Hyundai Santa Fe Common Problems

The Santa Fe is Hyundai's large seven-seat SUV. The CM (2006 to 2012) had petrol V6 and four-cylinder engines and a 2.2 CRDi diesel. The DM (2012 to 2018) offered a 2.4 GDi petrol (G4KJ) and a 2.2 CRDi R-series diesel (D4HB) with 6-speed manual or auto, plus a 3.3 V6 in some 2016 and 2017 special editions. The TM (2018 to 2024) launched with the 2.4 GDi and the 2.2 diesel with an 8-speed auto, and a 3.5 V6 petrol arrived later. From the 2021 update the diesel uses an 8-speed dual-clutch. The MX5 (2024 on) is mostly seen here as a hybrid. The diesel has the best name, while the 2.4 GDi and some AWD drivelines cause the most trouble.

Oil burning and engine failure (2.4 GDi G4KJ, DM and TM, 2012 to 2020)

The 2.4 GDi can suffer scoring of the cylinder bores. Symptoms are heavy oil use between services, knocking or tapping that is worst from cold, and in bad cases seizure when the oil runs low. Dealers usually confirm it with an oil consumption test. In 2017 some DM 2.4 GDi engines were recalled because debris may have been left inside during assembly, which could lead to engine failure. A class action has been filed in the Federal Court alleging defects in this engine; check its current status. The fix is a new or rebuilt engine, a bill of many thousands of dollars out of warranty.

DPF and EGR carbon build-up (2.2 CRDi D4HB, 2009 to 2024)

The 2.2 diesel is strong and durable, but it needs regular highway or country running to keep its particulate filter clear. Used mostly for short suburban trips, the filter fills and can block. Code P0401 (insufficient EGR flow) on these engines is often caused by carbon deposits rather than a failed valve. High-kilometre diesels can also blow black smoke under hard acceleration. A long highway run or a forced burn-off can clear a partly blocked filter. Otherwise a DPF clean, roughly $500 to $1,500, or a new filter is needed.

Rear diff, coupling and transfer case failures (AWD diesel, DM, 2012 to 2018)

Some owners of high-kilometre AWD DM diesels report rear diff failures. Others report a failed AWD coupling actuator, which leaves the car in front-wheel drive, or stripped transfer case splines. These are individual owner reports rather than a recall, but each is an expensive repair, and high kilometres are the common factor. Listen for whine or clunks from the rear and watch for AWD warning lights.

Dual-clutch faults and loss of drive (8-speed DCT, TM diesel, 2021 to 2024)

The updated TM diesel uses an 8-speed wet dual-clutch. Facelifted TM diesels were recalled because transmission software might not switch to its fail-safe mode properly when certain oil pump faults occurred. That could cause reduced acceleration and then a loss of drive. The fix is a software update. Some owners also report intermittent rough or hesitant shifting. A gearbox that still misbehaves after the update needs dealer diagnosis, and out-of-warranty DCT repairs are expensive.

Airbag light, tailgate and other electrical faults (DM and TM, 2012 to 2024)

A failed clock spring behind the steering wheel can bring on an airbag warning light. Individual TM owners report intermittent power tailgates, headlight faults, a leaking battery and infotainment dropouts. A DM owner reports an electronic park brake failure. Test every electrical feature before you buy, as some of these parts are costly once the warranty ends.

Timing belt and shift quality (2.7 V6, CM, 2006 to 2009)

The older CM's 2.7 V6 uses a rubber timing belt, commonly due around 90,000 km, so check the logbook. If it breaks, the engine can be badly damaged, so ask for proof it has been changed. Some early CM V6 automatics could make abrupt shifts, which reprogramming the engine computer usually fixed.

Recalls and safety

Some CM and DM cars were recalled because the ABS module could short circuit and cause a fire, even when parked. Other DM recall themes include a bonnet latch cable that could corrode and, on some 2017 cars, a steering wheel that could separate from the column. TM recall themes include curtain airbag mounting bolts, a fuel supply pipe on some 3.5 V6 cars, seatbelt pretensioners, the dual-clutch software, and an instrument cluster fault on some diesels. MX5 recalls have covered a rear side airbag wiring harness and instrument cluster software. Some CM diesels also had fuel hose recalls. Have a Hyundai dealer check the VIN for open recalls and see our recalls page.

Buying a used Hyundai Santa Fe? What to check

• Oil and cold start: On a 2.4 GDi, check the dipstick and listen for tapping or knocking from a cold start.
• Engine paperwork: Ask whether the engine was replaced, oil-tested or covered by the 2017 recall, and get the receipts.
• Diesel use: Ask how the car was driven, and check the DPF warning light has not been coming on.
• AWD driveline: Drive in tight circles and on the highway, listening for rear diff whine, clunks or binding, and watch for AWD warnings.
• Dual-clutch: On 2021 to 2024 diesels, crawl in traffic, pull away on a hill and reverse up a slope, feeling for hesitation or jerks.
• Towing history: A heavy towbar or caravan use means more wear on the gearbox, diff and rear suspension, so inspect those closely.
• Electrics: Test the power tailgate, headlights, park brake, airbag light and infotainment.
• Recall proof: Ask for paperwork showing the ABS module, steering wheel and dual-clutch software recalls were done.
• Service record: Look for on-time services in the logbook, as missed services weaken any engine or gearbox claim.

Run a Carify VIN check on the car, then work through our Hyundai Santa Fe buying checklist at the inspection.

The verdict

The 2.2 diesel is the Santa Fe to buy if you tow or drive long distances, in either a DM Series II or a pre-2021 TM with the conventional 8-speed auto. A 2021 to 2024 diesel is fine once the dual-clutch software recall is done and it drives cleanly. Approach the 2.4 GDi with care, and buy it only with a clean oil record or a documented replacement engine. On high-kilometre AWD diesels, check the rear diff and AWD system closely. The MX5 is too new for clear patterns.