2016 Hyundai Santa Fe

1. Component/System Failure & Availability: The failed component is the engine's internal Camshaft Variable Valve Timing (CVVT) phaser backing bolt within the 3.3L V6 engine assembly. An internal factory bolt unthreaded, backed out, and physically pierced directly through the upper valve cover. The vehicle and intact failed engine are currently located at an authorized Hyundai dealership service center in [XXX], and remain fully available for immediate physical inspection by federal investigators upon request. 2. Safety Risk: An internal engine bolt unthreading and puncturing through the valve cover creates an extreme safety hazard. A high-velocity metal bolt piercing the engine casing causes immediate engine seizure, sudden loss of motive power at highway speeds, loss of power steering/braking assistance, and massive pressurized oil discharge directly onto red-hot exhaust manifolds, posing a severe risk of sudden catastrophic vehicle fire and multi-vehicle highway collisions. 3. Dealer/Independent Confirmation: Yes. The failure was formally inspected, reproduced, and confirmed by an authorized Hyundai dealership service department. Dealership technicians logged official diagnostic findings under Prior Authorization Case #XXX. 4. Inspection by Manufacturer/Others: Yes. The defect was inspected and escalated directly to Hyundai Motor America (HMA) Corporate Engineering. Corporate engineering officially verified the defect and issued Techline Case #XXX, confirming that an internal factory CVVT backing bolt unthreaded and pierced the valve cover, recommending a full engine replacement. 5. Warning Lights & Prior Symptoms: There were no prior warning lamps, check engine lights, unusual sounds, or advance warning symptoms prior to the failure. The internal hardware failure occurred suddenly and without warning while operating the vehicle at standard operating parameters. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Was driving on a 5 hour car ride at 5pm on August 16th and was going up a hill, the vehicle quickly lost all power and the engine light lit. I was able to pull the car to the side of the road with the momentum that the car already had, but was not able to get the car to a safe space (its about 6 inches from an exit ramp lane), as the car would not drive. Once I got the car to the side of the road, I checked the engine and did not see any excessive heating or anything out of the ordinary. I tried to restart the car and the check engine light is lit and the battery system for the car turns on but the car will not start or try to turn over the engine. The car is currently sitting on the side of the road. My wife and my dog were in the car and we had to quickly move to a safer place away from the 70 MPH traffic. Calling a tow truck tomorrow to take it to a dealership. It was a little scary that the engine power cut out like that without giving an engine light notice in advance or giving time for me to navigate to a more safe space to park it.

Around three weeks ago, we start listening to a knocking noise in the engine. As soon as we heard this noise, we took it to a mechanic near our home and the mechanic told us that there was an internal problem with the engine and we needed to take it to an official Hyundai dealership to solve this problem. Moreover, they told me this is a common problem in Hyundai's cars and the dealership would do it for free. When I took it to the dealership, they told me that I had to replace the chain timing, tensioners, CVV, and many other stuff needed (I'm sending the receipt attached, see "car report 2024.pdf"). It was going to take 10 hours of work. Importantly, this was not covered by the Hyundai warranty or recalls. I bought the car 3 years ago, and both the previous owner and I did the year service to the car. I'm sending all the receipts and CARFAX of the services. Best regards, [XXX] . INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

6 months ago my rod bearing broke in my engine, and I needed a new engine. From the engine recall. With a broken rod bearing you get an oil consumption problem. Oil consumption ruing your cat converter. But they aren’t telling anyone that. 6,000 miles after my new engine, my catalac converter broke. These cars are dangerous. They’re not telling anyone that this is the next problem. They just put you back on the road. Not to mention bad for the environment!

