Tank Assembly Problems of Hyundai Santa Fe

Hyundai Santa Fe owners have reported 21 problems related to tank assembly (under the gasoline fuel system category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Hyundai Santa Fe based on all problems reported for the Santa Fe.

1 Tank Assembly problem of the 2006 Hyundai Santa Fe

Failure Date: 06/01/2016

2006 Hyundai Santa Fe. Consumer writes in regards to front coil spring corrosion recall notice and fuel tank replacement parts still not available to complete repairs.

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2 Tank Assembly problem of the 2007 Hyundai Santa Fe

Failure Date: 06/09/2014

The contact owns a 2007 Hyundai Santa Fe. The contact stated that the fuel tank gauge displayed inaccurate fuel level readings. As a result, the vehicle stalled due to lack of fuel. The vehicle was taken to an independent mechanic however, he was unable to repair the failure. The manufacturer was not notified. The approximate failure mileage was 65,000.

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3 Tank Assembly problem of the 2004 Hyundai Santa Fe

Failure Date: 06/01/2014

The contact owns a 2004 Hyundai Santa Fe. The contact stated that fuel was leaking from the rear of the vehicle. The vehicle was taken to an independent mechanic. The technician diagnosed that the fuel tank was crack and needed to be replaced. The vehicle was not repaired. The manufacturer was not notified. The failure mileage was 97,000.

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4 Tank Assembly problem of the 2007 Hyundai Santa Fe

Failure Date: 02/01/2014

Fuel gauge stopped working. Always registered empty, even when tank was full. Check engine light on. Repair involved both fuel level sensors be replaced, calibrated, and cleared codes.

5 Tank Assembly problem of the 2008 Hyundai Santa Fe

Failure Date: 01/21/2014

Fuel level sensor is bad causing fuel gauge to act erratically. Causes check engine light to constantly stay on. After filling gas tank, gas pedal must be pressed when starting and shifting into drive so car doesn't stall ,creating dangerous situation at the pump.

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6 Tank Assembly problem of the 2008 Hyundai Santa Fe

Failure Date: 12/27/2013

After filling the 2008 Hyundai Santa Fe with fuel, I started the engine and the fuel gauge was on e and the low fuel light was on. Later the fuel gauge needle moved but not to full. This has occurred several times since that first incident. The fuel gauge does not register accurately and the check engine light comes on occasionally. The distance to empty mileage indicator is also incorrect. There is no way to know how much fuel remains in the tank.

7 Tank Assembly problem of the 2008 Hyundai Santa Fe

Failure Date: 12/02/2013

Gas gauge started to malfunction. Also check engine light comes on. Gas tank is full and is reacting wildly. Dealer says it's a $650 fix. This should be a recall !!! safety issue.

8 Tank Assembly problem of the 2005 Hyundai Santa Fe

Failure Date: 11/06/2013

The contact owns a 2005 Hyundai Santa Fe. The contact stated that while driving 55 mph, he smelled gasoline. The contact discovered that fuel was leaking from under the vehicle. The contact took the vehicle to the dealer, who replaced the fuel tank due to excessive corrosion. The contact informed the manufacturer of the problem. The failure mileage was 76,264. Updated 12/20/cn.

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9 Tank Assembly problem of the 2007 Hyundai Santa Fe

Failure Date: 09/23/2013

Faulty fuel gauge. The fuel gauge will register empty and the fuel light will come on after filling up the tank. The gauge will waver and give faulty registers while driving, even climbing back to full after registering "empty" seconds before. Also will show check engine light when it is half full then go off when completely full.

10 Tank Assembly problem of the 2009 Hyundai Santa Fe

Failure Date: 08/20/2013

Fuel sensor failed and registered empty tank with low fuel warning light, check engine light activated. Since then the fuel gauge has not operated correctly and the check engine remains lit. Fault has been traced to fuel tank sensor which requires removal and replacement.

