What 352 owners told NHTSA about the 2012 Hyundai Santa Fe Hev

The engine rod broke creating a big whole in the engine which caused the engine and underneath of car to start on fire. There was a massive recall for this same issue in 2021-2023 for the year car! It is available for inspection! Yes safety was at risk, the car was on fire on the Highway in the middle of rush hour. The problem was confirmed by Progressive and I contact Hyundai. The car was inspected by the police and insurance company. No lights, messages and the car was running fine before the fire!

NHTSA ODI 11722965

My 2012 Hyundai Santa Fe caught fire on October 29, 2025. Prior to this, the dealership completed one recall but left another open. Hyundai denied my claim and refused to provide the inspection report. I am filing this complaint because I believe the incomplete recall may be related and I want NHTSA to review the issue.

NHTSA ODI 11700886

My engine caught on fire in the middle of the night ([XXX] on [XXX]). The fire department was called by my building’s security and they came to put out the fire. The security footage shows that the car engine caught on fire for no apparent reason. The fire department did not identify any foul play or vandalism nor did the security camera footage. Unfortunately since my car has been paid off, I only had liability coverage and could not get the coverage to assess. I had to junk the car. No one was hurt but there was broken glass and some parts around the parking lot due to fire and fire department having to shatter and pry open the engine bay. Please advise if someone can help me in my situation. Also this should be made aware to Hyundai. There was a recall but I was never notified. Nor does any recall history show up for this. See article: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11624650

The contact owns a 2012 Hyundai Santa Fe. The contact stated that while driving at 65 MPH, the check engine warning light illuminated as the vehicle began to shake. The vehicle merged to the shoulder of the roadway and suddenly another vehicle crashed into the entire driver's side of the vehicle while the contact was still in the vehicle. The driver who crashed into the contact did not stop at the scene and continued to drive after the crash. A police report was filed. The contact sustained injuries to her neck and chest area that did not require medical attention. The vehicle failed to start after the incident and was towed to the contact's residence where it currently remained. The vehicle was not diagnosed or repaired. The contact referenced NHTSA Campaign Number: 20V746000 (Engine) and had scheduled an appointment with the dealer prior to the crash. The manufacturer was notified of the failure. The approximate failure mileage was 159,000. The VIN was unavailable.

NHTSA ODI 11470415

The contact owns a 2012 Hyundai Santa Fe. The contact stated while driving at 40-45 MPH, she heard an abnormal ticking sound, and the vehicle inadvertently stalled. The contact stated she saw black smoke coming from underneath the hood of the vehicle. The contact did not recall whether a warning light illuminated. The contact and her husband exited the vehicle. The contact stated as they walked back to the vehicle, they notice that the smoke has stopped. The contact and her husband did not sustain any injuries. A police report was not filed. The vehicle was towed to the dealer who diagnosed that the engine needed to be replaced. The contact stated the vehicle had been waiting to be repaired under NHTSA Campaign Number: 20V746000 (ENGINE) for five months as the parts for recall repair were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure and a case was opened. The vehicle was not repaired. The approximate failure mileage was 70,000.

NHTSA ODI 11439383

On the way to get the recall fixed on this vehicle the car caught fire under the hood and was a total loss. This was a safety hazard to not only my family, but to the public passing by on the road. The fire service had to come put out the massive flames and the car was then towed to the dealer in Athens GA.

NHTSA ODI 11438491

TL* THE CONTACT OWNS A 2012 HYUNDAI SANTA FE. THE CONTACT RECEIVED NHTSA CAMPAIGN NUMBER: 20V746000 (ENGINE). THE CONTACT STATED WHILE STARTING THE VEHICLE THERE WAS AN ABNORMAL ODOR OF SMOKE. THE DETECTED LOCAL DEALER WAS NOT CONTACTED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 144,000. VIN TOOLS CONFIRMS PARTS NOT AVAILABLE.

