers are stuck in vehicle due to failure of doors opening from either inside, outside or both.
I am reporting a serious safety defect involving my 2013 Hyundai Santa Fe Sport equipped with a Theta II engine While driving and exiting the freeway with my wife as a passenger, the engine suddenly failed after knocking symptoms and completely seized/locked while the vehicle was still in motion. The vehicle immediately lost motive power and came to a stop, creating an immediate and dangerous traffic safety hazard. Had this engine seizure occurred moments earlier while traveling at freeway speed, it could have caused a catastrophic accident involving serious injury or death. The Hyundai dealership diagnosed the vehicle with rod bearing failure, which is the known defect associated with Hyundai Theta II engine failures. My VIN falls under the Theta II extended engine warranty program, and the dealership confirmed eligibility and accepted the vehicle for inspection under that coverage. Despite this, Hyundai denied the repair claim, first alleging maintenance-related issues and later stating the vehicle was out of warranty. I maintain that the vehicle was properly maintained with oil changes performed approximately every 6,000/8,000 miles. Some calendar-time gaps occurred because the vehicle was stored and driven very little during my recovery from a personal injury surgery and recovery, but the vehicle was maintained on mileage intervals. This engine defect resulted in sudden engine seizure and total loss of motive power while driving, creating a serious safety risk to vehicle occupants and surrounding motorists. I am reporting this defect so it can be documented and investigated.
On [XXX] while entering the parking lot of my office, I noticed a blinking check engine light on the car's dashboard. I've never experienced this before so I called my husband. He asked me to use a diagnositic tool he kept in the car. I did and there was a code "P1326" when I pressed the key for more information it said something about the manufacturer. My husband told me to call the nearest dealer. I called Castle Hyundai in Downers Grove. I was instructed not to drive the care and have it towed to the dealership as soon as possible which I did. Castle Hyundai verified the P1326 code and fixed the knock sensor, changed the oil. I picked the car up on March 13. On [XXX], the flashing check engine light returned while driving home from work. Again, we used the diagnostic tool and again the code P1326 appeared. The car was towed back to Castle Hyundai. On Monday, I spoke with Christain Jones the service director because I hadn't heard anything about the car. He called later in the day and said that the car needed a new engine. He asked for records of my oil changes since purchasing the car in 2021. I emailed him three from 2022, 2023 and 2024, the four change was done by Castle on March 12 2026. I was told that he would send the the information to Hyundai regarding a new engine. However, he stated that he was not confident the company would approve the claim. This after, I received an email from Eric Marcum with Castle. The email stated that Hyundai denied the engine replacement due to "lack of maintenance". He wanted to know if we wanted an estimate on replacement of the engine. I responsed that I needed Hyundai's rejection in writing and I also wanted an estimate of the replacement. I attempted to contact Hyundai's Customer Care, however, their offices were closed until Monday. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
While my vehicle was at an authorized Hyundai dealership for engine warranty repair, I reported a suspension grinding noise and requested that it be inspected. This concern was raised while the vehicle was in the dealership’s possession and was communicated as a safety concern. The engine repair was completed and the vehicle was returned to me. No inspection findings, documentation, or technician notes were provided addressing the suspension concern. The repair documentation I later received does not include any reference to the suspension issue or any inspection findings related to that concern. The dealership has also confirmed that no additional documentation exists beyond the repair order. After the vehicle was returned, warning lights appeared that were not present prior to the repair. A suspension grinding noise may indicate issues affecting steering, suspension, or vehicle stability. I am concerned that the vehicle was released without inspection or documentation of a reported safety related condition.
After having the ABS recall fixed a while back all of the lights came back on about a week ago. There has been a loss of oil meaning i have been adding oil in between oil changes at least once a week, there has been smoke coming from under the hood and if you run the heat or air you have to have circulate cabin air button pushed or it pulls the smell inside the car and it is overwhelming. The smoking has been going on for about at least a month now.
I was driving on March 20, 2026 at about 12:00 PM when I suddenly noticed smoke, a strong gasoline smell, an oil smell, and a burning odor coming from the vehicle. I pulled over immediately because I believed the vehicle was unsafe and at risk of fire. The vehicle had to be towed. An independent repair shop later found a fuel leak at the high-pressure fuel line / fuel pump area, a loose ground wire on the right-hand side of the engine, a valve cover gasket leak, and engine timing chain noise. I was informed that gasoline had sprayed throughout the engine bay. This created an immediate fire hazard even though no actual fire occurred. This problem was especially concerning because the vehicle had been inspected and serviced by an authorized Hyundai dealer in December 2025, less than about 3,000 miles earlier. The loose engine ground wire and fuel leak raise serious concerns about vehicle safety and the adequacy of the prior inspection. I contacted Hyundai the same day and reported this as a fire-risk safety issue, but I did not receive timely assistance. Because immediate dealer service was not available, I had to authorize emergency repairs at a local shop for safety reasons. No warning lights were noted before the incident. The failure was confirmed by the repair shop.
Circuit board inside the fuse box stopped working and there was no speed indicator, no cruise control, no odometer registering while driving. Also the mechanical fuel pump started leaking fuel at 148,000 miles and now at 156,000 miles it is burning through oil and no oil light came on and the engine went into limp mode and is also now going through coolant too.
