What 194 owners told NHTSA about the 2020 Hyundai Santa Fe Phev

Unknown

NHTSA ODI 11745371

I took it to Hyundai Dealership in November 2025 and did the Service Campaign 9C2 and TSB 25-01-087H software update. Since that happened my engine is jumpy and I have taken it back to dealer and they can't find anything. Several people with this issue have been found since on several forums after having the update. One said the dealer knows about the issue and so does Hyundai, but when I ask they know nothing.

NHTSA ODI 11743466

The contact owns a 2020 Hyundai Santa Fe. The contact stated that he received an unknown service campaign from the manufacturer indicating that a software update for emissions was needed. The vehicle was taken to a dealer where an ECU update was completed and an NP001-SC9C2 was installed for the engine and transmission. The contact stated that when his wife drove the vehicle home from the dealer, she noticed that something was wrong with the vehicle but did not specify the failures. The contact stated that the next day, while driving at an undisclosed speed, the vehicle hesitated and shifted improperly, and while depressing the brake, the vehicle accelerated forward. The contact stated that the failure persisted and became more prevalent in the morning after sitting overnight. The vehicle was then taken to the same dealer where a shift engine value reset, transmission value reset, shift adaptations were made (Part number 95447-6G200). The vehicle was repaired, but the failure reoccurred the next morning and has persisted every morning thereafter. The manufacturer was notified of the failure and a complaint was filed. The failure mileage was approximately 25,051.

NHTSA ODI 11740021

I took my car in for the EVM engine update. Since then whenever it starts it is jumpy. The rpm rev more than they should. It’s very concerning that it will rev and won’t stop and I could possibly hit someone. I took it back to the dealer and they called the timeline and they told them to do another update. They did and it is still like that. Was never like that before. I have connected with several people that have had the same thing happen. I will gave to take it in again and leave it which is a major inconvenience

NHTSA ODI 11735383

I was driving out of the parking garage at work and happened to catch the oil light flicker on and then go off. I immediately drove it to an auto shop where I told them what happened. They looked at the dipstick and there was no oil showing on the dipstick. If I had just written the light off as an oddity I would have driven the car home from work (around 20 miles) and the engine could have stalled at 60mph creating a safety hazard. I have the oil changed regularly (about every 5,000 miles) and have my receipts. My car has around 80,000 miles in it and I’m the original owner. The auto shop said that I would need to take it to the dealership for an oil consumption test. I called and scheduled the appointment immediately and am in the process of having the test completed. The dealership noted a TSB for the issue on the write up and based on my research online this is not an unusual problem. Why have owners not been made aware of this issue? I don’t feel safe driving my car and am frustrated that this seems to be a known issue. There was no oil on the dipstick, no indicator that stayed on indicating an issue.

NHTSA ODI 11733709

We purchased a used 2020 Hyundai Santa Fe with approximately 105,000 miles. The vehicle has had regular routine maintenance and oil changes. Around 107,000 miles, the check engine light came on and the vehicle simultaneously started running rough. It was diagnosed with a failed valve on the #3 cylinder and now needs a total engine replacement. This issue also coincided with excess oil consumption. Despite having an oil change fewer than 2000 miles earlier, the oil was almost completely gone from the engine despite not having any leaks present. This goes well beyond normal wear and tear and is indicative of a defect/design flaw.

NHTSA ODI 11732776

The vehicle (2020 Hyundai Santa Fe, 2.0T, ~88,500 miles) experienced a sudden engine failure with no warning signs—no oil light, knocking, or overheating. After sitting overnight, the vehicle would not start and was later diagnosed by an independent repair facility as having a seized engine requiring replacement. The failure was unexpected and creates a potential safety risk, as it could have resulted in a loss of power while driving. The manufacturer has been notified but denied warranty assistance due to lack of maintenance documentation. The vehicle is currently available for inspection.

