2016 Hyundai Santa Fe: engine knocking or ticking

Filed Jun 11, 2026 · Engine · NY · crash

WHAT FAILED: The engine — the 3.3L Lambda II GDI V6 (engine family GHYXV03.31XE per the federal emissions label) — failed catastrophically: a connecting rod penetrated the engine block. The failed engine IS available for inspection on request. It has been preserved unrepaired since the failure, the rod penetration of the block is externally visible, and the vehicle is currently at Niagara Hyundai in New York. WHAT HAPPENED / SAFETY RISK: On [XXX], I was driving at approximately 65 miles per hour on [XXX] southbound near Bath, New York, with four occupants aboard, when the engine failed suddenly and without warning — no warning lamps, messages, or symptoms preceded it. The vehicle immediately lost all motive power at highway speed. I was forced off the roadway and through brush and debris to bring the vehicle to a stop. The sudden total loss of power at highway speed created an immediate loss-of-control hazard to my occupants and to surrounding traffic. CONFIRMED BY OTHERS: The tow was dispatched through a 911 emergency call. A New York State Trooper was at the scene and observed the debris trail. The towing company's invoice (T&R Towing and Service, Call #[XXX], [XXX]) records "Break Down," winch recovery, vehicle not drivable, and the tow operator's handwritten condition description: "Motor go Boom." The vehicle is now in the possession of a Hyundai dealership (Niagara Hyundai), and Hyundai Motor America has an open case (#[XXX]); however, Hyundai has refused to inspect or diagnose the engine unless I first pay to repair unrelated damage, so the manufacturer has NOT yet inspected the failure — leaving this safety defect undiagnosed by Hyundai. RELEVANT BACKGROUND: In 2024, Hyundai issued warranty extension TXX8 (15 years / 150,000 miles) for connecting rod bearing failure in this exact engine, acknowledging the failure mode. Mileage at failure was under 100,000 miles. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jun 6, 2026 · Engine · GA

I filed a complaint when the first engine seized. It's a miracle we got off the road safely that day. While it was at the dealership, the engine was replaced with a used engine and covered by my extended warranty from Vroom. I believe the cost was approximately $14,000. I was told the engine had around 30,000 miles on it. I've put around 20,000 miles on this engine and the same thing happened again. This time, the engine had been knocking for a few months. When it started knocking, I took it to the dealership because the new extended warranty by Hyundai was in effect and I assumed it would be covered. Immediately, Autonation Hyundai in Savannah, GA said it would not be covered because it was a used engine. I don't understand why when the engine can be traced and the mileage known by the number on the engine. On XXX, my [XXX] granddaughter took her driving test in the vehicle. About 2 hours later, the engine seized with her driving. We were on the same road and it was about the same time of day. Once again, it was a miracle we got off the road safely. I just talked to Hyundai and we'll see what they say. From the stories I've seen, they'll do anything they can to avoid covering these engines and they get away with it. The people who get hurt the most from this are the ones who can least afford it. I'm a [XXX] widow raising my 5 grandchildren by myself and believed I was getting a good vehicle, mainly due to the report by Consumer Reports magazine. Even after the first engine failed and was replaced, I still wasn't in a financial position to get another vehicle and assumed if something happened again, it would be covered under the extended warranty Hyundai was made to provide. Obviously, that means nothing. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Apr 21, 2026 · Engine · PA

Rod bearing failure while driving, engine made a clanking noise. Engine made a loud bang and shut off. It was difficult for the driver to get control of the vehicle and get it to the side of the road. Engine threw the rod and piston through the oil pan causing catastrophic internal damage. The oil had been changed the day prior. The company that changed the oil sent an inspector to evaluate car at the scene. He stated this is a known problem with this engine. He pulled up pictures of other cars that had the same problem, also took pictures of the car oil pan and compared the pictures, they were exactly the same. Car was towed to Hyundai dealership that is refusing to replace the engine.

