Hyundai Repair: 03 Santa Fe 2.4L 59800 miles, air intake hose, crank sensor


Question
Ok just to give you a little background info on this situation...  First in January this year I had the car brought to the dealer for P0402 which is EGR related to insufficient flow.  They stated they replaced the hose with the green stripe on it.  Had to bring car back to them the very next day for the same code again which they replaced the EGR valve.

   Beginning of March had the vehicle towed to the dealer cause of a stalling issue which they stated it was a loose air intake hose to throttle body.

   Two weeks later I notice the check engine light would not illuminate 2 seconds when the key is turned to the 'on' position.  I hooked up the code reader to see if it would work  which it pulled again P0401.  Back to the dealer it goes...  After them having it a week they said everything was fixed except for the check engine light which they orded a relay for it, they returned the vehicle and said the part would be about 7 days or so...

    Two days after they gave it back, a tooth broke off the timing belt and wiped out the the crank sensor.  To the dealer again, and had all new belts and crank sensor put on along with the relay which did not work.  So now they narrowed it down to a cirucit board in the instrument cluster which would be another week for the part to come in...

   Now just the other day I had the car back at the dealer which they installed the new cicuit board and the check engine light works as it should now, however in the process of fixing this problem they (dealer) cracked the instrument cluster face (clear plastic in front)and told me they will order me a new one & the "D" indicator does not illuminate now when I shift into drive....which also means I have to bring the car back once again to have this done...  The real kicker is the evening I picked the car up from the dealer after them fixing the CEL that night the CEL came  on and it is now giving me another P0401...

    I am just very agrivated with the number of times I have to keep bringing the car into the dealer...  I understand about the timing belt issue and the CEL issue, but what is with the EGR problems?  I'm almost at 60000 miles, there is not another dealer I can go to, and I'm not sure my current dealer is trustworthy....

Answer
I must say that the whole check engine lamp not coming on issue is quite suspicious.  P0401 is one of the more difficult codes to diagnose.  (P0402 isn't used on your vehicle, and the definition you give is for P0401).  I'm suspecting the technician had difficulty finding the problem and then removed the bulb from the check engine lamp.

Ordinarily, I'd shy away from such statements, but the fact that a relay was ordered to fix the check engine lamp indicates that the dealer or mechanic either has absolutely no idea how the check engine lamp circuit works, or said they ordered the relay just to make you go away until they put the bulb back in on the next visit.  

I'd recommend calling Hyundai customer assistance (800-633-5151) and apprising them of the situation.  Just give them the facts pertaining to the check engine lamp and the P0401 code that you've given me.  Don't mention my speculation as to what happened, as it would be recorded and may cause the dealer to not want to assist you, especially considering they're the only game in town.  Explain to them your concern that you'd like the P0401 issue repaired under warranty since it's obvious you've had an ongoing problem from within the warranty period that has yet to be corrected.

Your case will go to the attention of the dealer and the factory representative.  Any factory rep worth his salt who looks at your history will have exactly the same suspicions I've had.  If you're lucky, Hyundai will commit to standing behind this issue until it's repaired properly.  In any event, stay in contact with customer assistance with any problems you have until the issue is resolved.