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11 Tank Assembly problem of the 2007 Hyundai Santa Fe

Failure Date: 08/15/2013

Fuel gauge ceased to work properly. False readings required replacement of fuel sensors located inside the fuel tank. Total cost of repairs exceeds $525. 00. Hyundai is aware of this problem on Santa Fe models from 2007 - 2010 but, has yet to initiate a recall or reimburse repair costs if vehicle warranty has expired.

12 Tank Assembly problem of the 2013 Hyundai Santa Fe

Failure Date: 12/03/2012

Vehicle delivered as new, immediately upon attempting to pump and fill gasoline tank, the pump clicked as full. However, gasoline gauge on dash only would and continues to show 3/4 full. There have been numerous attempts and replacement equipment to address and eradicate this situation and nothing has corrected the situation nor does Hyundai have any answers available to correct this situation. The vehicle has been in my favorite Hyundai service facility for many days and when finally returned the only answer I was given, was that the vehicle is an early production of the model and they have had some of same problem. In addition the electronic steering is a great disappointment as it is quite difficult to keep the vehicle on a true straight pathway no matter what the composition of the pavement. There was some sort of alert from the factory on an adjustment however and was addressed but is still terrible. Then there's an issue on the hitch whereby then trailer prep wiring was included on the invoice, installed by the selling dealer and the servicing dealer feels it not there duty/responsibility to repair it. I have been a Hyundai customer since 2001 as this is a very great disappointment and besides safety issues. These issues must be cleared up ASAP by both the Hyundai manufacturer and straightened out with their dealers. Please ! I would think the manufacturer admitting they know of the problem and cannot solve it they would replace my exact vehicle as I purchased it equipped and take back this one. They know of the problem so just simply replace my vehicle without any charges to me now!.

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13 Tank Assembly problem of the 2003 Hyundai Santa Fe

Failure Date: 12/17/2011

The contact owns a 2003 Hyundai Santa Fe. The contact stated while the vehicle was parked she smelled a fuel odor. The vehicle was taken to an independent mechanic and the contact was informed that the fuel tank was corroded and leaking fuel. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure and current mileage was 105,000.

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14 Tank Assembly problem of the 2004 Hyundai Santa Fe

Failure Date: 09/08/2011

Was having winter tires put on my car when mehanic said had a gas tank leak. . . He said it was the 5th car of Hyundai with the same problem that he saw. . . Said he never saw a car this young (7yrs) with this problem. . . Am a single mother with this car. . I have had no other problems. . I smell gasoline when I walk around this car and when I enter my car. . . Please tell me there is help. . . I do not have money and I do not feel safe. . Please help me.

15 Tank Assembly problem of the 2007 Hyundai Santa Fe

Failure Date: 08/31/2011

Shortly after having a new battery installed on my car by our local auto supply store a few months ago, I had to replace first one headlight bulb. . . Then a few days later, the other headlight bulb. . . A couple of weeks later I noticed the gas gauge going bad. It would wobble all over the place. Then I noticed that the guy who installed the battery did not tighten down the terminal. I took it back & he fixed that. Went to church one Sunday morning with an almost full tank of gas. When I started the car in the church parking lot the yellow empty warning light was on. Then I drove to the nearest gas station for a couple bucks of gas. The light went out, but the gauge continued to wobble. Then a week later the check engine warning light came on. After all this, the car passed inspection. Now both the yellow low-gas warning light and the check-engine light are on again & won't go off. The technician told us that the fuel sensor is bad & that repairs would cost up to $800. 00.

