2016 HYUNDAI SANTA FE SPORT Engine Problems

September 3rd, 2025, my engine failed, for the second time and left me stuck at a busy intersection, in the middle lane and can't move. The first time my engine failed (2022/same vehicle), I was about the get on the highway and it just stopped in the middle of the road right before getting onto the highway. Both times I've had to get out in traffic in order to move my vehicle. I'm causing a stop to traffic or a stop in the flow of traffic. In September when this happened, I had cops, mechanics and pedestrians stopping to help (thank goodness), but that caused a stop in the flow of traffic. Any of us could have been struck by a vehicle. It was also around 10/11pm at night There is an open recall on my vehicle and more specifically, the Theta II engine in my vehicle. It does not show when my VIN number is put in, but it's nationally known that there is an open recall and also a class action suit that was just settled in 2021 granting all customers with "Class vehicles" a lifetime extended warranty on the engines. They make it so that it's not that easy to just search and see there is a recall, but there is. My car has been at the Hyundai dealership since 9/4/25. So, yes it has been inspected by the manufacturer, and they confirmed that the diagnostic came back as positive for the recall. Yes, my check engine light would come on and off starting the end of 2024. Starting in April of 2025 I started having smoke come out of my exhaust and oil burning in days. All the while I have no puddle of oil underneath my car. I took it into Hyundai at that point, and they told me until my engine light was flashing and my car had stopped, they wouldn't be able to do anything in regard to the engine. Now my car has been there, I've provided service receipts that show proof of regular maintenance, I have the KSDS system installed, and they are denying my claim to replace my engine.

Six weeks ago the alternator and battery had also been replaced. My Hyundai Santa Fe Sport turbo engine, exhibited a persistent rubber-like odor for approximately three weeks after the latest maintenance. During this period, the push-start button intermittently failed, requiring multiple attempts to engage, and the vehicle experienced noticeable shaking. After being parked, smoke began to emerge from under the hood, followed by visible flames. Within roughly 3-5mins minutes, the vehicle was completely engulfed in fire and blew up 6 times. Notably, the car had undergone significant repairs in the past year, including an engine replacement, starter, OEM parts, O2 sensors, brakes, valve cover gasket, new tires, and routine oil changes.

There was no low oil indicator light, no smoke, and no oil on the garage floor. My wife was driving the vehicle on I-285 in Atlanta, returning from the ATL airport, when the vehicle began to lose power and started jerking and surging; the check engine light began flashing. She had to take surface streets to get home because the loss of power made the vehicle unsafe to drive on the freeway. When she arrived home, I checked the engine oil dipstick and it was completely dry. I took the vehicle to the garage that performs my oil changes, and they mentioned this is an ongoing issue with Hyundai—the vehicle is burning oil. The low oil level caused the knock sensor to trigger, which in turn caused the check engine light to flash and reduced power in an attempt to protect the engine. I never received any notification regarding a recall for this issue, and now my motor is more than likely damaged since I can still hear knocking when the engine runs at higher RPMs. My vehicle has over 100K miles, and I have never had an issue with it until now.

2916 Hyundai Santa Fe sport has an open recall of 953 for engine bearings knocking. It has been inspected. Yes, safety was put at risk, motor could lock up while driving causing a wreck. Yes, Tim Shorts Hyundai did confirm the engine was knocking. No lights were on in the vehicle. Was started sitting in the drive way, when the engine started knocking.

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated that while driving uphill, the vehicle failed to accelerate above 10 MPH. There was a burning odor coming from the vehicle with the check engine warning light illuminated. The contact stated that the engine had previously been replaced, but the failure persisted. The vehicle was towed to the dealer, who determined that the knock sensor needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 130,000.

Mileage: 130,000

Engine siezed, causing me to have to tow my vehicle. I was moved in the military to Germany in 2019, I had to have no open recalls on the car before I shipped it overseas. I completed a recall on the 5th of January 2019. On the 10th of January, Hyundai activated another recall on the vehicle. I was unaware of this recall and shipped my vehicle to Germany on the 16th of January 2016. The car returned from Germany in September of 2023. I had zero issues with this vehicle while I was over there, no check engine lights, no warning lights, nothing. I always changed the oil when told to do so, and when I returned from Germany it was the same thing, no issues and always completed oil changes when it was needed. I had no idea of the recall, Hyundai was sending it to an address I no longer lived at. I had no reason to take my vehicle to Hyundai to check for recalls. On [XXX], my vehicle engine stopped working at 84622 miles, and Hyundai said that it would be covered under warranty, but because I did not complete the recall that was activated on the 10th of January 2019, they denied the warranty and now my car is worthless. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