NHTSA ODI 11732577

Around Feb 15, 2026, at ~85,000 miles, the oil pressure warning light began illuminating at idle and extinguishing above idle speed. The vehicle had also been experiencing intermittent hard starts and occasional shuddering at idle — symptoms too subtle for a typical owner to connect to imminent engine failure. An independent mechanic performed a manual oil pressure test: 4 PSI (Hyundai minimum spec is 13 PSI). The authorized dealer confirmed 6 PSI and found metal shavings in the oil pan — the signature of connecting rod bearing wear documented in Theta II GDI engine failures. Dealer recommended full engine replacement ($8,500). Vehicle has been inoperable at the dealer since Feb 19, 2026. SAFETY CONCERN: At 4 PSI with metal debris in the oil system, this engine was at imminent risk of catastrophic seizure. I avoided highway driving after the warning appeared (max 50 mph, city streets only). Had the engine seized at highway speed, loss of power steering and brake vacuum assist would have created serious crash risk. The symptom profile — warning only at idle, clearing at speed, no knocking, no check engine light — is the pattern that puts less-vigilant drivers at risk of seizure at highway speed with no warning. KNOWN DEFECT: The 2.4L G4KJ Theta II GDI is identical to the engine subject to a $210M NHTSA civil penalty (2020), multiple recalls, and a ~$1.3B class action settlement extending lifetime warranties through MY 2019. The 2020 uses the same engine but was excluded. My failure mode is textbook Theta II. Hyundai Service Campaign 9C2 (ECU update for 2019-2020 Theta II, issued Nov 2025) was incomplete on this vehicle — I was never notified. Completed after the engine had already failed. Manufacturer denied coverage (Case #XXX). BBB AUTO LINE claim #XXX filed Apr 16, 2026. No crash. No injuries. No fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11731527

I was driving on the road and all of the sudden my car went limp and would only move 45 miles per hour. I took it to the dealer which I have lifetime powertran on my car. It has been there for over a month at the dealer. They asked me to provide all oil changes,services, and registrations. I did that and then fidelity asked them to tear down the engine again to see if I had carbon build up. Then after the dealer did that they ask the dealer to tear the motor down even further to see if the exhaust valve was bad and if it was bad they would not replace my motor. My car consumed so much oil that I was changing my oil so often. I have been renting a car just to get back and forth to work. In my contract it says that the exhaust valve is covered under my lifetime powertran. I feel like hyundai and fidelity are giving me the run around. I took very good care of my car and I have shown that. Hyundai has had alot of problem with there motors with the oil consumption and motors just going limp. I feel I will never buy a hyundai again. I am losing money everyday because of the dealer and fidelity. I need the motor replaced and it was no abuse on my part I took care of my car. I want fidelity to tell me how I abuse the exhaust valve. I did my oil changes and took care of my car. I am still paying on my Hyundai and can't afford another car. I have alot of medical bills that I pay. Any help would be great. Sincerely [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11720704

On the morning of February 20 2026 at around 6:35am. I was on my way to work when the engine light started flashing and the speed started to decrease. I was traveling on a major highway in heavy rain with a lot of traffic. I had to put on my hazard lights and quickly pull off the road. The code given is P1326 which has to do with the engine and wiring harness. I just purchased the vehicle on Jan. 17 2026. The Carfax stated no open recalls.

NHTSA ODI 11719921

Our vehicle has encountered a catastrophic engine failure (burnt valves) due to a known and ongoing issue with the piston rings install in this engine.

NHTSA ODI 11720024

HI! Leaking valve cover gasket which damages spark plugs, ignition coils and fuel injector. Defective High Pressure Fuel Pump and fuel injector causing fuel to spray into engine and into engine oil. Large amount of fuel found in oil pan when oil changed. Complaint filed with Hyuandia, no response at this time. Thank you, [XXX] . INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11719636

While driving, the engine catastrophically failed without warning, causing an immediate loss of power-assisted braking and steering. The failure occurred while traveling downhill. I was unable to slow or control the vehicle properly and was forced to proceed through a school bus’s flashing lights to avoid a potentially catastrophic collision, resulting in a traffic citation. My son was in the vehicle at the time. A sudden loss of engine power, braking assist, and steering assist while driving presents a serious safety defect. Vehicle was towed to Fred Beans Hyundai in Doylestown where it has been confirmed engine failure. This failure happened immediately and without warning.

NHTSA ODI 11716098

Excessive oil burn off. Oil is getting into the cylinder, causing scorching. This causing engine failure.

NHTSA ODI 11711761

Oil drain plug seal leaking, can’t tighten the bolt with the required torque setting to keep it from leaking.

NHTSA ODI 11708520

After 110,000, the engine started using oil and it began to knock. According to the history of these engines, it will lead to engine failure. They have a record of being a lemon engine and there is not a engine of this type that this does not happen. The engine needs to recalled and replaced, They are the Theda II GDI series of 2.0L and 2.4L four-cylinder engines from Hyundai/Kia.

NHTSA ODI 11707497

2020 SantaFe Limited AWD with ~81200 miles. This is the 3rd or 4th time the P07410 code pops up with the Engine Check light. Hyundai said they found no issues and cleared the code, again. There was once when the code came up and it cleared itself after 50 miles. Not sure exactly what the cause is and Hyundai is saying "there is nothing wrong". Most recent occurrence Sept.4.2025.

