Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. This bulletin provides instructions for updating the Engine Control Module (ECM) to address this condition.
full bulletin at NHTSA ↗2019 Hyundai Santa Fe engine problems
severe 42 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
42
Recalls
0
Avg fix
$3,100
4fires
When does it fail?
Of the 42 engine complaints filed for the 2019 Hyundai Santa Fe, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 42 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Engine accounts for 22% of all owner complaints filed against this vehicle, across 10 categories tracked.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Certain Santa Fe (TMA), Santa Fe Sport (AN), Sonata (LFA), and Tucson (TL) vehicles equipped with Theta II engines may exhibit elevated engine-out emissions. The California Air Resources Board has determined that these vehicles may be releasing air pollutants which exceed Federal and California standards.
full bulletin at NHTSA ↗Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.
full bulletin at NHTSA ↗Following completion of Service Campaign 9C2 (Theta II Emissions Improvement), certain vehicles may exhibit a brief hesitation or rough shifting condition during cold start operation. If present, this condition is expected to occur only within approximately the first 1-3 minutes after engine start, while the catalyst is reaching its normal operating temperature.
full bulletin at NHTSA ↗Certain 2019 – 2020 model year Santa Fe, 2017 – 2018 model year Santa Fe Sport, 2015 – 2019 model year Sonata, and 2018 – 2021 model year Tucson vehicles may exhibit elevated engine-out emissions. Hyundai is conducting a service campaign to update the Engine Control Module (ECM) Software for vehicles equipped with the (2.4 GDI) Theta II engine to improve engine combustion and fuel trim adaptations.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Engine problems dominate complaints on 2019 Santa Fe models, with two core patterns emerging. The first is excessive oil consumption: owners describe adding a quart of oil weekly or every 3,000 miles despite recent changes, with fuel contamination detected at 3.3% versus the 2% industry norm. One owner at 1,600 miles already had fuel in the oil. By 85,000–90,000 miles, many report engine collapse from bearing wear caused by running dry, requiring full replacement.
The second pattern is intermittent stalling at traffic lights. The Auto Start/Stop feature shuts the engine off, then fails to restart; owners push the start button 10+ times or wait 20 minutes for a restart. Dealers cannot reproduce the issue during test drives and diagnostics show no codes. In parallel, misfire in cylinder 3 is reported multiple times—one owner's spark plug looked brand new while others showed wear, a diagnostic red flag. Knock sensor faults recur despite repeated dealer replacement (at 14K, 39K, and 80K miles on one vehicle).
Catastrophic failures are documented: engines seizing mid-highway after oil loss, burnt valves at 102,000 miles, and at least two fires (one post-turbo repair, one with wiring-harness involvement). One owner had a prior Hyundai catch fire, bought a new Santa Fe, and discovered it carried the same recall. Dealers initially misdiagnose serious problems as coil or spark plug issues, only recognizing valve or piston damage after scope inspection—by which time the owner is out of warranty at 100,000 miles despite complaints starting thousands of miles earlier.
Same Hyundai Santa Fe engine reports on nearby years: 2016 · 2017 · 2018 · 2020 · 2021
Failure modes owners describe
Excessive Oil Consumption / Burning
Owners report the engine burns or consumes oil at abnormally high rates, requiring oil top-ups every 1-2 weeks or every 3,000 miles or fewer despite regular oil changes. Fuel dilution in the oil has been documented at over 3% at low mileage. This leads to low or empty oil levels between services, risking bearing and piston damage.
When: Starts between 85,000–90,000 miles on some vehicles; begins within weeks/months on others regardless of mileage. One owner reported at 1,600 miles.
Symptoms owners cite: Oil level drops to empty or near-empty 1,000–3,000 miles after oil change; Burning smell during acceleration; Check engine light illumination; Engine shaking and stalling after oil depletion; Engine restart failures due to low oil pressure; Fuel odor or fuel in oil (3.3% recorded vs. normal <2%)
Codes mentioned: P0300 (multiple cylinder misfire), P0401 (EGR flow), Oxygen sensor malfunction codes
Repairs/costs cited: Oil pan replacement, hose replacement, eventual full engine replacement required. Costs cited: $11,000 for used engine; dealership oil consumption test required before coverage determination. Owners report dealers overfill oil during tests to invalidate results.
