2022 Hyundai Santa Fe

Ref NHTSA TRACKING # 11557625 Vehicle broke down again within 5K miles and 45 days of prior repair referenced in above case. Similar conditions, highway speed, bucking and vibrating, loss of speed control, no warning. Subsequent repair confirmed same issue (fuel injector) as original breakdown/repair and my initial notification to NHTSA.

Vehicle began to shake, buck and emit a grinding noise while traveling on highway resulting in loss of speed control and associated fear. Check engine light appeared simultaneously. No prior indication of a problem. Managed to limp to next exit via shoulder. Had car towed to dealer as warranty was still in effect. Problem was diagnosed as fuel injector failure and repaired. Learned it is a common, recurring issue with Hyundai 4 cylinder engine. Not unusual to have multiple failures per vehicle. Hyundai is only authorizing repair/replacement upon individual failures, not pre-emptive even though common and recurring. Confirmed this is a common, recurring issue across Hyundai via our local mechanic and internet info. Vehicle has now experienced a second failure and is being towed to dealer.

On 10/31 I loss power while on the freeway for the 2nd time since August. The car was assessed and fixed according to the dealership. My car threw a 2nd code which was cleared and not fixed due to not showing issues according to the dealership. I got my car back in mid November. I immediately complained that I still had a rough idle and was told my car was fine by the manager via service rep. On 11/28 my car loss power on the freeway again for the 3rd time since August. According to the codes, all my cylinders are failing one by one. This is a huge safety concern. The dealership could care less.

Phantom emergency braking occurred on two separate occasions a few months apart while traveling at 50-60 MPH for no reason. Almost rear ended. Flashing red zigzag alert stating “Emergency Braking”. Vehicle towed to dealership for inspection and diagnostics. Afraid to drive on freeway or highway. Dealership unable to reproduce or solve issue first time. Now at another dealership for inspection.

The issue with Hyundai 2.5 L turbocharged engines is getting a lot of exposure on-line. My story begins about a year ago with me complaining to the Hyundai service department about my 2022 Santa Fe Limited hesitating, lurching, and stalling (once) following acceleration from a complete stop, all without the Check Engine Light (CEL) illuminating (which the dealership said is needed to initiate troubleshooting). In addition, there is a common thread where dealerships are telling owners that it is "... probably bad gas." On 2 October 2023 the SUV started and was idling very rough, and as I drove off, the CEL illuminated (finally). After turning off the SUV for five minutes, it started fine with no CEL. My OBD-II code reader pulled three codes from the SUV that afternoon: P0300, P0301, and P0302 (Misfire - General, Misfire - Cylinder 1, and Misfire - Cylinder 2). The trouble codes should be sufficient for the service department to locate a problem, and to their credit I was placed in a loaner vehicle when I dropped the SUV off on 7 October 2023. So far (24 October), they have not identified a problem, even though there is a fuel injector Technical Service Bulletin (TSB) for multiple Hyundai vehicles (including my Make/Model/Year) that may or may not apply to my specific vehicle. Bottom line: The vehicle is unsafe to drive (as I told the service manager), has had this problem for approximately one year, and if the vehicle stalls when I am entering traffic it is not going to end well - not for me in a stalled vehicle and not for Hyundai after they had an opportunity to address the problem.

Vehicle check engine light came On while driving and vehicle began misfiring. Vehicle was in the shop and injector was found defective. Vehicle again had same issue but intermittently and wife would have to pull over and shut down the car to be able to drive it safely home. Dealership tried blaming bad gas which was purchased a mile from dealership. Within 50 miles vehicle began acting the exact same way and Hyundai dealership says injector needs replaced but blaming contamination not a known issue Hyundai has with injectors. Found multiple instances of same issue and same made up issue of contaminated gasoline even at the same dealership I went to. Faulty injectors make the vehicle unsafe when traveling at highway speeds on busy highways.