NHTSA ODI 11403269

WHILE DRIVING ON THE HIGHWAY, WITHOUT ANY WARNING, AN INTERNAL PIECE OF MY ENGINE SHOT A HOLE THROUGH MY ENGINE BLOCK. FIRE STARTED SHOOTING OUT OF MY ENGINE AND THANKFULLY I WAS ABLE TO PULL OVER AND GET OUT WITHOUT THE FIRE GETTING WORSE. THE DRIVER BEHIND ME PULLED OVER AND TOLD ME THAT HE COULD SEE THE FIRE UNDER THE CAR WHILE DRIVING BEHIND ME. HE STOPPED TRAFFIC UNTIL WE CONFIRMED THAT THE FIRE WAS OUT. THE FIRE WAS STILL VISIBLE FROM THE UNDERSIDE OF MY VEHICLE FOR A COUPLE MINUTES BUT IT STOPPED WITHOUT THE WHOLE CAR IGNITING. I REPORTED THIS INCIDENT TO HYUNDAI USA. THEY ASSIGNED A CASE NUMBER TO ME BUT TOLD ME THAT THE HYUNDAI DEALERSHIP, THAT MY CAR WAS TOWED TO, DID NOT SEE EVIDENCE OF FIRE SO THEY DROPPED THE CASE. I TOLD THEM THAT I HAD A WITNESS, THE DRIVER BEHIND ME FROM THE NATIONAL GUARD, AND THEY TOLD ME THAT IT DIDN'T MATTER BECAUSE THEY DIDN'T SEE FIRE DAMAGE AND THEREFORE COULDN'T VALIDATE MY CLAIM REGARDLESS OF THE WITNESS. THE CAR HAD NO CHECK ENGINE LIGHT ON, THE OIL WAS CHANGED REGULARLY, AND THERE WAS NO REASON FOR THE ENGINE TO SUDDENLY, WITHOUT WARNING, BLOW OUT THE BLOCK AND SHOOT FIRE. I CAN ONLY ASSUME THAT THIS WAS A VERY DANGEROUS AND POTENTIALLY DEADLY MANUFACTURING DEFECT. MY ATTEMPTS TO PRESSURE HYUNDAI TO CHECK MY ENGINE AGAIN HAS ONLY LED TO THEM TO TELLING ME THAT IN 30 DAYS THEY COULD GET SOMEONE ELSE TO LOOK AT THE ENGINE TO VALIDATE MY CLAIM.

NHTSA ODI 11363994

WHILE DRIVING THE ENGINE WOULD DECELERATOR THEN CUT OUT. I CAN BE ON THE HIGHWAY GOING SPEED LIMITS OF 70 OR ON A SIDE STREET GOING 30 OR UNDER. IT EVEN HAPPENED WHEN I PULLED OUT OF MY DRIVE WAY AND DROVE DOWN MY STREET (4 HOUSES DOWN) AND GOT TO MY CUL-DE-SAC AND ALL POWER SHUT DOWN. NEIGHBOR HAD TO STOP TO AVOID HITTING ME BECAUSE I WAS ROLLING AND COULD NOT STOP. ALL POWER TO STEERING WHEEL AND BRAKES WOULD BE NON OPERATIONAL. I HAVE TO MANUALLY PULL THE WHEEL TO ONE SIDE TO AVOID TRAFFIC, CAUSING AN ACCIDENT, OR FROM BEING HIT BY HEAD ON TRAFFIC. THE FIRST OCCURRENCE WAS IN FEBRUARY OF 2017 AND THE MOST RECENT WAS JANUARY 18TH ON MY WAY HOME FROM WORK. IT HAS HAPPENED TO US OVER A DOZEN TIMES AND FOUND BLOGS THAT STATE THAT HYUNDAI DENIES THAT THIS IS HAPPENING.

NHTSA ODI 11173180

TL* THE CONTACT OWNS A 2012 HYUNDAI SANTA FE. WHILE DRIVING 55 MPH, THE VEHICLE STALLED AND SMOKE CAME FROM THE ENGINE COMPARTMENT. THE CONTACT ALSO MENTIONED THAT THE ENGINE MADE AN ABNORMAL NOISE. THE VEHICLE WAS TAKEN TO SOUTHTOWNE HYUNDAI (7665 US HWY 85, RIVERDALE, GA 30274, (770) 471-1000) WHERE THE CONTACT WAS INFORMED THAT THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 121,000. *TT CONSUMER STATED CAR IS UNDRIVABLE, ENGINE FAILURE OR SMOKE COMING OUT OF THE TAIL PIPE. IT SHOULD BE RECALLED. *JB