Recalls/TSBs owners mention: Class-action lawsuit against Hyundai for Theta II engine piston and valve issues; some owners report manufacturer offers engine replacement under warranty at or before 100,000 miles if documented; others denied coverage after warranty expiration. Hyundai recommends shorter oil change intervals (7,500 miles instead of standard 10,000).
Engine Stalling / Loss of Power at Stops
The engine shuts off or loses power unexpectedly while stopped at red lights, stop signs, or during low-speed driving. The Auto Start/Stop feature intermittently fails to restart the engine, leaving the vehicle immobilized. Multiple restart attempts or extended waiting periods (10–20 minutes) are required.
When: Occurs throughout vehicle life; documented at 16,000 miles to 126,000 miles. First episodes may begin within days of purchase (used examples) or appear suddenly.
Symptoms owners cite: Engine shuts off completely at traffic lights or stop signs; Engine stalls during deceleration or braking; Engine will not restart with Start/Stop button; multiple push attempts required (10+); Message on dashboard claiming vehicle is already running when it is not; All warning lights flash during stall event; Loss of brake power when engine stalls; Vehicle lurches or jerks during loss-of-power event
Codes mentioned: Check engine light (generic; specific codes often unclear in reports), Oxygen sensor malfunction (P0171, P0174 implied)
Repairs/costs cited: Dealers unable to replicate failure during test drives (77 miles reported). Some owners cite coil or spark plug replacement; one owner replaced coil 3 without resolution. Oxygen sensor and spark plug replacement attempted but ineffective in some cases. No permanent repairs documented.
Recalls/TSBs owners mention: Hyundai provided case numbers but referred owners back to dealers. No recalls specific to this failure are documented in these narratives. One owner was told dealers had no known cause.
Engine Misfire / Single Cylinder Failure
The third cylinder misfires or fails to fire, causing rough acceleration, bucking, and hesitation. A spark plug in the affected cylinder often appears unworn while others show normal wear, or coil packs degrade. Fuel-injection issues suspected but not confirmed.
When: After 30,000+ miles; one owner began experiencing misfire immediately after purchase (used vehicle with unknown prior history).
Symptoms owners cite: Car will not accelerate normally from a stop; requires hard acceleration, restart, or shift manipulation to recover; Random misfire events at red lights and stop signs; Engine stumbles or hesitates; Spark plug in third cylinder appears unworn or brand new while others show wear; Check engine light illumination
Codes mentioned: P0303 (Cylinder 3 misfire), P0300 (random misfire)
Repairs/costs cited: Coil 3 replacement and spark plug replacement attempted; tune-up with Heet fuel injector cleaner did not resolve. Second mechanic confirmed misfire in cylinder 3; owner was advised serious dealer diagnosis needed.
Recalls/TSBs owners mention: Dealership unable to diagnose problem in September and October 2022; no recommended action or recall communicated.
Engine Failure (Catastrophic)
The engine fails completely, causing total loss of propulsion and vehicle shutdown while driving at highway speeds. Causes include valve and piston damage, compression loss, burnt valves, floating unseated valves, and internal mechanical failures.
When: After 31,950 miles (oil-related seizure); after 90,000–102,000 miles (valve/piston failure); one fire event at 41,000 miles.
Symptoms owners cite: Engine completely stops during highway driving; Complete loss of acceleration; vehicle cannot exceed 30 mph; Engine shaking violently before shutdown; Check engine light and all warning lights illuminate; Vehicle requires towing; does not restart; White or grayish smoke from engine/cabin; Burning smell prior to failure
Codes mentioned: Low oil pressure warning, Check engine light (generic until tear-down)
Repairs/costs cited: Oil-related seizure at 31,950 miles attributed to missing drain plug and oil leakage (Brake Check oil change facility blamed; no proof of installer fault). Valve/piston failures require full engine rebuild or replacement; costs cited: $11,000+ for used engine or full rebuild. Dealers initially misdiagnosed as spark plug/coil issues until owner provided prior independent shop diagnosis.
