Hyundai Santa Fe

The Theta II 2.4 GDi is also covered by the worldwide Hyundai recall. 3.9 million vehicles affected. Warranty extended to 15 years / 150,000 miles for connecting rod bearings.

Symptoms: Knocking from the engine, oil pressure drop, sudden engine stall, fire risk from metal swarf.

The G4KJ 2.4L GDi is part of the Hyundai Theta-II recall series. Metal swarf from crankshaft machining blocks oil galleries and causes connecting rod bearing failures. Affected models include various Sonata, Santa Fe and ix35 model years.

Symptoms: Metallic knocking, engine warning, oil pressure drop, engine stall

Like all Theta-II engines, the G4KJ is prone to timing chain stretch when oil changes are neglected. A jumped chain contacts valves against pistons. Workshop repair involves a complete chain kit and often cylinder head reconditioning.

Symptoms: Chain rattle on cold start, power drop, engine misfires

Like all GDi direct-injection engines, the G4KJ accumulates deposits on the intake valves. Regular engine flush or walnut-blasting every 60,000–80,000 km recommended.

Symptoms: Rough idle, acceleration stumble, P030x misfire codes, power loss.

The G4KJ tends toward measurably elevated oil consumption above 100,000 miles due to piston ring and seal wear. The class-action lawsuit against Hyundai for excessive oil consumption explicitly included the Theta engine.

Symptoms: Rising oil consumption to 0.5–1 L/1,000 km, oil pressure warning, blue smoke

Dirt and moisture can penetrate the ABS module and cause a short circuit leading to fire risk. 91,900 vehicles affected worldwide, of which 2,778 in Germany.

Faulty control of the electric oil pump causes pressure drop in the dual-clutch transmission and loss of drive force. Recall 21D155 affects production March 2021 to April 2022, 1,701 vehicles in Germany.

Steering wheel can separate from the steering column while driving, leading to complete loss of vehicle control. Recall NHTSA 18V118000 affects 41,070 vehicles.

Recall on the Santa Fe TM due to inadequate fuel tank reinforcement that poses a fire risk in certain crash scenarios. Affected vehicles received reinforcement plates.

Worn camshaft bearings on the 2.0 CRDi have been documented from as little as 33,000 km. A material defect in the cylinder head causes severe running noises and engine damage without any obvious prior warning.

The high vehicle weight of over 1,900 kg puts disproportionate stress on the braking system. Rear brake discs and pads wear faster than expected and need replacing sooner.

The vehicle identification number (VIN) stored in the eCall emergency call system may be incorrect and transmit wrong vehicle data in an emergency. Correction by dealer via software.

Leaking shaft seals at the transmission driveshaft are reported on the Santa Fe TM. Brown-rusty transmission fluid leaks out; the seal must be replaced multiple times if the shaft is worn.

Control arm ball joints and boots wear on the Santa Fe TM due to the high vehicle weight. First knocking noises after 40,000–80,000 km; MOT criticises axle joints.