NHTSA ODI 11150343

WHILE DRIVING THE 2012 HYUNDAI SANTA FE TO TENNESSEE FROM ATLANTA, WITH MY WIFE AND DAUGHTER AS PASSENGERS, I FELT A HEAVY BUMP ON THE INTERSTATE, AND WONDERED IF A TIRE HAD GONE FLAT. SHORTLY AFTER THIS, I SAW HEAVY SMOKE IN MY REARVIEW MIRROR, LETTING ME KNOW THAT THERE WAS A PROBLEM WITH MY CAR. A PERSON DRIVING IN A LANE TO MY LEFT TOLD ME THE CAR WAS ON FIRE, SO I PULLED OVER IMMEDIATELY. I GOT MY WIFE AND DAUGHTER OUT OF THE CAR, AND WALKED THEM TO A SAFE DISTANCE ABOUT 150 FEET FROM THE CAR. I HAD THE CAR TOWED TO A REPAIR SHOP. THE MECHANIC TOLD ME THAT A PISTON (OR PISTONS) HAD BLOWN THROUGH THE BOTTOM OF THE ENGINE, AND I WOULD NEED TO REPLACE THE ENTIRE ENGINE. IT WAS TOWED BACK TO MY HOUSE, AND WILL NO LONGER START. THIS WAS THE FINAL FRIDAY IN APRIL 2018. THE VEHICLE WAS IN MOTION, AT A SPEED NEAR 60 MPH, ON I-75 NORTH FROM ATLANTA, DRIVING STRAIGHT AHEAD.

NHTSA ODI 11141534

DRIVING ON INTERSTATE HIGHWAY THE ENGINE HAD A FAILURE AND A ROD WENT THROUGH THE ENGINE BLOCK AND THE OIL DUMP STARTED A FIRE.

NHTSA ODI 11140752

WAS DRIVING ON THE HIGHWAY AND HEARD A RATTLING/CLUNKING, MY RPM'S SHOT UP AND I COULDN'T ACCELERATE PAST 60. THE CHECK ENGINE LIGHT CAME ON AND THEN SHUT OFF BRIEFLY. THEN ALL OF THE LIGHTS ON MY DASHBOARD CAME ON AND I PULLED OVER BUT HAD NO POWER STEERING. ONCE I PULLED OVER THE CAR BEGAN TO SMOKE SO I TURNED IT OFF. I THEN HEARD A LOUD POP AND SAW A THICK BLACK SMOKE COMING FROM THE HOOD AND WITHIN 30 SECONDS THE FRONT OF MY CAR WAS IN FLAMES. IT IS BELIEVED TO BE AN ISSUE WITH THE ENGINE AND THERE IS THE START OF A CLASS ACTION LAW SUIT ON THIS ENGINE.

NHTSA ODI 11139181

TL* THE CONTACT OWNS A 2012 HYUNDAI SANTA FE. WHILE DRIVING 65 MPH, THE CONTACT HEARD AN ABNORMAL NOISE AND NOTICED BLACK SMOKE COMING FROM THE HOOD. THE CONTACT PULLED OVER, LIFTED THE HOOD, AND NOTICED FLAMES. THE CONTACT WAS ABLE TO EXTINGUISH THE FLAMES. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE DEALER (MCGRATH CITY HYUNDAI, 6750 W GRAND AVE, CHICAGO, IL 60707) WAS CONTACTED AND STATED THAT NO OIL WAS GOING TO THE ENGINE. THE MANUFACTURER WAS ALSO CONTACTED AND UNABLE TO ASSIST. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 120,000.