The engine has been reported as failed. It is available for inspection. The safety of the persons in the vehicle and on the road around us were at risk, specifically with the loss of acceleration and power while driving in traffic and merging. Vehicle became unsafe for use for our family to use so we towed it to be evaluated at odometer reading of 97,181. What happened: Vehicle suddenly started making knocking noise. While driving the vehicle a sudden loss of acceleration and inability to accelerate. Engine started to shut off when it had been in park and then placed into gear. Towed vehicle to be assessed by a mechanic. When assessed at a mechanic, the problem was confirmed and it was also noted that oil had been consumed and noted to be loosing oil internally and has burn on dipstick. No oil spots noted in area where car had been parked or leaking oil on engine. Mechanic assessed that there was engine failure and the engine would need to be replaced. Mechanic also ran diagnostic testing and noted to only have active codes for the tire pressure monitor system of C1212 VSS. Diagnostic health report noted to have no issues. Readiness monitors completed with no issues. Diagnostic health report available. Transported vehicle to dealership, where it was inspected and engine issue was confirmed as well as identical health diagnostic report. It was reported that this model was not part of the recall and warranty extension because it is a V6 engine and not a 4 cylinder so manufacturer would not be replacing engine. Due to being the second owners of this vehicle, we do not meet criteria to utilize the 100k mile warranty. All of this has occurred with out an engine warning light turning on the dash or service code being found when computer was interrogated.

I was driving my 2016 Hyundai Santa Fe to my morning job, & noticed a slight trembling of the vehicle initially. Upon approaching a stop sign at a 2 way stop, I noticed that my brakes were not fully engaging so I pumped them a couple times. Immediately my car started accelerating on its own faster and faster until my brakes were not stopping the car at all even with my foot pushing the brake pedal down as far as possible. My foot wasn’t on the accelerator at all. I noticed a pickup truck about to cross the intersection for which I needed to stop. Because I had no control over the car to get it to stop, I slammed the car into park, & it finally stopped just before my car crossed through the intersection. If I had not done that I would’ve been hit directly on my drivers side door by a truck going at least 55 mph. The car revved really high for several seconds after putting the car in park. I drove 10 mph to my work destination, & experienced exactly the same symptoms when I was pulling into my parking spot. As soon as I started braking to come to a stop to park, the car immediately started to accelerate again beyond my control & the ability to engage my brakes, even with my brakes pushed down as far as they would go. Again I slammed the car into park, otherwise my car would’ve run through the side of a barn & a horse stall with a horse and the barn owner inside. I checked to make sure nothing was impeding the movement of my accelerator and braking pedals, and nothing was. No warning lights came on at any time. I am very concerned as I am reading multiple reports of almost identical incidents for other Hyundai Santa Fe owners of a variety of years, & because this issue can’t be reproduced, there is no recall, and no code comes up, owners are not being given a solution or any type of support by Hyundai dealers or the manufacturer itself. I absolutely do not feel safe driving my car for my own safety & the safety of those on the road with me. I was almost killed today.

While driving the car experienced a catastrophic engine failure as well as loss of steering and brakes. Was able to get to the side of the road without injury. This could have resulted in injury or loss of life if the drivetrain would have locked up. The vehicle is at the dealer now, after a 250-mile tow. The dealer said that they have eight cars at their dealership with the same blown engine issue. No warning lights came on prior to the incident.

The engine control module (CPU) failed and at first the car experienced random warning lights thatwhen placed on diagnostic computer, no codes were noted. the next issue was a strong gasoline smell in the cabin. the cpu read this as a faulty fuel pressure regulator. when a second code pull was done it was reported as evaporator canister failure requires changing. The problem was in fact a leaking fuel injector rail and two injectors with defective improperly seated "O" rings. Explainig the gas smell and poor milage. "Ms. G" owns the 2016 santa fe sport with 2.0 GDI motor. There are about 80K miles The intermittent warning lights became and issue during the annual inspection/tag renewal. the DMV inspector saw the traction control, ABS, incline parking brake light and the service engine soon warnings intending to fail the car after the problemwas explained he connected his code reader, and found no codes. About April of 2022, a recal notice was recieved noting especially the 2,0 GDI MOTOR. I explained everything to the Huyndai rep. who informed me that the recall was directly related to the matters we discussed. When i described the final episode where the motor simply shut off. I explained it was towed to my shop ,again placed ot the full spectrum scanner / computer. At this time a complete systems diagnostic was preformed, ignition on - motor not running, including a complete sensor check. It was during this portion of the testing that I noticed that asensor was not reporting any data, or the existance of an oil pressure sensor. Now the ignition switch was then turned on/off the designated number of times and the car was started and a definite knock was detected. Ms. G is by no means uninformed regarding automobiles her parents restored several vintage Jags, And a 1966 330GTS Ferrari.The point being had she had any warning the vehicle was low on oil she would have checked and added as needed. In the end the Hyundai rep assured us the engine replacement was free.