NHTSA ODI 11706847

2020 Hyundai SantaFe Limited AWD ... burning excessive oil. This only was noticed because the low oil light intermittently started coming on, and has only started happening in the last few months. low oil indicator flashing - 4QT low, went for an immediate oil change 78788 miles - oil changed 80252 miles - low oil - added 1QT 80628 miles - low oil - added 1QT 81376 miles - oil changed 81999 miles - low oil - added 1QT 82755 miles - low oil - added 2QT These are the most recent events since we started logging it.

NHTSA ODI 11706851

Excessive oil consumption under warranty, . Hyundai says its normal consumption within 1,000 miles. engine its doing stalls now.

NHTSA ODI 11706311

My engine has been sucking up oil since the day I bought it. Once I hit 100k miles it started sucking up oil faster than the recommended oil changes. I was driving home two weeks ago. I went to get in a major highway and she would not go past 35 mph. I went to trade it in and was told it needs a new engine and a new turbo. This is a known problem and Hyundai will not fix it. This car is not even 4 years old. I got it in April 2021

NHTSA ODI 11705956

I had been driving about 1.5 hours when I exited the Interstate and the car engine shut off at a traffic light. When I shifted the car into park and tried to restart the car, smoke filled the cabin. Unbeknownst to me, an oil leak occurred while driving. No warning lights or other indicators that anything was awry. I had the vehicle towed to the nearest Hyundai dealer. Though the suv is under warranty, they say the oil leak was caused by improper oil plug installation at the last oil change. The oil leak caused the motor to seize and the resulting damage is in excess of $10,000. Hyundai says the warranty won't cover this as it is a service issue. Jiffy Lube says their technician did nothing incorrect and they won't take responsibility for the repairs.

NHTSA ODI 11703389

Excessive oil consumption. Mechanic who changed oil said oil level was too low and he could find no leaks. He said this is a known Hyundai problem. The dealer acknowledged this. There was no warning light saying the oil was low. It was discovered during a routine oil change.

NHTSA ODI 11703237

I had my oil changed at a reputable service center November 19, 2025 and the mechanic said my oil drip pan and plug needed to be replaced in the next few months because they were showing wear and could fail. He asked if I knew about a pending lawsuit against Hyundai concerning these items causing major issues. I said I was unaware, so I researched it. It seems to be legit. During my research there were multiple reports that many had oil leaking problems and some owners reported that the vehicle completely stopped running. That is especially dangerous driving on an Interstate. I was quoted about $350.00 to replace the pan and plug but I was told to contact the local dealership to see if they would replace it. They wanted $215.00 for a diagnostic plus parts and labor. That is quite a chunk of money for a drip pan and plug.

NHTSA ODI 11702997

The contact owned a 2020 Hyundai Santa Fe. The contact stated that while driving 40 MPH onto the ramp, the vehicle failed to accelerate as intended while depressing the accelerator pedal. The contact was able to pull over to the side of the road. The vehicle stalled and shut off, and the contact was unable to restart the vehicle. The contact was calling for Roadside Assistance and noticed white smoke coming from under the hood. The stated that the smoke then turned dark brown and then black, and then flames appeared under the hood. The contact grabbed several things of value and exited the vehicle and started running. The vehicle was engulfed in flames, and the EDR was destroyed. The contact sustained minor scratches after falling while running away from the vehicle. No medical attention was sought. The Police and Fire Department were called to the scene. The contact stated that a Police report was not filed due to the incident not being related to a crash. The vehicle was towed to a tow yard. The local dealer where the vehicle was purchased was contacted; however, no assistance was provided. The manufacturer was not notified of the failure. The contact stated that the vehicle had been purchased two months prior to catching on fire. The vehicle was inspected by the Insurance provider and declared a total loss. Upon further investigation, the contact related the failure to NHTSA Campaign Number: 23V181000 (TRAILER HITCHES); however, the VIN was not included. The failure mileage was approximately 94,400.

NHTSA ODI 11701574

The contact owns a 2020 Hyundai Santa Fe. The contact stated that while driving approximately 40 MPH, the vehicle started shaking and lost power. The check engine warning light was illuminated. The vehicle was restarted immediately. The vehicle was taken to a dealer, where it was diagnosed and determined that the engine had an air leak with the fuel. The contact added that the leak was stopped after an undisclosed repair, but the failure reoccurred a day later. The vehicle was taken to the same dealer however, the failure could not be duplicated. The vehicle was then taken to the same dealer and was diagnosed and determined that the throttle body needed to be replaced. The vehicle was repaired, but the failure reoccurred two days later. The manufacturer was notified of the failure. The failure mileage was approximately 72,700.

NHTSA ODI 11699220