Recalls/TSBs owners mention: Hyundai denied warranty claim citing third-party oil-change facility (Brake Check) fault for missing drain plug. Owners with documentation of prior warranty complaints (15,000+ miles before expiration) argued for coverage but were denied. One owner received investigator inspection (fire case) with determination of aftermarket wiring harness as cause; Hyundai offered purchase assistance then withdrew.
Engine Fire
Engine fire originating from defective wiring harness or internal engine fault, destroying the vehicle. At least one owner's previous Hyundai vehicle caught fire, then purchased a new one only to have it also recalled for the same issue, creating distrust and safety concern.
When: One documented at 41,000 miles; another recent (post-turbo replacement in April 2025 for one owner; April 18 for another).
Symptoms owners cite: Thick grayish smoke enters cabin from rear/passenger side without warning; Fire visible under hood; Vehicle completely destroyed by fire
Repairs/costs cited: Vehicle deemed total loss by insurance. One fire occurred while vehicle was parked/off in driveway 15 minutes after shutdown.
Recalls/TSBs owners mention: Hyundai investigator determined wiring harness at trailer hitch was defective (aftermarket installation). Offered initial purchase assistance, then withdrew. One owner reported being forced to buy back a previous fire-damaged vehicle, then purchased new Santa Fe which was recalled for same defect; Hyundai customer service unresponsive.
Spark Plug Deterioration / Fracture
Spark plugs prematurely split, shatter, or fail, with ceramic fragments falling into the engine and damaging pistons. One plug fractured in half with porcelain chips contaminating cylinders.
When: Timing variable; one owner reported after 1 month of ownership post-initial diagnosis misfire.
Symptoms owners cite: Engine skipping on acceleration, especially uphill; Spark plug physically splits or shatters; Ceramic plug fragments visible between pistons; Engine stalls; vehicle disabled
Codes mentioned: Misfire codes (P0300/P0303 implied)
Repairs/costs cited: One fractured spark plug caused piston warping; full engine replacement recommended by dealer with 1-month lead time for new engine.
Recalls/TSBs owners mention: Dealer initially misdiagnosed as incorrect drive mode selection, dismissing owner's mechanical concern. Once vehicle was delivered by rollback for second inspection, full engine replacement was required.
Turbocharger Failure
Turbocharger leaks oil internally or fails prematurely, leading to subsequent engine oil-burning issues after replacement. Turbo light illuminates on dashboard even when feature is not activated.
When: One documented failure in October 2024; another at 90,000 miles.
Symptoms owners cite: Turbo light illuminates without activation; Turbocharger leaks oil; Vehicle fails to accelerate from stoplight; Auto Start/Stop feature fails to restart engine during failure event; Excessive oil burning begins after turbo replacement
Codes mentioned: Turbo activation warning light
Repairs/costs cited: Turbocharger replaced under warranty at dealership. However, excessive oil burning persists after replacement, suggesting underlying engine damage or secondary failure.
Recalls/TSBs owners mention: Turbo replacement covered under warranty. Follow-up oil-burning issue referred back to dealership for separate diagnosis.
Auto Start/Stop Feature Malfunction
The Idle Stop & Go (ISG) automatic start/stop feature disables or stalls the engine unexpectedly without warning. The ISG button fails to toggle properly, and the feature remains on or off contrary to user intent. Engine may not restart after feature triggers shutdown.
When: Occurs throughout vehicle ownership; one owner reported feature suddenly quit working several months after purchase; another at 16,000 miles.
