2003 Hyundai Santa Fe Engine Problems

Your 2003 Santa Fe is leaking fuel from the tank onto the ground, creating a fire hazard that makes it unsafe to park anywhere. The fuel gauge also stopped working properly after refueling, and the engine lost power multiple times while driving, causing it to stall on the interstate and exit ramp. The dealer refused to cover the repair under warranty citing high mileage, but Hyundai has issued a warranty extension for this fuel tank issue. You'll likely need a fuel tank replacement or repair, which should be covered under the extended warranty program.

After installing a set of DuraLast Gold spark plug wires, you experienced charging system problems that turned out to be caused by the wires themselves. The wires were causing arcing in the engine cylinders, which created electrical issues. The problem may require replacing the spark plug wires with a different set or having them inspected for proper installation and insulation.

ENGINE DIED MULTIPLE TIMES WHILE IN OPERATION ON A CITY STREET GOING STRAIGHT, APPROXIMATELY 35-40 MILES PER HOUR AND ON HIWAY GOING APPROX. 60 MPH TWICE. WE NO LONGER DRIVE IT ON A HIWAY. REPAIR SHOP CAN'T FIND ANYTHING WRONG.

MY DAUGHTER AND HER FRIENDS WERE DRIVING THE 2003 HYUNDAI SANTE FE HOME FROM A SKI TRIP IN THE MOUNTAINS. SHE SAID THE CAR KEEPS ACCELERATING ON IT'S OWN UP TO 55-60MPH, ESPECIALLY WHEN THEY WERE GOING DOWN HILL. WHEN SHE PUT THE CAR IN PARK OR NEUTRAL, THE CAR'S ENGINE REV UP TO 3000 RMP ON IT'S OWN. SHE BARELY PUT HER FOOT ON THE PEDAL AND IT WAS DRIVING 55 MPH. SHE HAD TO USE THE BRAKES A LOT TO SLOW THE CAR DOWN. IT WAS VERY SCARY BUT THEY MANAGE TO MAKE IT HOME SAFELY. I DID SOME RESEARCH ON THE INTERNET AND SEEMS LIKE A LOT OF PEOPLE HAD THE SAME PROBLEM. *JS

TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE WOULD SUDDENLY STALL WITH OUT WARNING. THE CONTACT MENTIONED THAT WITHIN 2 TO 3 SECONDS THE VEHICLE WOULD RESTART AND OPERATE AS NORMAL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED BUT NO SOLUTION WAS OFFERED. THE FAILURE MILEAGE WAS 73,100.

2003 HYUNDAI SANTA FE. CONSUMER WRITES IN REGARDS TO ELECTRICAL PROBLEMS AND ENGINE COMPARTMENT FIRE. *SMD THE CONSUMER STATED WHILE DRIVING, THE ENGINE BEGAN TO OVERHEAT. *JB

TL* THE CONTACT OWNS A 2003 HYUNDIA SANTA FE. THE CONTACT STATED HAT WHILE DRIVING APPROXIMATELY 5 MPH, A LOUD NOISE EMITTED FROM THE FRONT END OF THE VEHICLE. THE ENGINE STALLED WITHOUT WARNING AND FAILED TO RESTART. THE VEHICLE WAS TOWED TO AN INDEPENDENT AUTO SHOP WHO STATED THE MALFUNCTION WAS CONTRIBUTED TO THE ENGINE MOUNT BRACKET BOLT. THE VEHICLE WAS NO REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE WAS 170,000.

TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. THE CONTACT STATED THAT THE VEHICLE WOULD HESITATE TO ACCELERATE, ESPECIALLY WHEN DRIVING UPHILL. THE CHECK ENGINE LIGHT WAS ILLUMINATED AND THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC SEVERAL TIMES WHERE NUMEROUS REPAIRS WERE PERFORMED BUT TO NO AVAIL. THE FAILURE MILEAGE WAS 119,000 AND THE CURRENT MILEAGE WAS 122,000.

