Engine Belts And Pulleys problems of the 2003 Hyundai Santa Fe

Purchased as a used vehicle with 30,000 mi. In 2008 from a dealership with owners manual missing. On 8-1-2010 while driving home from work, the vehicle engine stopped running on a bridge on a busy roadway, causing the vehicle to lose power steering and power brakes. Other vehicles in the area had to take evasive action causing a immediate hazardous condition. Upon having the vehicle towed to a repair garage, it was determined that the cause of the catastrophic engine failure was the result of a defective timing belt that was a known issue for this model and make of vehicle. The manufacturer recommended changing of the timing belt was to be 60,000 miles, thus telling me the belt should have been changed in 2007 at the 60,000 mile mark. As you can see, I bought the vehicle in 2008 will 30,000 miles on it (no owners manual). I was told I was to be responsible for the cost of the replacement motor, which of course was a used motor because they redesigned the 3. 5 liter engine in 2005 when this problem was evident and those engines would not fit my 2003. Why was there not a recall then on this for engine failure at that time? they had replaced the belt with a new design timing chain for the newer vehicles. While my vehicle was under repair, another 2003 Santa Fe was also in for the same issue. Fortunately, I was not injured, but the possibility was there. A minute earlier, I was traveling down a steep grade prior to the engine failure. This looks like an inherent problem for the Hyundai 3. 5 liter engine, they had to get my replacement engine from texas. Were used car buyers aware of this problem with the Hyundai 3. 5 liter engine models prior to 2006? this is a serious safety violation. The vehicle engine failed without warning! how about Hyundai reimbursing me $4000. 00?.

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.

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.

At 5,980 miles engine started to create engine noise. Dealer said that there's a problem on the vehicle's crankshaft. 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.