Symptoms owners cite: Engine shuts off mid-highway or at traffic lights via ISG feature without expected restart; ISG button stays off when it should remain on, or stays on when it should reset; Engine will not restart after ISG shutdown despite accelerator pedal depression; Multiple restart attempts required (10+ presses of start button); Brake power lost during ISG-induced stall; Dashboard warning lights flash during malfunction
Codes mentioned: Check engine light (generic)
Repairs/costs cited: Dealers unable to reproduce issue during test drives. No repairs documented as successful. One owner disabled feature manually by turning ISG button off before each drive to prevent stalling.
Recalls/TSBs owners mention: Hyundai investigation reported in media for ISG-related fires and stalls on similar model years; referred to dealer for service. No systematic fix offered in these narratives.
Oil Pan Leak / Crankshaft Seal Leak
Oil pan develops hairline cracks below the drain plug after normal tightening, or crankshaft seal leaks oil. Excessive oil loss occurs without impact or damage.
When: Oil pan crack appeared after normal oil pan plug tightening (timing unclear but vehicle was moved short distance after service). Crankshaft seal leak at 44,700 miles.
Symptoms owners cite: Large fresh oil stain on driveway after oil change; Excessive oil loss without visible engine damage; Oil pressure warning may appear
Repairs/costs cited: Oil pan replacement required, plus new tools and 5 quarts of oil. Cost: full pan replacement out of pocket (not covered under warranty per dealer). Crankshaft seal repair: $2,448 per dealer quote.
Recalls/TSBs owners mention: Crankshaft sensor recall exists (separate from seal issue), but dealer did not address seal under warranty. Oil pan damage deemed owner responsibility despite defective design.
Knock Sensor Failure / ECM Recall
Knock sensor fault repeatedly triggers, requiring multiple dealer visits and part replacement. Vehicle enters limp mode and cannot accelerate above 60 mph when sensor fails.
When: First service 12/3/2019 at 14,242 miles (ECM manufacturer recall); 7/13/2021 at 38,615 miles; 1/7/2025 at 79,882 miles.
Symptoms owners cite: Knock Sensor hardware notification on dashboard; Check engine light illumination; Vehicle limited to 60 mph acceleration; Recurring failures after dealer repair
Codes mentioned: Knock Sensor fault code (specific code not stated)
Repairs/costs cited: Hyundai ECM manufacturer recall performed 12/3/2019; sensor replaced 7/13/2021 and again 1/7/2025. Sensor requires repeated replacement.
Recalls/TSBs owners mention: ECM manufacturer recall (Hyundai); knock sensor repairs covered under warranty at each visit, but repeated failures indicate design defect.
No Compression / Cylinder Failure
One or more cylinders lose compression, causing engine failure and inability to accelerate. Loss of compression occurs without warning at highway speeds.
When: At 100,000+ miles; one documented at 102,000 miles.
Symptoms owners cite: Engine shaking and check engine light illumination while driving; No compression in cylinder 2 (one case); Hole in intake valve (one case); Floating valve not seated properly (one case); Vehicle unable to accelerate
Codes mentioned: Check engine light (generic until scope inspection)
Repairs/costs cited: Bioscope performed at dealership revealed burnt valve and hole in intake valve. Full intake valve replacement and partial engine rebuild required. Owner reported prior warranty complaints over 15,000 miles before expiration; Hyundai initially misdiagnosed as spark plug/coil issue, then demanded payment for repairs.
Recalls/TSBs owners mention: Initial diagnosis: spark plugs and engine coil. Upon scope inspection, burnt valve and damaged piston identified. Warranty denied because failure occurred at 102,000 miles (beyond 100,000-mile coverage), despite owner's documented complaints starting at 87,000 miles.
Cold-Start Engine Rattle / Knock
Engine produces loud rattling or knocking sound during cold startup that subsides after 2–3 seconds. Occurs only when engine is completely cold or after extended idle.
When: At 21,000 miles; ongoing since purchase.
Symptoms owners cite: Loud rattle/knock sound for 2–3 seconds during cold startup; Sound absent once engine warms; Occurs after complete overnight cold soak or multi-hour idle
Repairs/costs cited: No repair documented; owner notes vehicle still operates normally after rattle.