THE VEHICLE FOR THE LAST 3 YEARS WAS NOT GETTING THE GAS MILEAGE SUGGESTED BY MANUFACTURER. IT WAS TAKEN REPEATEDLY TO DEALER WHERE WE WERE TOLD, "EVERYTHING CHECKED OUT JUST FINE". ALL MAINTENANCE WAS DONE AS REQUIRED BY DEALER". AS CAR BECAME MORE SLUGGISH AND FINALLY QUIT RUNNING ALTOGETHER- WE TOOK IT TO AN OUTSIDE MECHANIC AND LEARNED THAT THE CATALYTIC CONVERTER HAD GONE BAD. I CHECKED THE INTERNET AND THIS IS A COMMON COMPLAINT WITH THIS VEHICLE- DEALERS ARE REPAIRING TRANSMISSIONS AND EMISSION CONTROLS AND CUSTOMERS ARE STILL COMPLAINING ABOUT BAD GAS MILEAGE, SLUGGISH VEHICLES. NOW THAT THE CATALYTIC CONVERTER HAS BEEN REPLACED- THE CAR IS GETTING THE CORRECT GAS MILEAGE AND RUNNING BETTER. *TR

TL* THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 20 MPH, THE ENGINE REVVED WHICH CAUSED THE RPMS TO INCREASE EXCESSIVELY HIGH. THE BRAKES WERE APPLIED AND THE GEAR WAS SHIFTED INTO THE PARK POSITION TO STOP THE VEHICLE. THE VEHICLE RESTARTED AND WAS DRIVEN TO A PARKING LOT, AND THE ENGINE WAS TURNED OFF. THE CONTACT WAITED FIFTEEN TO TWENTY MINUTES BEFORE RESUMING TO OPERATION WITH EXTREME CAUTION. CURRENTLY, THE VEHICLE WAS BEING DIAGNOSED AT AN AUTHORIZED DEALER. THE FAILURE MILEAGE WAS 131,000.

2003 SANTA FE STALLS AT HIGHWAY SPEEDS BUT IMMEDIATELY STARTS AGAIN. STALLING HAS ALSO BEEN NOTICED AT LOWER SPEEDS AND WHILE IDLING AT STOP LIGHTS. THIS OCCURS SPORADICALLY AND WITH NO INDICATION THAT ANYTHING IS WRONG, CHECK ENGINE LIGHT IS NOT ON SO A DIAGNOSTIC SCAN IS USELESS. I HAVE SEEN MANY OTHER COMPLAINTS ABOUT THE SAME PROBLEM WITH NO SOLUTION FROM HYUNDAI. ALSO RECALLS ON 2001 AND 2002 FOR THE SAME PROBLEM. *TR

ABOUT 3 MONTHS AGO, MY AIRBAG LIGHT CAME ON AND WAS NOT GONE OFF SINCE. I WONDERED IF THIS MEANT I HAD NO AIRBAG FUNCTION, BUT NOW AFTER READING THESE COMPLAINTS I KNOW IT IS NOT WORKING. THIS PROBLEM COMBINED WITH THE ENGINE THAT MYSTERIOUSLY AND SUDDENLY SHUTS DOWN WHILE DRIVING ON THE INTERSTATE IS NOT A GOOD COMBINATION. I SMELL TROUBLE. *TR

