What 108 owners told NHTSA about the 2018 Hyundai Santa Fe Hybrid Hev

In September 2024, my 2018 Hyundai Santa Fe experienced an unexpected engine lock-up while driving, creating an immediate safety hazard. Vehicle lost power, began smoking, and posed a potential fire risk. Fire department responded to prevent the engine from catching fire and had to spray the engine compartment with high-pressure water. Following this incident, vehicle remained in Hyundai’s possession for ~9 months for engine-related repairs. When we picked up the vehicle after the prolonged repair period, front-facing camera had completely stopped functioning. This camera has always worked prior to the engine lock-up and was functioning the day of the incident. This was reported to the dealership, Hyundai Motor America. A case manager (Nemesh) took the case. Very supportive, helpful and provided a thorough process for investigating the situation. However, all the sudden case was assigned a new case manager (Bryan) and the process immediately changed and the claim was denied. Given the timing and circumstances, the camera failure appears to be the result of electrical or component damage caused during the engine failure/fire-prevention event. The dealership also confirmed that no independent inspector ever assessed the vehicle for secondary damage despite my repeated requests. Hyundai later denied responsibility without conducting any physical inspection of the damage. This sequence of events — sudden engine failure, required fire-response intervention, prolonged repair, and subsequent electrical component failure — raises significant concerns about safety and the potential for related electrical or wiring issues caused by the engine incident. I am reporting this because the underlying engine failure and fire-risk conditions represent a serious safety defect, and related component failures may indicate broader issues with damage resulting from these events. Also Hyundai not letting the independent inspector assess gives me great concern something was missed.

NHTSA ODI 11699482

The contact owns a 2018 Hyundai Santa Fe. The contact stated while driving 55 MPH, the vehicle made an abnormal rattling sound and there was fire coming from underneath the hood. There was no warning light illuminated. The contact stated that she immediately veered to the side of the road and exited the vehicle with her son. The contact stated that the fire died out before the fire department arrived. A fire department report was filed. There was no police report filed. There was no injury sustained. The vehicle was towed to the dealer, where it was diagnosed that a fractured rod in the engine block had caused the engine to explode, and the engine needed to be replaced. The dealer also informed the contact the fire had burned the electrical wiring. The vehicle was not repaired. The manufacturer was notified of the failure and offered to cover half of the repair. The failure mileage was approximately 142,732.

NHTSA ODI 11540580

THE CAR BEGAN SHUTTERING WHILE DRIVING DOWN A MAIN STREET (45-50MPH). WHEN WE PULLED OVER WE SMELLED GASOLINE AND BURNING. THE CAR WAS TOWED TO HYUNDAI SERVICE DEPARTMENT. THE SERVICE DEPARTMENT INFORMED MY THE FUEL INJECTORS WERE LEAKING CAUSING A FIRE. THE ARE REPLYING THE FUEL INJECTORS AND TOLD ME IT WOULD BE WISE TO HAVE THEM REPLACE ALL SPARKS PLUGS ($190) WHILE THEY HAD THE ENGINE OPENED UP.

NHTSA ODI 11385531