My engine seized at approximately 80mph on the interstate [XXX] ). The engine light came on only after I lost power. I only avoided a multiple car accident due to quick reaction and taking an exit ramp. Police came to my stalled vehicle and helped my push it off a major road to a nearby parking lot. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Subject: Engine Failure Due to Bearing Defect – No KSDS Recall Notification Vehicle: 2016 Hyundai Santa Fe Sport VIN: [XXX] Date of Purchase: April 2016 Complaint Summary: I am filing this complaint regarding my 2016 Hyundai Santa Fe Sport, which experienced catastrophic engine failure due to the known Theta II GDI engine bearing defect. Hyundai has an active class action settlement covering this defect, which requires owners to install the Knock Sensor Detection System (KSDS) update to be eligible for free repairs or the lifetime warranty. Despite owning my vehicle since April 2016 and holding clear title in my name for over 6 years, I never received any notice or communication about this required software update. Hyundai’s records still list the prior owner, Hertz, even though I have maintained valid registration and insurance in my name since the purchase. This lack of notice prevented me from having the KSDS update installed before the engine failed. I understand this defect does not show as an open safety recall on the NHTSA database because Hyundai classified it as a Product Improvement Campaign under the class action settlement. This does not change the fact that it is a known safety hazard and Hyundai failed to properly notify me, which denied me the chance to protect myself and my vehicle. I believe this is a major safety concern because the engine can stall or catch fire without warning. I am requesting that NHTSA hold Hyundai accountable for failing to properly notify current owners and ensure compliance with the class action settlement. Desired Resolution: Require Hyundai to honor the warranty and cover my engine replacement in full. Investigate whether Hyundai is failing to properly notify owners about this critical software update. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

As we were driving down the interstate we began to see smoke coming out our vents and after a few seconds saw flames coming from the passenger side of car. We quickly tried to pull over but brakes weren’t working. Safely pulled into grass median. Luckily we were able to quickly exit through the driver door. After about 30 seconds the car was engulfed in flames.

I need to replace engine block assembly and the following codes P1326 C1207 C1210 C1211 C1206 C1208

The vehicle lost power, and the engine started to make a knocking noise, and the check engine light came on. I plugged in the obd2 scanner and the p1326 code came out. It was a knock sensor that needed to be replaced. I replaced the sensor that the issue got worse. I looked up online about this issue and then I found a video of that explained the incident. The manufacture of the crank at the factory did not properly clean the holes of the oil passages. When they machined it, all the files they don't clean them good enough, so they go to one side and plug up the oil passages and it doesn't get oil. we were on the highway when this issue started and it lost power. The problem has not been solved because the Hyundai dealer and the corporate office did not want to help me with this issue. They claim that my title is salvaged but I contacted the DMV, and they confirmed that my title is clean and there is no issue. The second time they said the vehicle was used as a rental and that automatically disqualifies the vehicle's warranty. The vehicle has not been inspected. No warning at all until the day it happened. I just purchased this vehicle seven months ago for seven thousand dollars and this happened.

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the dealer for assistance. The approximate failure mileage was 63,000.

Mileage: 63,000

Dear NHTSA, My 2016 Hyundai Santa Fe Sport (VIN: [XXX] , 2.0L Theta II, 64,000 miles) suffered engine failure with knocking and power loss, matching NHTSA Recall #20V-746 (Hyundai #198). This defect risks stalling or fire, threatening my safety and others’. Hyundai Motor America and Hyundai of Tacoma (Tacoma, WA) refused repair, citing the rebuilt title, despite the factory defect. Recall #20V-746 addresses Theta II bearing wear. My vehicle’s symptoms align, yet the dealer denied service, claiming the title voids eligibility. Hyundai’s April 2025 email noted three unrelated recalls (turbo oil pipe, ECM update, hood latch) were completed but ignored #20V-746, redirecting me to the dealer without addressing the engine or title issue. I’ve called Hyundai (1-800-633-5151) and emailed multiple times since March 2025, receiving only generic responses. The dealer’s refusal and Hyundai’s inaction leave the vehicle inoperable, posing a ongoing safety hazard on the road. The rebuilt title should not exempt a factory defect tied to a safety recall. The low mileage (64,000) supports my claim. I haven’t obtained a diagnostic report but am willing to pay for one (~$100–$200) if required. Hyundai’s refusal to honor #20V-746 violates safety obligations. Please investigate Hyundai’s denial, confirm if the Knock Sensor Detection System was installed, and clarify if a rebuilt title excludes eligibility. I seek engine replacement per the recall or a clear explanation. This issue has caused significant financial and safety concerns, and I urge swift action. Contact me at [XXX]or [XXX] Sincerely, [XXX] [XXX] . INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated that the engine and oil lights illuminated whenever the brake pedal was depressed. The vehicle was taken to the local dealer where it was diagnosed and determined that the cause of the failure was due to the engine. The dealer informed the contact that the pistons were not covered, and the engine was consuming an excessive amount of oil. The dealer instructed the contact to continue to drive for 1,000 miles and come back to the dealer for an evaluation. The vehicle was not repaired. The manufacturer was not contacted. The failure mileage was approximately 77,000.