I PURCHASED A 2003 HYUNDAI SANTA FE 09/2007 WITH 78K MI. IN MAY 2009 I TOOK VEHICLE TO DEALERSHIP FOR OIL CHANGE & ASKED THEM TO CHECK IT OUT BEFORE I WENT ON A ROAD TRIP. I WASN'T HAVING ANY PROBLEMS, JUST WANTED TO BE SURE EVERYTHING WAS OK. SERVICE TECH RECOMMENDED TRANSMISSION FLUSH, REPLACEMENT OF TIMING BELT, & REPLACEMENT OF CRANK SENSOR. I AGREED TO RECOMMENDATIONS BECAUSE I WANT TO DRIVE A SAFE & RELIABLE VEHICLE. SINCE MAY I HAVE RETURNED TO SERVICE DEPT. AT LEAST 4 TIMES BECAUSE THE VEHICLE NOW STALLS WHILE I'M DRIVING, NO WARNING, JUST QUITS. IT STARTS BACK UP AFTER A FEW MINUTES. THESE EVENTS ARE INTERMITTENT. THE FAILURES HAVE OCCURRED AT SPEEDS BETWEEN 15 & 55 MPH, WHILE A/C ON, OUTDOOR TEMP 80+ & HUMID. SOMETIMES FAILURE OCCURS WHILE ACCELERATING FROM A STOP, OTHER TIMES AT HIGHER SPEED ON HWY. SERVICE TECH HAS BEEN UNABLE TO DUPLICATE OR GET A READ ON THE PROBLEM. HE HAS EVEN DRIVEN THE VEHICLE HOME & BACK (60 MI) AT LEAST TWICE, STATING HE HAD NO PROBLEMS. EACH VISIT I AM TOLD "NO PROBLEM FOUND" YET FAILURES PERSIST. HYUNDAI USA HAS ADVISED ME IF IT HAPPENS AGAIN, HAVE IT TOWED TO DEALERSHIP SO THEY MAY DIAGNOSE/DUPLICATE THE PROBLEM. THE PERSON I SPOKE TO AT HYUNDAI USA SEEMED VERY FAMILIAR WITH THIS ISSUE. TO ME, THIS IS A VERY SERIOUS SAFETY ISSUE. SO FAR I'VE BEEN LUCKY TO AVOID AN ACCIDENT. DO SANTA FE DRIVERS HAVE TO BE SERIOUSLY INJURED OR KILLED BEFORE HYUNDAI MAKES THIS ISSUE A PRIORITY? I HAVE READ MANY SIMILAR COMPLAINTS ONLINE, SOME DATING BACK TO LATE 2003. ALMOST ALL MENTION BEING TOLD ITS A PROBLEM WITH CRANK SENSOR OR RELATED COMPONENTS. ALSO, HYUNDAI APPARENTLY DID RECALL 2001 & 2002 MODELS WITH THE SAME OR SIMILAR PROBLEMS. MY VEHICLE DIDN'T STALL UNTIL THE CRANK SENSOR WAS REPLACED, COULD BE A COINCIDENCE, BUT I DON'T THINK SO. BESIDES THE SAFETY ISSUE, THIS IS A FINANCIAL RIP-OFF. $90/HR LABOR ADDS UP QUICKLY. HYUNDAI KEEPS PROFITING FROM A DEFECT THEY SEEM TO BE AWARE OF, YET REFUSE TO CORRECT. *TR

TL*THE CONTACT OWNS A 2003 HYUNDAI SANTA FE. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE JERKED AND THE ENGINE STALLED WITHOUT WARNING. ROADSIDE ASSISTANCE WAS CALLED TO THE SCENE AND THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING. THE THROTTLE POSITION SENSOR WAS REPLACED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER ON A SEPARATE OCCASION FOR THE IDENTICAL FAILURE AND THE THROTTLE POSITION SENSOR WAS REPLACED AGAIN. THE VEHICLE HAS NOT BEEN REPAIRED PROPERLY AND THE FAILURE STILL PERSISTS. THE FAILURE MILEAGE WAS 22,112 AND CURRENT MILEAGE WAS 41,496.