While traveling at approximately 80 mph on the highway, my vehicle suddenly lost all response to the accelerator pedal. Despite continued pressure on the gas, the vehicle rapidly decelerated to approximately 40 mph on its own. There were no warning lights, unusual noises, or physical indicators of a problem before, during, or after the event. I was able to safely navigate the vehicle off the highway. The vehicle appeared to operate normally afterward. The following day, I brought the vehicle to a mechanic who was unable to replicate the issue and found no stored fault codes. No repairs were made. Given the known concerns surrounding the Theta II engine in this model year, I am submitting this incident for documentation purposes and to contribute to any ongoing or future investigation into sudden acceleration loss in 2013 Hyundai Santa Fe vehicles.
Day 1 – Feb 11 at 4pm incident occurred my daughter was driving the vehicle on [XXX] , she was in the far right hand lane preparing to take an upcoming exit. Suddenly and unexpectedly the hood opened obstructing her view of the roadway and smashed the front windshield. Because she was in the right hand lane she was able to pull the vehicle to to the shoulder of the road immediately. No other vehicles were involved because of both her location (right hand lane) and ability to access the shoulder immediately. She could have been killed! The problem has not been confirmed Hyundai has informed me it will take 5/6 weeks to determine if an inspection is warranted. -Thursday February 19 We got the vehicle to the closest Hyundai dealer Metro West in Framingham Massachusetts on Thursday February 19 - I explained to the service representative the history (recall and repair in 2017) and a request to investigate recurrence of the recall defect as well as to prepare an estimate for repair. I never received a phone back so I called them on Wednesday February 27 and was informed that the vehicle estimate and inspection was in progress. At that point I contacted Hyundai corporate offices and was given a case number. On March 3, I called again and completed the preliminary investigation report - i was informed they would get back to me in approximately 48 hours. - On 3/9/26 after a phone conversation I was emailed a request to inspect my vehicle authorization form and another form (11 questions that had been answer numerous time by phone already) both were completed and submitted the following day 3/10/26. Dealership now threatening storage fees - Because the vehicle experienced failure of a component that was previously repaired under a federal safety recall, I am formally requesting that Hyundai preserve all evidence relating to the hood latch assembly and related components for purposes of regulatory review and potential insurance subrogation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.
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 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.
During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Hyundai Sonata and Santa Fe vehicles equipped with Theta II and Lambda II engines (approximately 1.3 million vehicles). ODI also reviewed field data of other Hyundai vehicles equipped with Theta II, Gamma, Nu and Lambda engines (approximately 4.8 million). As a result of this PE, Hyundai has issued NHTSA Recalls 20V-746 and 21V-727 to address potential engine failures and fires in certain Hyundai vehicles equipped with various engine types. Additional information on these and other related recall actions is available in the downloadable version of this resume available at NHTSA.gov. In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure rewlated recalls mentioned above and conducted previously. See the EA21-003 Opening Resume available at NHTSA.gov for more information. Also available in the downloadable version of this resume is a list of the reference numbers for the 302 ODI reports, or Vehicle Owner Questionnaires (VOQs), cited above which ODI received through mid-November 2021. Note that the Manufacturer reports cited above are customer complaints received through March 2019.
In a letter dated June 11, 2018, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a safety defect investigation into non-collision related fires on model year (MY) 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles. In a letter dated July 24, 2018, CAS requested that MY 2010-2015 Kia Soul vehicles be added to the petition. CAS stated that there is a higher number of complaints to NHTSA regarding non-crash fires on these vehicles compared to other similar vehicles. The Office of Defects Investigation (ODI) had already opened Recall Queries (RQ17-003 and RQ17-004) on all Kia and Hyundai vehicles equipped with Theta II engines for engine failures that may cause stalling and fires.The queries cover most of the petition subject Optima, Sorento, Sonata, and Santa Fe vehicles but not any of the subject Soul vehicles.On August 21, 2018, ODI opened a Defect Petition (DP18-003) to evaluate whether to grant or deny the CAS petition. ODI sent Information Request letters to Kia and Hyundai (September and October 2018) requesting information on all engine and non-engine related fires in the petition vehicles.ODI performed extensive analysis on the information obtained from Kia and Hyundai. During the DP18-003 analysis, Kia and Hyundai each initiated three additional safety recalls related to engine compartment fires on certain petitioned and non-petitioned vehicles (nearly 740,000 total vehicles: Recalls 18V-907, 18V-934, 19V-101, 19V-063, 19V-120, and 19V-204). Based on ODI?s review of the applicable materials, including responses to Information Requests sent to multiple manufacturers, Vehicle Owner Questionnaires (VOQ), and Early Warning Data, NHTSA decided to grant the petition.The CAS petition was granted on March 29, 2019. Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) have been opened to assess the scope, frequency, and potential safety-related consequences of alleged defects relating to non-collision vehicle fires in the 2011-2014 Kia Optima and Sorento, 2011-2014 Hyundai Sonata and Santa Fe, and 2010-2015 Kia Soul.Attached is a list of the reference numbers for the 404 VOQs cited above.
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.