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 ↗2020 Hyundai Santa Fe engine problems
moderate Owners of the 2020 Hyundai Santa Fe have filed 50 NHTSA complaints about the engine at roughly $3,100 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See engine across all vehicles →
Complaints
50
Recalls
0
Avg fix
$3,100
| Model year | engine complaints |
|---|---|
| 2016 Santa Fe | 134 |
| 2017 Santa Fe | 508 |
| 2018 Santa Fe | 42 |
| 2019 Santa Fe | 42 |
| 2020 Santa Fe (this page) | 50 |
| 2021 Santa Fe | 15 |
| 2022 Santa Fe | 23 |
| 2023 Santa Fe | 19 |
| 2024 Santa Fe | 4 |
2fires
When does it fail?
Of the 50 engine complaints filed for the 2020 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 50 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 25% of all owner complaints filed against this vehicle, across 11 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
The 2020 Hyundai Santa Fe's Theta II GDI engine is failing prematurely across a cluster of distinct mechanisms. The most critical pattern is low oil pressure with bearing wear: owners hit oil pressure warnings at idle (4–6 PSI versus 13 PSI spec) with metal shavings in the pan, followed by engine seizure at highway speed without knocking or check-engine codes—a silent failure that kills power steering and brakes mid-drive. Second, the engine burns oil at 1+ quart per 500–1,000 miles despite no visible leaks; dealerships dismiss this as "normal" and refuse warranty coverage despite TSBs and pending litigation. Third, the oil drain plug seal fails catastrophically, causing sudden total oil loss and seizure, sometimes blamed on independent shops—but Hyundai investigation reveals a design defect. Fourth, owners report mysterious check-engine codes (misfires, knock sensor, MAP sensor, torque converter), multiple failed repairs, and ultimate engine failure. One owner documented valve cover gasket failure followed by engine fire eight minutes after dealer pickup. ECU updates introduced uncontrolled high-RPM idle in multiple vehicles. Knock sensor failures occur in rain at highway speed but the 2020 is excluded from the manufacturer's own multi-year recall. Throughout, Hyundai denies warranty claims on the identical engine that triggered $1.3 billion in class-action settlements for MY 2019 and earlier.
Same Hyundai Santa Fe engine reports on nearby years: 2017 · 2018 · 2019 · 2021 · 2022
Failure modes owners describe
Low Oil Pressure / Bearing Wear Failure
Internal bearing failure with metal shavings in oil pan, oil pressure drops to 4-6 PSI well below the 13 PSI Hyundai minimum spec. Owners report oil pressure warning light only at idle, clearing at speed—a pattern that masks imminent catastrophic seizure until loss of power steering and brake vacuum occur at highway speed.
When: 80,000–110,000 miles
Symptoms owners cite: Oil pressure warning light illuminating at idle and extinguishing above idle; Intermittent hard starts; Shuddering at idle; Metal shavings in oil pan (documented by dealer)
Repairs/costs cited: Full engine replacement; cost $8,500 reported. Dealer confirmed 6 PSI and metal debris.
Recalls/TSBs owners mention: Hyundai Service Campaign 9C2 (ECU update for 2019–2020 Theta II, issued Nov 2025) was incomplete on affected vehicles. Owners not notified. Coverage denied by manufacturer. Engine identical to units subject to $210M NHTSA penalty (2020), multiple recalls, and ~$1.3B class action settlement extending lifetime warranties through MY 2019; 2020 model excluded.
Excessive Oil Consumption (Burning)
Engine consuming 1+ quart per 500–1,000 miles with no external leaks detected. Oil levels drop from full to empty or near-empty within 3,000–4,000 miles despite regular 5,000-mile service intervals and manufacturer-recommended synthetic oil. No visible leak from pan or external components.
When: 22,000–110,000 miles; accelerates after 80,000 miles
Symptoms owners cite: Oil level dropping 3.5–4.5 quarts between oil changes; Oil warning light flashing intermittently at idle or during driving; No external leaks visible; Engine shuddering as oil becomes critically low; Check engine light (misfire codes in some cases)
Codes mentioned: P1326 (knock sensor or deep internal failure)
Repairs/costs cited: Dealers often dismiss as 'normal consumption within spec' and deny warranty coverage. TSBs exist but owners report dealership reluctance to conduct $700–$800 oil consumption tests. No parts or repair costs recovered by owners.