THE VEHICLE JERKED VIOLENTLY AND THEN SUDDENLY STALLED SEVERAL TIMES ON THE HIGHWAY AT SPEEDS AROUND 60 MPH, CAUSING DANGEROUS DRIVING CONDITIONS. A FEW DAYS LATER THE VEHICLE WOULD NOT START AT ALL. THE VEHICLE WAS BROUGHT TO A REPAIR FACILITY AND IT WAS DISCOVERED THAT THE CRANKSHAFT POSITION SENSOR WAS CRACKED AT THE SENSOR END NEAR THE CRANKSHAFT AND TIMING BELT. REPLACING THE PART WAS LABOR INTENSIVE SINCE SEVERAL ENGINE COMPONENTS HAD TO BE REMOVED TO REACH THE SENSOR, THEREFORE THE REPAIR COSTS WERE HIGH. THE DEALERSHIP WANTED AROUND $1,000 TO REPLACE WITH THE PART ONLY COSTING $90. I BROUGHT THE VEHICLE TO AN INDEPENDENT REPAIR SHOP AND HAD THE CRANKSHAFT POSITION SENSOR REPLACED, THE VEHICLE NOW STARTS. BOTH THE HYUNDAI DEALERSHIP AND HYUNDAI MOTOR AMERICA REFUSED TO COVER REPAIR COSTS WHILE THE VEHICLE WAS IN NEED OF REPAIR AND BEFORE I BROUGHT IT ELSEWHERE. BOTH DEALER AND MANUFACTURER CONTINUE TO REFUSE NOW TO REIMBURSE COSTS AFTER I HAD TO GO TO A LESS COSTLY REPAIR FACILITY. MY CASE # WITH HYUNDAI MOTOR AMERICA IS #3467755. I HAVE ALSO CONTACTED THE ALTERNATIVE DISPUTE RESOLUTION LINE AT THE BETTER BUSINESS BUREAU. I NOTIFIED THE REPRESENTATIVE AT HYUNDAI THAT THIS SAME PART WAS RECALLED ON THE 2 PRIOR YEARS MODELS OF SANTA FE (NHTSA CAMPAIGN ID# 03V520000) AND THAT NUMEROUS COMPLAINTS WERE MADE TO NHTSA FOR THE SAME PROBLEM WITH 2003 CRANKSHAFT POSITION SENSORS. CURRENT NHTSA ODI COMPLAINT #'S THAT ARE NEAR EXACT MATCHES FOR THE 2003 MODEL ARE ODI ID# 10238818, 10176719, 10133625, AND 10115680. SIMILAR ARE #10203556, 10199900, 10195530, 10183323, 10128836, AND 10050501. ALSO SEE NHTSA CAMPAIGN ID 03V520000 AND THE EPA RECALL #1791 - MFR# 49. A SIMILAR RECALL WAS DONE IN CANADA, SEE TRANSPORTATION CANADA RECALL #2002008, CAMPAIGN CODE R33. APPARENTLY THE PART CONTINUED TO DEFECTIVE AT THE POINT OF MANUFACTURER IN THE 2003 MODELS AS WELL. HIGH SPEED STALLS AND VIOLENT JERKING POSING RISK OF INJURY AND DEATH. *TR

2003 HYUNDAI SANTA FE WITH DEFECTIVE AIRBAG CONTROL MODULE. CONSUMER STATES THAT THE MECHANIC HOOKED THE VEHICLE UP TO THE SCANNER THAT CAME ACROSS THAT PROBLEM. IT WILL COST ALMOST $400 DOLLARS TO HAVE THE AIRBAG CONTROL MODULE REPLACED. *KB THE DEALER STATED THERE WAS AN INTERNAL FAULT CODE CAUSING THE AIR BAG LIGHT TO ILLUMINATE. THE OIL PAN WAS LEAKING. *JB

WENT TO THE DEALER TO GET MY VEHICLE FIXED 4 TIMES AND GOT CHARGED FOR A TUNE UP THAT I DID NOT NEED. THE LAST AND 4TH TIME WHEN PICKING UP MY VEHICLE , THEY HAD THE PARTS OUT AFTER I HAD TOLD THEM 2 TIMES NOT TO WORK ON IT ANYMORE AND THEY TOOK IT APART ANYWAY. THEY TOLD ME I NEEDED TO TOW IT OUT OF THEIR SHOP . I TOLD THEM I WANTED THE CAR BACK JUST THE WAY I BROUGHT IT THERE . THEY GAVE MY A MUCH STRESSFUL HARD TIME FINALLY THEY PUT IT BACK AND I GOT IT BACK THE NEXT DAY IN WORST CONDITION. THERE IS A LOT MORE STORY BUT NOT ENOUGH LETTERS LEFT SO I WILL END IT HERE FOR NOW. *JB

