What 235 owners told NHTSA about the 2016 Hyundai Santa Fe Hybrid Hev

WHAT FAILED: The engine — the 3.3L Lambda II GDI V6 (engine family GHYXV03.31XE per the federal emissions label) — failed catastrophically: a connecting rod penetrated the engine block. The failed engine IS available for inspection on request. It has been preserved unrepaired since the failure, the rod penetration of the block is externally visible, and the vehicle is currently at Niagara Hyundai in New York. WHAT HAPPENED / SAFETY RISK: On [XXX], I was driving at approximately 65 miles per hour on [XXX] southbound near Bath, New York, with four occupants aboard, when the engine failed suddenly and without warning — no warning lamps, messages, or symptoms preceded it. The vehicle immediately lost all motive power at highway speed. I was forced off the roadway and through brush and debris to bring the vehicle to a stop. The sudden total loss of power at highway speed created an immediate loss-of-control hazard to my occupants and to surrounding traffic. CONFIRMED BY OTHERS: The tow was dispatched through a 911 emergency call. A New York State Trooper was at the scene and observed the debris trail. The towing company's invoice (T&R Towing and Service, Call #[XXX], [XXX]) records "Break Down," winch recovery, vehicle not drivable, and the tow operator's handwritten condition description: "Motor go Boom." The vehicle is now in the possession of a Hyundai dealership (Niagara Hyundai), and Hyundai Motor America has an open case (#[XXX]); however, Hyundai has refused to inspect or diagnose the engine unless I first pay to repair unrelated damage, so the manufacturer has NOT yet inspected the failure — leaving this safety defect undiagnosed by Hyundai. RELEVANT BACKGROUND: In 2024, Hyundai issued warranty extension TXX8 (15 years / 150,000 miles) for connecting rod bearing failure in this exact engine, acknowledging the failure mode. Mileage at failure was under 100,000 miles. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11743619

Driving on a slight upgrade, lost power and smoke started to come out of the vents and from under the hood. Had no brakes and by the time we were able to drift to a stop, the engine compartment was on fire. There was no warning lights. Witnesses saw fire under the car while we were coming to a stop. The car and all contents were totally consumed. Following some research on NHTSA vin decoder we found that this car has the same engine (GDI THETA II) that has been involved in many fires and is involved in class action suits. Even though this car has the same engine, it was never recalled. That may indicate that there are other cars out there that may have the same problem but have not been informed.

NHTSA ODI 11617604

I was rear-ended and the driver's seat did not maintain it's position and fell into the seat behind it.

NHTSA ODI 11613053

Someone backed out of a parking lot and I crashed into their rear passenger side. Other party at fault but my air bags for 2016 Hyundai Santa Fe Sport did not deploy.

NHTSA ODI 11577547

Had an accident where driver side front of vehicle was hit. The severity of crash resulted in total loss. The driver was hurt and concussed due to her head hitting the side window, driver side. The vehicle was equipped with front side impact and curtain airbags and all failed to deploy. The other vehicle's side curtains were deployed.

NHTSA ODI 11577047

We recently had the car to the local dealership for engine problems. It took over 3 months, but they finally determined that the camshaft was "bent" and they had to remove the engine to replace it, costing almost $5000. We had it back for about 3 months but didn't drive it much since my wife works remotely from home now. My son was driving it on the interstate and the engine threw a rod, spilling oil onto the exhaust, which caught on fire. He managed to pull over and get out of the car and by then another motorist had called 911. There was a firetruck at the exit he had just passed who showed up in just a few minutes and put the fire out before the fuel system caught on fire, thankfully. While I'm glad my son was uninjured, I'm still very upset by this, especially since they just worked on the engine. After some searching on the internet, I have found that this is a very common occurance for this vehicle (and other Hyundais) yet the company is not doing anything about it. I also read that there is a separate class action lawsuit for this particular engine (in addition to the one for the smaller 4 cylinder engines), but I'm afraid it will be settled too late to help us out.

NHTSA ODI 11542917

WE WERE HIT HEAD ON BY A LARGE PICKUP TRUCK. WE SUSTAINED A LOT OF DAMAGE FROM THIS HEAD-ON COLLISION. WE WERE TRAVELING AROUND 10 MILES AN HOUR BUT THE OTHER CAR WAS GOING AT LEAST 20 MILES AN HOUR. THE AIRBAGS NEVER DEPLOYED DESPITE BEING HIT HEAD ON AND SUFFERING A LOT OF DAMAGE UPON IMPACT. WE WERE SLOWING DOWN FOR A STOP SIGN. THE OTHER CAR TURNED INTO OUR LANE AND WAS ACCELERATING TOWARDS US.

NHTSA ODI 11255432

THE CAR WAS AT A COMPLETE STOP IN A DRIVEWAY. THE CAR WAS STILL RUNNING BECAUSE I WAS GETTING OUT OF THE CAR TO GET THE MAIL. I PUT THE CAR IN PARK AND WENT TO GET OUT OF THE VEHICLE. AS I GOT OUT THE VEHICLE STARTED GOING IN REVERSE AND PULLED ME UNDERNEATH THE CAR AND THE VEHICLE RAN OVER ME. I'M NOT SURE IF THE TRANSMISSION SLIPPED OUT OF PARK TO REVERSE ON ITS OWN OR IF THE SHIFTER WASN'T ACTUALLY PLACED IN PARK. I THOUGHT THE VEHICLE COULD SENSE IF NO ONE WAS IN THE DRIVERS SEAT AND AUTOMATICALLY PUT THE CAR INTO PARK OR NEUTRAL. THE HEATED SEATS AND AIRBAG WON'T TURN ON UNLESS IT SENSE WEIGHT IN THE SEAT.

NHTSA ODI 11186984

RECENTLY WE COULD NOT UNDO THE SEATBELT THAT OUR 6 YEAR OLD GRANDSON WAS STRAPPED IN. THE MORE TRIED TO EXTEND IT TO RELEASE THE TENSION THE TIGHTER IT BECAME. MY GRANDSON WAS BEING CRUSHED AND WAS SCREAMING. THE VEHICLE WAS NOT RUNNING AND WAS PARKED IN THE DRIVEWAY. I HAD TO RUN INTO THE GARAGE AND GET A PAIR OF SCISSORS AND CUT THE SEATBELT TO GET HIM OUT. TO REPLACE THE SEATBELT IS GOING TO COST OVER $400 AND THE DEALER WILL NOT PAY FOR IT AS THEY SAID IT WAS OUR FAULT.

NHTSA ODI 11103563

2016 HYUNDAI SANTE FE INVOLVED IN A NEAR HEAD ON COLLISION. COMBINED TOTAL SPEED OF IMPACT APPROXIMATELY 80 MPH. TWO OCCUPANTS BOTH WEARING SEATBELTS AT TIME OF CRASH. DRIVER SIDE AND PASSENGER SIDE AIRBAGS DEPLOYED DURING CRASH. PASSENGER SHOULDER HARNESS FAILED (LOCKING MECHANISM DID NOT LOCK) RESULTING IN PASSENGER HEAD IMPACT WITH WIND SHIELD CAUSING SIGNIFICANT DEFORMATION OF WIND SHIELD AND HEAD INJURY TO THE PASSENGER. LAP BELT RESTRAINT PREVENTED PASSENGER FROM SIGNIFICANTLY WORSE INJURY. PHOTOS ARE AVAILABLE. *TR

NHTSA ODI 10904763