NHTSA ODI 11104590

MILEAGE AROUND 82,000 MILES | ALWAYS HAD ROUTINE, ON TIME, MAINTENANCE | NO ENGINE LIGHT ON (OR ANY OTHERS) | ON A TRIP DRIVING DOWN THE HIGHWAY GOING AROUND 65MPH WITH CRUISE CONTROL SET (2 ADULTS AND 1 CHILD IN THE CAR, NOT TOWING ANYTHING), OUR SUV STARTED MAKING A STRANGE NOISE WHEN ACCELERATING, THEN PROGRESSED TO A CONSISTENT NOISE WHETHER ACCELERATING OR NOT. WE DECIDED WE NEEDED TO STOP IN THE NEXT TOWN (ABOUT 20 MILES AWAY) TO TAKE A LOOK, BUT BEFORE WE COULD REACH THE NEXT TOWN THE CAR WITHOUT WARNING SHUT DOWN, STARTED SMOKING, AND PIECES OF THE CAR FELL FROM BELOW THE CAR. MY HUSBAND RAISED THE HOOD AND NOTICED THE ENGINE WAS ON FIRE, AND QUICKLY PUT IT OUT. WE HAD THE CAR TOWED TO A HYUNDAI DEALERSHIP AND JUST BY RAISING THE HOOD THE MECHANIC KNEW THE ENGINE EXPLODED, AND INFORMED US IT WOULD BE AROUND $6500 FOR A USED ENGINE. FROM THE TIME THE NOISE FIRST STARTED UNTIL THE ENGINE BLEW UP WE DROVE 12 MILES. WE HAVE TRIED CONTACTING HYUNDAI TO NOTIFY THEM OF THE ISSUE, AFTER WAITING ON HOLD FOR 30+MINUTES ALL THEY CAN SAY IS THERE IS NOTHING THEY CAN DO SINCE WE ARE OUT OF WARRANTY, WHEN WE ASK TO SPEAK TO A MANAGER ONE IS NEVER THERE AND THEY PROMISE THAT WILL HAVE THE MANAGER CALL US BACK, BUT WE HAVE NOT RECEIVED A PHONE CALL. AFTER RESEARCHING THIS ISSUE, IT SEEMS WE ARE NOT THE ONLY ONES HAVING ISSUES WITH THE ENGINE. MY HUSBAND USED TO SELL HYUNDAI'S AND KNOWS FOR A FACT THAT THE SANTA FE AND SONATA'S HAVE THE SAME ENGINE - THE 2011-12 SONATA ENGINE HAD A RECALL, WHY DIDN'T THE SANTA FE HAVE A RECALL? THE SANTA FE IS MY SECOND HYUNDAI TO OWN, I WILL NOT BUY ANOTHER DUE TO THE ISSUES WITH MY SANTA FE AND LACK OF CUSTOMER SERVICE. SIDE NOTE, WHY WOULD I SPEND $6500 ON ANOTHER ENGINE, WHEN THERE SEEMS TO BE AN EXPLODING PATTERN.

NHTSA ODI 11044183

TL* THE CONTACT OWNED A 2012 HYUNDAI SANTA FE. WHILE DRIVING APPROXIMATELY 20 MPH, THE CONTACT WAS ALERTED OF FLAMES UNDER THE VEHICLE AS BLACK SMOKE POURED FROM THE ENGINE. THE CONTACT CRASHED INTO A POLE. THE AIR BAGS DEPLOYED. THE CONTACT RECEIVED BRUISES ON THE FACE AND CHEST AND EXPERIENCED TROUBLE BREATHING. MEDICAL ATTENTION WAS RECEIVED. A POLICE REPORT WAS FILED. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE MANUFACTURER WAS NOTIFIED. THE VEHICLE WAS TOWED AND DESTROYED. THE APPROXIMATE FAILURE MILEAGE WAS 70,000.