DT*: THE CONTACT STATED THERE HAS BEEN A CONTINUOUS HESITATION AND SURGING OF THE VEHICLE, AS WELL AS, EXTREMELY POOR GAS MILEAGE. THE VEHICLE WAS INSPECTED BY A SERVICE DEALER, THE HESITATION AND SURGE COULD NOT BE RECREATED AND NO PROBLEM WAS DIAGNOSED. WHEN INSPECTED AGAIN BY THE SAME SERVICE DEALER, A DETACHED CABLE WAS FOUND UNDER THE VEHICLE. THERE WAS ALSO A SPRING UNDER THE ACCELERATOR PEDAL FOUND TO BE DISCONNECTED. ONCE THE ITEMS WERE REPAIRED, THE MILEAGE IMPROVED, BUT THE HESITATION AND SURGING CONTINUED. AN INDEPENDENT MECHANIC TEST DROVE THE VEHICLE AND CONFIRMED THERE WAS IN FACT A HESITATION AND A SURGING. ON THE NEXT VISIT TO THE SERVICE DEALER, A KNOCK SENSOR WAS REPLACED. THE MANUFACTURER WAS ALERTED WHO RECOMMENDED THE CONTACT TRY ANOTHER SERVICE DEALER. UPON INSPECTION BY ANOTHER SERVICE DEALER, THE KNOCK SENSOR WAS OBSERVE TO BE LOOSE AND IT WAS CRIMPED TO TIGHTEN IT. HOWEVER, THE HESITATION AND SURGING CONTINUED. THE CONSUMER STATED THE VEHICLE HAS STALLED ON SEVERAL OCCASIONS. UPDATED 08/25/06. *JB

WHILE DRIVING AT ANY SPEED VEHICLE STALLED. DRIVER WAS NOT ABLE TO RESTART VEHICLE, AND HAD IT TOWED TO THE DEALER FOR INSPECTION. MECHANIC DETERMINED THAT THE CRANKSHAFT POSITION SENSOR NEEDED TO BE REPLACED, AND REPLACE IT. HOWEVER, THE PROBLEM RECURRED, AND THE VEHICLE WAS TAKEN BACK TO THE DEALER FOR INSPECTION. THEN, MECHANIC REPLACED THE ENGINE COMPARTMENT RELAY, FUEL SENSOR ASSEMBLY, AND THE COMPUTER MODULE. *AK CONSUMER STATED THERE HAS BEEN 6 INCIDENTS/FAILURES THAT ARE CAUSING SERIOUS CONCERNS WITH STARTING AND STALLING. IT BECAME MORE FREQUENT AND STARTED HAPPENING WHILE DRIVING SANTA FE ON ROADS AND HIGHWAY. CONSUMER HAVE CONFIDENCE IN THE VEHICLE AND FEAR OF IT STALLING IN THE CENTER LANE WHERE THERE IS LITTLE OPTIONS EXCEPT GETTING HIT AND POSSIBLE GETTING SERIOUSLY INJURED. *BF

ON NOVEMBER 5, 2004 AT APPROX 7:30 PM OUR 2003 SANTA FE WITH ONLY APPROX 14,000 MILES SUDDENLY "DIED" IN THE MIDDLE OF THE ROAD. ALL OF THE VEHICLE WARNING LIGHTS CAME ON, THE HEATER AND RADIO BEGAN MAKING STRANGE NOISES, THE HEADLAMPS FAILED, AND THE VEHICLE ENGINE STOPPED RUNNING AND WOULD NOT START, LEAVING THE VEHICLE IN THE MIDDLE OF THE ROAD, STRANDING ME AND MY PREGNANT WIFE, WITH NO LIGHTS OR FLASHERS IN THE MIDDLE OF THE ROAD ON A COLD NIGHT. HYUNADAI ROADSIDE SERVICE CONTRACTOR CROSS COUNTRY MOTORCLUB CLAIMED THAT IT WOULD TAKE OVER 3 HOURS TO GET THE VEHICLE TOWED, SO FINALLY 9 AFTER NEARLY 2 HOURS) COUNTY POLICE TOWED THE VEHICLE AS A TRAFFIC HAZARD TO FAIRFAX HYUNDAI. *JB