Recalls/TSBs owners mention: Lawsuit documented regarding Theta II engine excessive oil consumption. Extended warranty may not cover consumption testing. Hyundai acknowledges issue only after owner insistence; typically denies warranty claims citing lack of maintenance documentation.
Oil Drain Plug / Oil Pan Seal Failure
Oil drain plug comes loose, fails to seal, or washer deteriorates, causing rapid oil loss and engine seizure. Multiple reports of dealers initially blaming independent service shops; subsequent investigation reveals this is a known Hyundai design defect affecting the oil pan and drain-plug assembly.
When: 22,000–107,000 miles; can occur shortly after oil changes
Symptoms owners cite: Sudden large oil leak (puddle under vehicle overnight or while driving); Oil light illuminating during driving; Complete loss of motive power or engine seizure without warning; Oil trail visible on road
Repairs/costs cited: Retightening plug temporarily stops leak; replacement of plug and/or washer provides temporary fix but leak recurs. Full engine replacement required if seizure occurs; cost ~$7,800–$8,500. Service advisors quote $215–$350 for pan/plug preventive replacement.
Recalls/TSBs owners mention: Manufacturers initially deny responsibility, blaming independent service shops for improper installation. Investigation reveals pending lawsuit against Hyundai covering this defect. Warranty denial common; manufacturer claims no responsibility despite design flaw.
Engine Seizure / Catastrophic Failure (Premature)
Engine seized without warning—no preceding knock, no check engine light, no overheating indicator. Diagnosis reveals oil drain plug failure, bearing wear with metal shavings, or combination of excessive oil consumption and inadequate warning system. Vehicle loses all motive power, often at highway speed.
When: 14,500–107,000 miles
Symptoms owners cite: Sudden complete engine shutdown with no restart; No warning lights or audible knock prior to failure; Towing required; vehicle immobilized; Occasionally accompanied by burning smell or smoke
Repairs/costs cited: Full engine replacement required; cost $7,800–$8,500. Vehicle remains inoperable at dealership for weeks to months while diagnosis is completed.
Recalls/TSBs owners mention: Warranty denial common, citing lack of maintenance documentation or claiming no known defect despite matching Theta II pattern. Some cases opened with manufacturer but no assistance provided. No recalls covering 2020 models despite identical engine to recalled prior-year vehicles.
Check Engine Light / Misfire / Power Loss
Check engine light illuminates, often accompanied by sudden loss of motive power, rough running, or limp mode on highway at speed. Diagnostic codes include misfires (P0300-range), torque converter codes, knock sensor codes, and fuel/air system codes. Multiple dealer repairs and TCM updates fail to resolve.
When: 72,700–100,363 miles
Symptoms owners cite: Check engine light flashing or steady; Vehicle enters limp mode (power reduction) at highway speed; Rough idle, hesitation during acceleration; Vehicle stalls or loses power momentarily; Black smoke from exhaust in some cases
Codes mentioned: P0300-range (misfire on cylinders 1, 3), P2565 (MAP sensor), Knock sensor fault, Torque converter damage code
Repairs/costs cited: Spark plugs replaced; knock sensor replaced; throttle body replaced; TCM updated multiple times—failures recur. Ultimately determined to be engine failure (burnt valves, piston ring defect) requiring full engine replacement.
Recalls/TSBs owners mention: No manufacturer assistance documented in these complaints. Owners denied warranty coverage despite repeated dealer repairs.
High Idle / Uncontrolled RPM After ECU/EVM Update
After dealer-performed EVM engine update or other ECU reprogramming, vehicle exhibits uncontrolled RPM revving at startup, with RPM exceeding normal range (5,000+ RPM) before owner releases brake. Defect appears after update was performed; second update does not resolve.
When: Post-update (timing of mileage not specified)
Symptoms owners cite: Engine revs to 5,000+ RPM at startup before throttle input; RPM does not return to normal idle without intervention; Concern of unintended vehicle movement or collision risk; Multiple owners report same issue post-update
Repairs/costs cited: Repeated ECU/EVM updates by dealership failed to resolve. Vehicle requires return visit and extended downtime (owners report major inconvenience).
Recalls/TSBs owners mention: Dealer performed initial EVM engine update and secondary update at manufacturer instruction; no permanent fix provided. Multiple owners connected and report same failure pattern post-update.