16 Tank Assembly problem of the 2007 Hyundai Santa Fe

Failure Date: 03/31/2011

Fuel sending unit. I had it replaced in December 2011. Having problems with gas smell in cabin of SUV. Hall Hyundai of newport new on jefferson Ave. Put the unit it. Since the unit was install I have smell gasoline. Took it in to hall Hyundai if newport news on Saturday, March 31, 2012 and they stated they could not smell anything. I explain to them if, it is full you get a strong odor of gas. If it is at half tank, no smell. So I was advised to bring it in at half tank. Nothing was resolved. Still smelling gas. Took vehicle over to hall Hyundai of chesapeake April 7th, 2018. I filled the tank up so the order could be smell and it was noticed. They stated that they took out the back seat and took the unit out and put it back in and tightened it. They say the cleaned the carpet and ionized it. I was there from 9:40 a. M. Until 4:20 p. M. When I got into the SUV a strong odor of cleaning solution was present. It is now Monday, April 9th 2012 and the present of the smell of gas it still there. I am so tired of driving and getting headaches. All I want it the SUV repair. Question: why would[xxx] at the chesapeake say, she is going to contact the service manager at newport new hyundia and let them know what was done. So, was something wrong and if it is who is going to pay for it. That is the big battle between the dealers. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

17 Tank Assembly problem of the 2003 Hyundai Santa Fe

Failure Date: 02/26/2011

The contact owns a 2003 Hyundai Santa Fe. The contact stated the bottom of the fuel tank was rusted and leaking fuel. Whenever the vehicle was parked there was fuel on the ground under the vehicle. The dealer was contacted who advised that they had never heard of the type of failure and there were no recalls for the vehicle. The vehicle was repaired at the contacts expense. . The manufacturer was notified, but no assistance was provided. The failure mileage was 86,000.

18 Tank Assembly problem of the 2010 Hyundai Santa Fe

Failure Date: 01/21/2011

I purchased the 2010 Hyundai Santa Fe new with only 60 miles on it in June 2010. In January 2011 we began smelling a fuel smell. This occurred only after the car was running and shut off then subsequently turned back on less than an hour later like when running errands. I never smelled gas if the car sat overnigt. We also would experience an intermittent long crank. I brought the car to the dealer in January 2011 and they replaced 2 o-rings that they stated were leaking and found fuel around. After these were replaced, I still had the same problems. I brought the car back in February 2011 and no known problems were found by the dealer. Again, I brought the car back in March. This time they found fuel in the charcoal canister. They stated I was overfilling the tank which was why there was fuel in the charcoal canister. After speaking with the manager, they agreed to cover the part and labor at no charge and replaced the charcaol canister. After this was replaced, I no longer experienced the long crank but I still smell gas after running errands. Hyundai will again be looking at the car for any other problems, but the dealer is really stumped so far on this.

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19 Tank Assembly problem of the 2003 Hyundai Santa Fe

Failure Date: 09/14/2010

The contact owns a 2003 Hyundai Santa Fe. The vehicle was parked when the contact noticed fuel on the ground and that the fuel tank was leaking. The vehicle was taken to a repair shop where the contact was informed that the fuel tank was corroded and rusted. The contact called the manufacturer who stated that the vehicle was no longer under warranty and offered no assistance. The failure mileage was 90,060.

20 Tank Assembly problem of the 2007 Hyundai Santa Fe

Failure Date: 08/18/2008

Major problems with our 2007 Hyundai Santa Fe including gas tank door latch needing to be replaced, car shaking uncontrollably, which the dealer diagnosed as a coil issue. The last problem led to the car being towed to the dealer. They are replacing the transmission due a failure of the car to accelerate and then lurch into gear, creating a very dangerous situation.

21 Tank Assembly problem of the 2001 Hyundai Santa Fe

Failure Date: 08/11/2001

When getting gas, the pump always 'clicks off' when tank is 1. 5-2 gallons from being full. The only way to ensure a full tank is to continue pumping until gas comes out the top of the filler neck. This usually means overriding as many as 50 pump 'click offs'. On the edmunds chat room I have seen other Santa Fe owners complaining about the same problem so I believe this is a design flaw with the vehicle. By the way, I have yet to find any gas station where this does not occur. Obviously, this method of getting a full tank is not desirable but what's the point of having a 17 gallon gas tank if it will only take 15 gallons of gas? thank you.

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Other Common Gasoline Fuel System related problems of Hyundai Santa Fe


Safety Ratings of Santa Fe Cars
Fuel Economy of Santa Fe Vehicles
Santa Fe Service Bulletins
Santa Fe Safety Recalls
Santa Fe Defect Investigations