Hyundai Recalls Santa Fe and Tucson Models Due to Potential Engine Stall and Fire Risk

Hyundai Motor America is initiating a safety recall affecting approximately 29 model year 2025-2026 Hyundai Santa Fe and Tucson vehicles sold in the U.S. According to the U.S. Department of Transportation’s National Highway Traffic Safety Administration (NHTSA), the issue stems from a potential error during engine assembly at Hyundai Motor Manufacturing Alabama, where connecting rod bolts may have been installed with insufficient torque. This manufacturing defect could lead to serious engine problems and increase the risk of a crash or fire.

The defect involves the engine’s connecting rods, which, if not properly torqued during assembly, could result in abnormal engine noises, illumination of the oil pressure warning light, or a reduction in motive power. Continued operation of a vehicle experiencing these symptoms may cause significant engine damage, potentially leading to a stall while driving. A stall at highway speeds heightens the risk of a collision. In more severe cases, a damaged connecting rod could breach the engine block, causing oil to leak onto hot engine components. This oil leakage could then create a fire hazard. The root cause is attributed to an error in the loading process for the visual/torque inspection station, which may have led to a failure to properly inspect the torque on these critical bolts.

Hyundai has identified that 7 Santa Fe vehicles and 22 Tucson vehicles produced between February 5, 2025, and August 8, 2025, are potentially affected. The company first became aware of the issue on August 15, 2025, when Hyundai Motor N.A.’s North America Safety Office was notified by Hyundai Motor Manufacturing Alabama. Following an investigation and review of technical details, Hyundai convened its North America Safety Decision Authority on August 18, 2025, leading to the decision to conduct this safety recall. As of the recall filing, Hyundai has not reported any crashes, fires, or fatalities linked to this specific defect in the U.S. market.

The remedy for affected owners involves a complimentary engine replacement at any authorized Hyundai dealership. This repair will be provided at no cost to owners, irrespective of whether the vehicle is still covered by Hyundai’s New Vehicle Limited Warranty. Owners who have already paid for repairs related to this recall condition may be eligible for reimbursement for out-of-pocket expenses incurred, in accordance with Hyundai’s reimbursement plan submitted to NHTSA. The replacement engines are equipped with connecting rods that have been installed with the correct torque specifications. To prevent further occurrences, the logic controller for the visual/torque inspection process was reprogrammed on August 12, 2025, with updated protocols.

Hyundai plans to notify dealers electronically about the recall on October 24, 2025. Owners will receive notification via certified mail by the same date, with instructions on how to schedule their vehicle for the necessary engine replacement. Vehicle Identification Numbers (VINs) will be searchable on the NHTSA recall website starting August 27, 2025, allowing owners to check if their specific vehicle is included in this safety campaign. As a precautionary measure, owners of potentially affected vehicles are advised not to drive them and to park them outdoors until the necessary repairs are completed.

Article by Mel Anara, based upon information from Hyundai Motor America

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