Knock Sensor Failure
Knock sensor fails, triggering check engine light and loss of power at highway speed during weather conditions (rain, fog). Multiple reports indicate this has been a recall issue for several years but 2020 Santa Fe remains uncovered despite identical engine to recalled models.
When: Highway driving in adverse weather
Symptoms owners cite: Check engine light illuminates during wet driving conditions; Vehicle slows and jerks at highway speed; Loss of motive power in traffic
Codes mentioned: P1326 (knock sensor)
Repairs/costs cited: Knock sensor replacement attempted; cost not specified. Defect recurs or remains unresolved.
Recalls/TSBs owners mention: Acknowledged as multi-year recall issue for other model years, but 2020 Santa Fe not included despite matching engine platform.
Valve Cover Gasket Leak / Secondary Damage
Valve cover gasket fails, allowing oil to seep onto spark plugs, ignition coils, and fuel injectors. Subsequent dealer repair can trigger secondary failures (engine fire documented in one case). Gasket replacement by dealer does not prevent recurrence.
When: During warranty period
Symptoms owners cite: Oil seeping from valve cover area; Contamination of spark plugs and ignition coils; Engine light and rough running; Fuel found in oil pan (high-pressure fuel pump/injector overfueling)
Repairs/costs cited: Valve cover gasket replacement performed by dealer. In one case, 8 minutes after repair pickup, engine caught fire. High-pressure fuel pump and fuel injectors also implicated as root cause in one complaint.
Recalls/TSBs owners mention: Warranty covers initial gasket replacement, but subsequent failures and secondary damage (fire) not addressed. Root cause (fuel pump, injector design) not acknowledged.
Engine Fire
Vehicle caught fire in engine compartment, destroying vehicle. One case occurred 8 minutes after dealer valve cover gasket repair; fire department report filed indicating fire originated in engine compartment. Another case involved power loss/stalling at low mileage followed by fire after parking.
When: Low mileage (80 miles documented); post-repair (8 minutes after service)
Symptoms owners cite: Smoke from engine hood; Flame visible at passenger window; Strong burning smell prior to fire; Loss of power / stalling before fire in one case
Repairs/costs cited: Vehicle destroyed and towed away. Fire department called; fire report filed.
Recalls/TSBs owners mention: Cause not determined by dealer or independent mechanic in low-mileage case. Manufacturer case opened but no further information provided. Post-service fire not investigated for service-related cause.
Power Loss / Stalling at Idle (Intermittent)
Engine randomly stalls or shuts off without warning during driving—at traffic lights, intersections, or while decelerating. No warning lights, no diagnostic trouble codes retrievable after restart. Problem cannot be reproduced by dealership. Occurs multiple times over weeks.
When: 33,000–88,500 miles
Symptoms owners cite: Engine shuts off suddenly at idle or low speed; No warning lights or check engine code present; Vehicle restarts normally after incident; Occurs in traffic, creating unsafe restart conditions
Repairs/costs cited: No diagnosis or repair performed; dealers state problem cannot be reproduced. Vehicle left unrepaired.
Recalls/TSBs owners mention: No manufacturer involvement documented.
Synthesized from 50 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 9 most recent
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.
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…
Excessive oil consumption under warranty, . Hyundai says its normal consumption within 1,000 miles. engine its doing stalls now.
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…
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.
Vehicle emitted smell of burning turned on check engine light and oil. Warranty service indicates that the fault corresponds to the oil pump, what is a safety hazard. Santa Fe 2020
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…
The contact owns a 2020 Hyundai Santa Fe. The contact stated while driving at higher speeds, the vehicle experienced a momentary loss of motive power. The check engine warning light was illuminated. An unknown local dealer was contacted, but the vehicle was not diagnosed or repaired due to the cost. The contact stated that prior to the failure, the vehicle was taken to Auto Zone where a…
The contact owns a 2020 Hyundai Santa Fe. The contact stated while driving at an undisclosed speed, the check engine warning light flashed on the instrument panel, prompting her to pull into a parking area and contact Roadside Assistance. The vehicle was towed to the dealer, who diagnosed a failure with the knock sensor. The vehicle was repaired, but the failure reoccurred. The vehicle was again…
Had engine trouble with your 2020 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 2020 Hyundai Santa Fe?
It's a documented issue but not catastrophic. 50 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Based on the 50 complaints filed, engine issues most often appear around 61,652 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
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/2020/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.