Filed Mar 19, 2026 · Engine · OH

Beginning about a month ago, I noticed a rattle upon the engine start up that lasted for a 1-2 seconds then stopped and everything sounded normal. I thought it could be b/c of the cold weather. I went in to get a routine oil change on 03/11/2026 and they said the oil looked fine, but it was about a quart low, indicating it was burning some oil somehere. They said to check in in a few months and they would top it up if needed. I asked them about the rattle and they thought is might be from a bad (timing chain tensioner) but said I should get it checked out. I called on Friday 03/13/26 to schedule an appt at my local Hyundai Dealership on 03/17 . The night before(03/16), I was driving my vehicle and suddenly on the road, I heard a loud noise in the engine, and the power shut off, the Engine and oil light came on and I just had enough time to pull off the busy state route. My car would not start or turn over. I had it towed to the dealership and they did determine that it was a "Rod Bearing Failure" that caused the engine to sieze. I provided them evidence of my oil changes which from 10k-93k miles on my car since I have owned it. I have had the oil changed 10 times. They are saying they only allow 8k between oil changes to honor the warranty and have initially denied my claim. The service associate at the dealership said my valvetrain was 'somewhat' dirty, but nothing to where it was the cause for this issue. And since it was the Rod bearing that failed, the exact part that was recalled, he was surprised they were not even offering any good-will offer, to split the cost of the engine replacement. I have reached out to Hyundai Consumer Affairs and am waiting to hear back to see if they will be fair and work with me on this to honor the warranty issue or at least share the cost burden for this "well-known" failure in their engine.

Filed Feb 21, 2026 · AL

The motor began to making a knocking noise and started smoking like a fire was starting. We immediately turned off the vehicle preventing from a full fledge fire. We had children in the car as well which posed a safety concern for them. We had no prior warning lights or issues. It has yet to be inspected by anyone.

Filed Feb 7, 2025 · Engine · NY

This is my 2nd engine on my 2016 Santa Fe Sport. My car has 190,000 miles and had a catastrophic engine failure, it’s been at the dealership for 2 months. Hyundai said my lifetime warranty on my engine is not covered cause I had a misfire in the #4 cylinder with less than 2,000 miles on the spark plugs. Hyundai warranty department only spoke to the dealership directly and had me speak to a case manager (which did nothing, they never even talked to the warranty department only the dealership) So in December I dropped my car off, it took over 2 weeks to take pictures and send them in to Hyundai warranty department, a week later Hyundai asked the dealership to further take the engine apart and get pictures of the rocker’s. The dealership is down to 2 technicians and said they will get to it when they can (remember I’m without a car and waiting for approval for my engine so they can get me in a rental car while my engine gets replaced). Over 3 week later the dealership finally sends the pictures in of the rocker’s, I know cause I called and asked the dealership. I then asked why does the warranty department need pictures of the rockers for my engine failure (misfire in 4th cylinder) and they said to check for sludge. They also pointed out my engine isn’t bad and don’t have sludge so the warranty department should approve my engine replacement. A week later my case manager called and said that they will only approve 50% and I said NO there a lifetime warranty and I’m the original owner, so they went up to 65%. I feel betrayed by the dealership, case manager and Hyundai warranty department for NOT honoring the engine replacement knowing there’s a class action law suit due for failing rod bearings which they said wasn’t the issue. How would they know? The rod bearings are on the bottom of the motor and if they took it apart they would see THAT WAS the cause, but they say they don’t warranty misfire’s yet tens of thousands of Hyundai buyers are having same problems. Help

Filed Jan 13, 2025 · Engine · NY

While driving down the highway at 65mph my 2016 Santafe Sport experienced engine failure. We sat on the side of the highway, next to an on ramp with high traffic beside a cement wall. When the tow truck arrived the driver was nearly ran over! There was no way to get the car to a safer location. After being towed to the dealership they said the engine failure would be submitted under warranty due to an issue with the connection rod bearing damage causing the engine to fail. It was denied because I was not the initial owner. A week later I received information about a class action suit against Hyundai for this very problem. As part of the suit they had extended the warranty. The dealership resubmitted my information and it was turned down again, this time for high mileage. Several months later the dealership wanted my car removed from their property, I asked them to submit it again. This time turned down because the KSDS was not updated prior to the engine failure. I now have a like new vehicle that I owe $9,000 on with a known defect that was never corrected because the required KSDS update was listed as a service campaign rather than a recall and so went unnoticed by the dealership I bought it from, or the NY inspection centers during my annual inspection and unknown to myself because when I checked for recalls there were none. Recently I found a Hyundai best practice document that states the KSDS update is no longer a prerequisite. I had my car towed once again to the dealership, where it was again denied for not having the update done prior to engine failure. Hyundai customer service says they can’t help change the denial even though the company is at fault for producing a bad product.