ON 10/23/04, MY 2003 HYUNDAI SANTA FE WITH 21,600 MILES, BEGAN TO EXPERIENCE A VERY LOW IDLE AND THEN STALLED OUT EACH TIME I HAD TO STOP AT A STOP SIGN OR A STOP LIGHT. I COULD START THE VEHICLE WITHOUT A PROBLEM EACH TIME BUT AS SOON AS I WOULD SHIFT INTO "DRIVE", THE CAR WOULD REPEAT THE LOW IDLE/STALL OUT PROCESS AND I COULD NOT MOVE THE CAR AN INCH. THE CAR HAD TO BE FLATBED TOWED TO THE DEALERSHIP. THE DEALERSHIP SAID THEY DROVE THE CAR AND HOOKED THE CAR UP TO THE COMPUTER BUT COULD NOT DUPLICATE OR FIND A REASON FOR THE PROBLEM. ON 10/29/04, TWO DAYS AFTER I PICKED THE CAR UP FROM THE DEALERSHIP WITH A CLEAN BILL OF HEALTH, THE EXACT SAME SCENARIO OCCURRED AGAIN AND THE CAR WAS AGAIN FLATBED TOWED TO A DIFFERENT DEALERSHIP TO TRY TO GET ANOTHER MECHANIC'S VIEW OF THE SITUATION. THEY ALSO COULD NOT DUPLICATE THE PROBLEM AND NOTHING WAS FOUND WRONG WITH THE CAR. I AM UNABLE TO RELY ON THIS VEHICLE BUT AM FRUSTRATED THAT 2 DIFFERENT HYUNDAI DEALERSHIPS CANNOT SEEM TO DISCOVER THE PROBLEM. THEY KEEP TELLING ME "THERE IS NOTHING WRONG WITH THE CAR".*JB

VEHICLE STALLED INTERMITTENTLY WHILE DRIVING AT ANY SPEED. DEALER WAS UNABLE TO DUPLICATE THE PROBLEM. *AK

AT 5,980 MILES ENGINE STARTED TO CREATE ENGINE NOISE. DEALER SAID THAT THERE'S A PROBLEM ON THE VEHICLE'S CRANKSHAFT. *LA THE CONSUMER BEGAN TO HEAR NOISE IN THE ENGINE COMPARTMENT. THE DEALER REPLACED MANY COMPONENTS; CRANKSHAFT, TRANSMISSION, BELT TENSIONER AND PULLEY. NONE OF THOSE REPAIRS CORRECTED THE NOISE. THE CLOCK SPRING FAILED AND CAUSED THE HORN AND CRUISE CONTROL TO BE INOPERATIVE. *NM

I PURCHASED A 2003 SANTA FE LX 4WD WITH THE 2.7L ENGINE. ALMOST FROM THE TIME I PURCHASED THE VEHICLE, IT HAS BEEN SUFFERING FROM A SULFUR SMELL. THE DEALER MADE ONE REPAIR THAT SEEMED TO LAST FOR ABOUT A WEEK, UNFORTUNATELY, THE ODOUR IS BACK. THE DEALER CLAIMS THAT THEY CANNOT DUPLICATE THIS CONCERN, HOWEVER, THEY ONLY DRIVE THE VEHICLE 2 OR 3 MILES WHEN I TAKE IT TO THEM TO BE SERVICED. FUNNY HOW EVERYONE EXCEPT THE DEALER CAN SMELL THIS FOUL DISGUSTING ODOR. *AK

WHILE DRIVING VEHICLE "DIED" AND WOULD NOT RESTART. DEALER DIAGNOSED THE CAMSHAFT GEAR HAD BROKEN. *AK *SCC *JB