Mileage: 77,000

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated that while attempting to make a left turn after the vehicle was idling, the vehicle suddenly lost motive power and became inoperable. There were no warning lights illuminated. The vehicle was towed to the dealer, who determined that the engine had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure and opened a case. The manufacturer decided not to deny the claim for assistance with the engine replacement. The failure mileage was approximately 80,000.

Mileage: 80,000

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated that while her husband driving at an undisclosed speed, the vehicle inadvertently lost motive power. The driver was unable to pull over to the shoulder of the roadway. The vehicle failed to restart. There was no warning light illuminated. The vehicle was towed to the dealer, who diagnosed a failure with the engine. 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.

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated while driving, the vehicle failed to exceed 60 MPH. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed that the knock sensor was defective. The vehicle was then towed to the dealer, where the engine was replaced; however, the failure recurred, and the vehicle failed to exceed 50 MPH. The vehicle was towed to the dealer, where the knock sensor was replaced; however, the failure recurred while driving. The contact stated that while driving at various speeds and depressing the accelerator pedal, the vehicle hesitated to respond and was sluggish. The vehicle was towed to the dealer, where the knock sensor was replaced; however, the failure persisted, and the vehicle remained at the dealer for 3 months. The contact followed up with the dealer, and the dealer informed the contact that additional diagnostic tests was needed to determine the cause of the failure. The vehicle was not repaired. The manufacturer was notified of the failure and a case was opened. The failure mileage was approximately 110,000.

Mileage: 110,000

See attached document for complaint

The contact's mother owns a 2016 Hyundai Santa Fe Sport. The contact stated that on several occasions while driving at various speeds, the RPM’s decreased and the vehicle lost motive power. The contact stated there was a clicking sound coming from the engine compartment. The check engine warning light illuminated. The vehicle was steered to the side of the roadway. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 150,000.

Mileage: 150,000

Engine caught fire while driving. Vehicle is a total loss as fire department did not arrive for 20 min. Currently at a Copart yard in Gainesville, ga. Lucky I was on a rural road and my dog and I were able to get out of car. Only injury is cough that has not gone away after 4 weeks. No warning lights, but did smell what seemed like burning brake fluid prior to fire. Both Hyundai and Farmers insurance have inspected the car. Of note is that Hyundai replaced the engine at around 60k miles due to engine oiling issues.

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated that while driving at a slow speed, the engine seized. The check engine warning light was illuminated. The vehicle was towed to the local dealer. The vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 70,000.

Mileage: 70,000

This Hyundai had the motor replaced with a Hyundai recall... they did not replace the one-time use fuel line that HAS to be replaced when removed. Started leaking fuel out of that line. while I was driving the fuel from the line caught the exhaust on fire and within seconds had flames engulf the car.

The contact's granddaughter owns a 2016 Hyundai Santa Fe Sport. The contact stated while the owner was driving at an unknown speed, the vehicle began to make an abnormal noise, and then the vehicle stalled. The contact stated no warning light was illuminated. The vehicle was not drivable. The owner towed the vehicle to an independent mechanic and was informed that the engine needed to be replaced. The vehicle was not repaired. The owner towed the vehicle to the local dealer, where it was diagnosed with needing the engine to be replaced. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 105,000.