Recalls/TSBs owners mention: No manufacturer response documented; owner suspects knock sensor or internal knock issue but has not pursued warranty service.
Low Oil Pressure
Oil pressure drops to dangerously low levels (5 psi recorded), requiring engine replacement. Occurs without prior warning or performance issues.
When: After 2 years of routine maintenance with no prior issues.
Symptoms owners cite: Oil pressure warning light or low oil pressure condition identified during independent shop inspection; No prior warning lights or sounds before failure
Codes mentioned: Oil pressure warning (specific code not stated)
Repairs/costs cited: Engine replacement required due to low pressure condition.
Recalls/TSBs owners mention: No manufacturer response documented in narrative.
Brake System / Anti-Lock Brake (ABS) Malfunction During Engine Loss-of-Power Events
When engine stalls or loses power, brake pedal engagement fails or brakes do not function properly. Brake Collision Avoidance (BCA) system engages inappropriately. All warning lights illuminate.
When: Occurs concurrent with engine stall events; one at 17 mph, one at 16,000 miles.
Symptoms owners cite: Brake pedal loses engagement during engine stall; BCA system engages unexpectedly; All instrument panel warning lights illuminate; Loss of vehicle steering or control due to loss of power assist
Codes mentioned: BCA system fault (specific code not stated)
Repairs/costs cited: Vehicle reset by turning engine off and on restored brake function. No specific brake repair documented; issue attributed to engine loss-of-power cascade failure.
Recalls/TSBs owners mention: Manufacturer provided case number and loaner vehicle in one instance; unable to duplicate during test drive.
Cabin Pressure / Low-Frequency Vibration Noise
Vehicle produces painful low-frequency pressure wave or vibration in cabin during idling and low-speed driving (under 30 mph). Symptom is consistent and stops only when vehicle is stopped or accelerating hard.
When: Occurs consistently during routine driving.
Symptoms owners cite: Low-frequency cabin pressure sensation (painful to occupants); Occurs during idling and speeds under 30 mph; Stops when vehicle is stopped or accelerating above 30 mph
Repairs/costs cited: No repair documented; may be related to engine knock, miss, or exhaust leak.
Recalls/TSBs owners mention: No manufacturer response documented.
Synthesized from 42 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 4 most recent
Tl* the contact owns a 2019 Hyundai santa fe. While driving 17 MPH, the bca braking system engaged, the vehicle lost power, and all the warning indicators illuminated on the instrument panel. The contact turned the vehicle off and back on, which returned it back to normal. The vehicle was taken to o'brien Hyundai ft myers (2850 colonial blvd, fort myers, fl 33966, (239) 880-8631) where it was…
Oil Pan leaks after an oil change. Oil pan has a hairline crack just below the drain plug after normal tightening of the plug. Excessive oil was found on my driveway. No obvious engine damage, considering the vehicle was only moved from one spot to the other. The dealer stated the oil pan isn't covered under warranty. I simple internet search revealed there was a high number of complaints. It was…
Previous Hyundai vehicle caught fire. At the time the cause was unknown. Was forced by Hyundai to buy back vehicle and purchased a brand new Hyundai vehicle. I was never told that this was a brand wide issue and that the new vehicle I purchased would end up under the same recall that caused previous vehicle to catch fire. I am terrified to drive this vehicle. I contacted Hyundai to explain the…
Vehicle is consuming oil at an exceptionally fast rate. In October 2025, when taken in for an oil change and my complaint of a burning smell upon quick acceleration, the technician documented no oil was found on the dipstick. Just a month later, in November 2025, the oil level was already extremely low, the vehicle was taken back to the dealer, and an oil consumption test is currently being…
Had engine trouble with your 2019 Hyundai Santa Fe?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2019 Hyundai Santa Fe?
It's a meaningful issue. 42 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 10 complaints that reported odometer mileage, most engine failures cluster between 16,000 and 75,000 miles, with the median around 40,000. A quarter of owners report trouble before 16,000; a quarter make it past 75,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2019/Hyundai/Santa Fe.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.