NHTSA ODI 10861488

WHILE DRIVING AT FREEWAY SPEED, CAR SHUT DOWN UNEXPECTEDLY, AND RESTARTED. DURING INTERIM 20 SECONDS, ATTEMPTED TO PULL VEHICLE TO LEFT SHOULDER AS I WAS DRIVING IN FAR LEFT LANE. I FELT "ENGINE DROP" OR A FEELING WHEREAS THE CAR NO LONGER FELT POWERED, CUE THAT THE ENGINE HAD WENT OFF. POWER STEERING WENT MANUAL ALONG WITH OTHER POWER ASSIST DEVICES LIKE POWER STEERING. ON DIRT SHOULDER OF FREEWAY ATTEMPTING WITH MANUAL BRAKES AND STEERING TO BRING VEHICLE OFF ROADWAY. VEHICLE RESTARTED DURING MANEUVER. STILL MOVING AT SAFE SPEED ATTEMPTED TO MERGE BACK ONTO THE FREEWAY, HAVING NOT YET DECELERATED ENOUGH YET TO CONTINUE TO PULL OVER....CLEAR AND DRY CONDITIONS IN NORTH LA COUNTY. THIS VEHICLE HOWEVER HAS ALWAYS HAD "OVERLY RESPONSIVE" OR "VERY TIGHT" STEERING, FOR LACK OF BETTER TERMINOLOGY. I LEASED THE VEHICLE AND DID NOT FULLY REALIZE, UNTIL SOME TIME PASSED, WHAT THIS 'STEERING CHARACTERISTIC' WOULD MEAN IN THE FUTURE, IN AN EVENT REQUIRING ACCURATE AND RESPONSIVE STEERING COMBINED WITH THE ABILITY TO MAINTAIN CONTROL. THE SUDDEN ENGINE POWER RESUMING, COMBINED WITH, WHAT THIS WRITER WOULD DESCRIBE AS "TIGHT STEERING" TO BEGIN WITH, MADE THE VEHICLE ROLL. THE VEHICLE, WITH WHAT FELT LIKE A "HIGH CENTER OF GRAVITY" ALWAYS FELT LIKE IT WOULD ROLL IF ONE WERE TO HAVE TO MOVE QUICKLY TO AVOID SOMETHING IN THE ROAD FOR EXAMPLE. I DID NOT REALIZE THIS FEATURE DURING MY TEST DRIVE. BEING A LESSEE I WAS OBLIGATED TO KEEP THE VEHICLE FOR 3 YEARS. THE VEHICLE ROLLED SEVERAL TIMES WHILE CROSSING 3 LANES OF AN OCCUPIED NORTHBOUND HIGHWAY 14. A SUDDEN JOLT RESULTED IN A FRACTURE OF L1 VERTEBRAE. DURING ROLL, JACK BECAME UNDONE FROM WHERE IT WAS FACTORY MOUNTED UNDERNEATH LIFT UP COVER, AND HAD NEVER BEEN REMOVED. FLAILING AROUND IN THE VEHICLE NOW WAS THIS HEAVY SCISSOR JACK BOUNCING AROUND IN THE VEHICLE COMPARTMENT WITH ME. I AM GLAD TO BE ALIVE. *TR

NHTSA ODI 10703815

IN STOP AND GO TRAFFIC, I TOOK MY FOOT OFF THE BRAKE TO COAST TOWARDS THE CAR IN FRONT OF ME. THIS PATTERN HAD BEEN GOING ON FOR SEVERAL MILES. I WAS NOT TOUCHING THE ACCELERATOR AND IN FACT, MY FOOT WAS NOT ON THE BRAKE EITHER, AND THE CAR SUDDENLY ACCELERATED FULL THROTTLE. I HAD JUST A COUPLE OF SECONDS TO TRY TO AVOID HITTING THE VEHICLE IN FRONT OF ME. I SWERVED TO THE RIGHT, TOWARDS THE SHOULDER, BUT I HIT THE TRUCK IN FRONT OF ME. I WAS BRAKING THE ENTIRE TIME, BUT IT WAS NOT ENOUGH TO STOP THE SUDDEN UNINTENDED ACCELERATION. MY LEFT BUMPER HIT HIS TRUCK ON THE RIGHT HAND SIDE OF HIS BUMPER. MY RADIATOR WAS DAMAGED AND LEAKED ALL THE FLUID OUT ONTO THE HIGHWAY. THE CAR WAS NOT DRIVABLE BECAUSE OF THE RADIATOR. *TR

NHTSA ODI 10493260

IN STOP AND GO TRAFFIC, I TOOK MY FOOT OFF THE BRAKE TO COAST TOWARDS THE CAR IN FRONT OF ME. THIS PATTERN HAD BEEN GOING ON FOR SEVERAL MILES. I WAS NOT TOUCHING THE ACCELERATOR AND IN FACT, MY FOOT WAS NOT ON THE BRAKE EITHER, AND THE CAR SUDDENLY ACCELERATED FULL THROTTLE. I HAD JUST A COUPLE OF SECONDS TO TRY TO AVOID HITTING THE VEHICLE IN FRONT OF ME. I SWERVED TO THE RIGHT, TOWARDS THE SHOULDER, BUT I HIT THE TRUCK IN FRONT OF ME. I WAS BRAKING THE ENTIRE TIME, BUT IT WAS NOT ENOUGH TO STOP THE SUDDEN UNINTENDED ACCELERATION. MY LEFT BUMPER HIT HIS TRUCK ON THE RIGHT HAND SIDE OF HIS BUMPER. MY RADIATOR WAS DAMAGED AND LEAKED ALL THE FLUID OUT ONTO THE HIGHWAY. THE CAR WAS NOT DRIVABLE BECAUSE OF THE RADIATOR. *TR

NHTSA ODI 10492316