Mileage: 105,000

The contact owns a 2016 Hyundai Sante Fe. The contact stated that after she purchased the vehicle while driving, she rear-ended another vehicle. The vehicle was towed to the dealer where the engine was replaced however, the contact stated that two to three hours later while driving, the RPM’s failed to increase over number two and the engine failed to engage at 45 MPH. The contact then stated that while driving or idling, she heard a rattling noise in the engine, and the check engine warning light was illuminated. The vehicle was towed to an independent mechanic where it was diagnosed that the fuel pressure sensor regulator and the camshaft timing belt failed. The contact then stated that the vehicle was taken back to the dealer where it was diagnosed that two head gaskets failed and the engine needed to be replaced. The manufacturer was notified of the failure however, the contact stated that no warranty information was provided and was unable to contact the manufacturer. The failure mileage was approximately 172,000.

Mileage: 172,000

Car was stolen.Car was send to body shop for repairs.Car was started at body shop after battery was replaced.Car was driven out of shop after repairs.After going less than 1000feet car shut down.Tried to start Hyundia and smoke poured out from up hood.It looked as if car was going to burst into flames.I did not raise hood and smoke died down.Wrecker returned car to body shop.They checked car and engine was completely locked up.Geico sented car to Thornton Road Hyundai Lithia Springs,Georgia for engine replacement.

The contact owns a 2016 Hyundai Santa Fe Sport. The contact stated while driving approximately 35 MPH, the vehicle inadvertently stalled. The contact stated that the check engine, oil, and battery warning lights were illuminated. The contact was able to pull over and had the vehicle towed to a local mechanic where it was not diagnosed or repaired. The manufacturer was informed of the failure and informed the contact that the repair was not covered. The failure mileage was approximately 133,000.

Mileage: 133,000

VEHICLE CAUGHT FIRE SPONTANEOUSLY AT A PARKING LOT. CAR WAS JUST SERVICED AND INSPECTED A MONTH PRIOR AT THE HYUNDAI DEALER WHERE I PURCHASED IT AND HAD NO PROBLEMS REPORTED. CAR WAS PARKED AT THE TIME OF THE INCIDENT. FROM THE INITIAL REPORT FROM THE FIRE DEPARTMENT THE CAUSE OF THE FIRE WAS A MECHANICAL ISSUE. THE VEHICLE WAS A TOTAL LOSS.

Mileage: 48,000

TOOK CAR IN 1 MONTH AGO FOR SERVICE CAMPAIGN (SOFTWARE UPDATE) 2016 SANTA FE SPORT 83,000 MILES. WHILE DRIVING ON FREEWAY YESTERDAY ENGINE LIGHT STARTED FLASHING AND CAR WENT IN TO 'SAFE MODE' WAS ABLE TO GO ABOUT 1/2 MILE BEFORE IT COMPLETELY STOPPED.. HAD IT TOWED TO DEALERSHIP WAS INFORMED TODAY THE ENGINE FAILED. WAITING FOR APPROVAL FROM HYUNDAI FOR NEW ENGINE. I'M COMPLETELY STUCK IN THIS VEHICLE NOW. NO ONE WILL PAY WHAT IS OWED AND I WILL LOSE TRADING IT IN.

Mileage: 83,000

TL* THE CONTACT OWNS A 2016 HYUNDAI SANTA FE SPORT. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE CHECK ENGINE LIGHT HAD ILLUMINATED AND THE VEHICLE FAILED TO ACCELERATE PROPERLY. THE VEHICLE WAS TAKEN TO THE DEALER KEFFER HYUNDAI ( 9010 EAST INDEPENDENCE BLVD, MATHEWS, NC) WHO DIAGNOSED THAT AN ENGINE HARNESS WAS FAULTY AND NEEDED TO BE REPLACED. THE HARNESS WAS REPLACED BUT THE FAILURE CONTINUED TO OCCUR. THE VEHICLE WAS TAKEN BACK TO THE SAME DEALER WHO DIAGNOSED THAT THE NOX SENSOR WAS FAULTY AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT YET REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 32,000.

Mileage: 32,000

TL* THE CONTACT OWNS A 2016 HYUNDAI SANTA FE SPORT. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE VIBRATED INTERMITTENTLY WITHOUT WARNING. THE CONTACT STATED THAT THE FAILURE OCCURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO COASTAL HYUNDAI (915 W NEW HAVEN AVE, MELBOURNE, FL 32901) WHERE IT WAS DETERMINED THAT THE VIBRATION WAS NORMAL. THE MANUFACTURER WAS NOTIFIED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 33,000.

Mileage: 33,000