Filed Oct 16, 2024 · Engine · NC

Engine has serious recall that I was not made aware of during purchase. My car has been burning oil and the engine has been on. I've taken out to several local mechanics who said "these model Hyundai's burn oil once they are over 100,000 miles" and that I would just need more frequent oil changes. I was also told the engine light was either an old code being thrown, or the pump valve, but nothing to worry about because it really only effects gas milage. My engine went out and I had to get it towed to another mechanic, who upon seeing the car, knew it had an engine recall and could hear a distinctive knock in the engine due to a failing rod bearing. Upon Hyundai's request, we towed it to a dealership to have them inspect it. They agree it's the engine that's bad, but since a "knock sensor" was never installed by the previous owner, they say they are not liable to cover the repair, and that since the recall is "public knowledge", it was my responsibility to find out. If you go onto the website, and type in my VIN number, the information says "0 unrepaired recalls", therefore making it impossible for me to have known about the recall without Hyundai letting me know, which they didn't.

Filed Aug 19, 2024 · Engine · SC

We were driving through our neighborhood at about 25 mph and we heard a slight knocking noise and then the engine shut off, no warnings or lights, just engine failure. The electronics worked, but car wouldn’t start. Had it towed to a local mechanic where he said the engine is seized. We were thankful this happened at a low speed in a safe place, can’t imagine how awful it would have been if we’d been going 75 mph down the 4 lane interstate. Of note, we have always kept the vehicle current on oil changes/maintenance. Prior to this, the car drove great! Never had any issues that would point to impending trouble.

Filed Jul 26, 2024 · Driver assistance, Engine · PA

Vehicle was driven on a highway approximately 45-50 mph when a loud knocking sound occured. The vehicle began to shake erratically and a bunch of lights displayed. I pulled over at a safety point and turned the vehicle off to inspect it. A large amount of smoke poured from under the hood. The vehicle sat for about 45 minutes to cool down before I attempted to start it again. The engine continued to make a loud knocking sound and kept stalling. At the given time of engine failure, I was driving on a fairly busy highway with my two toddlers where we were forced in a dangerous situation to be struck by a vehicle. Hours later, I went back to start the vehicle where I was able to get it started and drive approximately 15 mph to a safer area for the vehicle to be parked. The vehicle has been at the Hyundai Bowser Chippewa location in Beaver Falls, PA. I was denied for any assistance through Hyundai and the BBB-Hyundai due to 3 open recalls, mainly the engine knock system not being updated. All issues and diagnostics were conducted at the dealership where the vehicle is being stored. No police report has been filed, nor was an insurance claim conducted. No lights or warnings came about until the engine started to noticably fail. I didn't receive any notifications from Hyundai regarding recalls, and nothing is displayed on the federal safety agency site.

Filed Jun 12, 2024 · Engine · WA

The vehicle began making a knocking sound upon starting. I contacted the local dealership for a service appointment and learned that they were out a couple of months on their appointment schedule. A day or two later, my vehicle shut off while driving, I was fortunate to have enough momentum to pull of the road safely. Upon having it towed to a local mechanic, I learned that the engine seized and needed to be replaced. I contacted Hyundai and they have scheduled me for an appointment next week. Keeping my fingers crossed they will do right by me since I have always had the vehicle serviced at their Hyundai dealership. The car has approximately 118,300 miles on it.

Filed Jun 11, 2024 · Engine · 94,000 miles · MD

The contact owned a 2016 Hyundai Santa Fe. The contact stated while driving 50 MPH, he heard an abnormal knocking sound coming from the engine compartment. No warning lights were illuminated. The vehicle was towed to the dealer, who determined that there was a misfire in cylinder #3, and the catalytic convertor system efficiency was below threshold. The vehicle was not repaired. The manufacturer was notified of the failure but referred the contact to the federal safety agency Hotline for assistance. The failure mileage was 94,000. The VIN was not available.