Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Hyundai Santa Fe owners, lightly cleaned up (personal details are redacted by NHTSA).
In transit, it began smoking and the engine light came on. After pulling to the side, flames erupted and it became fully engulfed, followed by a small explosion. The vehicle and it's contents were a total loss.
Last night my mothers 2004 Hyundai Santa Fe caught fire the car had been parked for hours, the keys were not in the car it was completely off. It made absolutely no since untill I done some research and seen the lawsuit for this same thing and I wondered why this model was not included. I also seen multiple people wondering the same thing about their 2004 Hyundai Santa Fe. My father was the only one iat the house and in the house he could have lost his life and everything they own the only way he knew it was on fire was a neighbor saw and started screaming and started backing up to the vehicle to pull it away from the house a police report was made but what is she supposed to do for a vehicle? When no one even started the fire.
This vehicle was driven approx. 1/2 mile from home when power steering and brakes failed. It was pulled off of the road and stopped with the emergency brake. Immediately flames shot up the windshield. The entire interior was completely destroyed as well 3/4 of the exterior.
Allstate found that there was 1) water pump failure 2) some form of drive belt failure, and 3) the interference engine had parts collide within the engine leading to a fire. This occurred as my pregnant wife was driving down the road. Hyundai is currently negotiating with me to reimburse me for the total loss. Of course, they are not offering me what I lost on the investment at this point. The dealership was found to not be liable by the bbb; therefore I am communicating directly with representatives at Hyundai motor co. I am very concerned about the safety of this vehicle, and I am curious about whether we are the only family that this has happened to. I can provide you with the 12 page insurance company report; I lack any knowledge of engines and how they work, but it appears to me that this is an extreme danger to consumers. I believe this should be investigated further. …
As I approached a stop light and my car began to slow, it didn't shift all the way into first gear. While stopped at the light, it remained at a high RPM while the brake was pressed. When the light changed, and the gas pedal was pressed, my car "kicked" down into first and immediately back in to second. A few days later while at a stop light, my car died. After a few minutes, it started back up. After bringing it to the dealer (it had died on my three times at this point) to have it serviced, I was told that they could not find anything wrong with the vehicle. They were able to "feel" the shifting issues when stopping but they couldn't tell me what was wrong with it. …
I have a 2004 hyundia Santa Fe and the engine started with loud knocking sounds in my driveway. I had it toll to avondale earnhardt hyundia's dealership. The diagostic was "found engine knock can be heard at bottom end of engine. Failure in rod bearings is causing excessive noise in bottom end. Engine required" replacement. The car has 125,000 miles which exceeds the 100,000 powertrain warranty. However, my engine failure is the same as the current "engine failure recalls (theta ii engines) caused by manufacturing processes. Except the 2004 hyundia Santa Fe was not included on the recall list. I spoke and submitted twice a compliant to hyundia customer care department to replace my engine and was denied an engine replacement. I have been without a car since November 20, 2020. Today, customer care department notified me by phone of the second rejection. …
2004 Hyundai Santa Fe 2.7 liter engine, high idles at 3,000 RPM on start up and never goes down even when engine reaches normal operating temperature, automatic transmission not even acting right since this problem started, this is a hazard and can cause an accident. The car shows no engine codes, or transmission codes, it has had lower intake, upper intake gaskets changed, iac motor changed, throttle position sensor changed, temperature sensor changed, cleaned throttle body bore where throttle plate closes, changed vacuum hoses, made sure throttle cable and cruise control cable were binding or holding throttle open, and none off these things have helped. …
Car stalls without warning while driving. First occurrence was over a year ago. I was driving down i5 going 70 MPH when the car suddenly died. I lost my power steering and brakes. I managed to coast to the next exit. It started after sitting a few minutes. And I was able to make it home. I've received codes for camshaft sensor, misfires, low catalyst. I've changed the cam and crank sensors, coils, spark plugs, timing belt and assembly, fuel pressure regulator and fuel pump over the past year. Still having the issue. Car drives fantastic for about 10 miles and stalls out. After waiting about 5 min. It can be driven for another few miles before stalling out again. Check engine light does not turn on when it stalls now. Very dangerous when trying to drive in town or attempting to merge into traffic. You never know when it will stall out.
My pregnant wife was driving down the highway. There was no accident. There were no warning signs before it was to late. Wife saw smoke coming up from the engine of our 2004 Hyundai Santa Fe (odo 24,000 miles). She pulled over to the curb. The vehicle had never done this before. My pregnant wife was pulled out of the burning vehicle by a passerby. Wife suffered a contusion to her right cheek during this incident. She did not know the vehicle was on fire. She notified 911 who sent a fire truck and police officer. The vehicle exploded at least 3 times as she waited outside in the cold, frenzied by the disaster. The fire was so intense that the front wheels were melted. A policeman and 2 fire trucks responded to the blaze. The vehicle has been declared a total loss by allstate. Reliable imports (springfield, mo.) would not even help us obtain a rental car. …
After starting vehicle and while driving, engine shuts down immediately and without warning. Was able to steer to the side of the street it as it was still rolling. No indications came on as to what the issue May point to. I shut the engine off and waited for a tow to my home which I total took about 45 minutes. Once at home the vehicle started with no issues. For the next two days my vehicle was at my mechanics and he could not reproduce the problem. I went ahead and had the transmission. Flushed as him and I had discussed as one of the last things to get serviced before winter. Later that day I drove a longer distance with top speed about 65 MPH with no issues. Just as I was returning home the car shutdown as I was crossing a busy intersection. Luckily, again I was able to steer the rolling vehicle to the side of the road. …
Engine complaints in other Santa Fe years
Frequently asked questions
How common are engine problems on the 2004 Hyundai Santa Fe?
NHTSA has 38 complaints about the engine & cooling of the 2004 Hyundai Santa Fe, 13% of the model year's 303 complaints. The component named most often is engine (5 mentions).
Is there a recall for 2004 Hyundai Santa Fe engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Hyundai Santa Fe, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Hyundai Santa Fe engine problems start?
Half of the complaints with a recorded mileage happened before about 60,000 miles, and 29% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 5 fires and 1 injury to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.