Hyundai Recalls Over 135,000 Santa Fe Models Due to Fire Risk

More than 135,000 Hyundai Santa Fe vehicles from model years 2024 and 2025 are being recalled due to a potential fire hazard, according to Hyundai Motor America. The recall affects vehicles equipped with 2.5-liter turbocharged engines that were manufactured between December 28, 2023, and July 7, 2025.

The issue stems from the starter motor assembly, where a cover may not have been fully secured over the starter motor’s “B+” terminal during manufacturing. In specific crash situations that cause deformation in the engine compartment, this exposed terminal could come into contact with the cooling fan assembly. Such contact could lead to an electrical short, significantly increasing the risk of an electrical fire. There are no reported warning signs that precede this condition.

Hyundai Motor Manufacturing Alabama is identified as the component manufacturer for the affected battery wire harness. The recall process began following a National Highway Traffic Safety Administration (NHTSA) crash test on November 20, 2024, where smoke was detected emanating from the engine compartment of a 2024 Santa Fe. This incident prompted an investigation by Hyundai, which involved inspections of the test vehicle and recovered parts.

Subsequent bench testing by Hyundai replicated the potential shorting mechanism between the exposed starter motor terminal and the cooling fan motor housing. Further investigations, including surveys of post-production vehicles, revealed that some vehicles had incomplete or no terminal cover coverage. Hyundai reviewed its manufacturing records and assembly processes, concluding that while current production standards show no issues, a defect in the installation process of the terminal cover was the root cause. Durability tests confirmed that a correctly installed terminal cover remains secure under various operating conditions.

As of the recall filing date, Hyundai is aware of one U.S. New Car Assessment Program test result that indicated a thermal event. However, there are no reported field incidents, crashes, injuries, or fatalities linked to this specific defect in the United States.

Hyundai will notify owners of affected vehicles by first-class mail, providing instructions to bring their Santa Fe to a Hyundai dealer. At the dealership, the starter motor’s “B+” terminal cover will be inspected and, if necessary, reinstalled at no cost to the owner, regardless of warranty status. Hyundai will also offer reimbursement for any out-of-pocket expenses incurred by owners seeking a remedy for this condition prior to the recall. The remedy involves the correct installation of the terminal cover.

An improved installation and inspection process for the terminal cover was implemented in production in June 2025. Owners can expect to be notified by mail starting December 1, 2025. Vehicle Identification Numbers (VINs) will be searchable for recall status beginning October 4, 2025. Owners of affected vehicles are advised not to drive the vehicle and to park it outside due to the potential fire risk.

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

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