2012 HYUNDAI SONATA Engine Problems

My 2012 Hyundai Sonata recently had an engine replacement completed under a Hyundai recall. Immediately after the recall repair, the vehicle began shaking while driving, produced a burning smell, and the air conditioning stopped working, none of which occurred prior to the recall repair. These symptoms started immediately after the engine replacement, indicating a possible improper or unsafe installation. I believe the vehicle is unsafe to drive due to the burning smell and shaking. I contacted Hyundai Customer Service and was told the issue must be resolved with the dealership. However, the dealership has refused timely inspection, has dismissed my safety concerns, and has declined to provide a rental or loaner vehicle, leaving me without safe transportation. This is a post-recall safety issue, and I am concerned about the risk of fire or mechanical failure due to the burning smell and vehicle instability. I am requesting this issue be formally...

The contact owned a 2012 Hyundai Sonata. The contact stated that while driving to her residence at unknown speeds, the vehicle suddenly caught fire while making a U-turn. The brakes and emergency brake were inoperable. The seatbelt was inoperable. The driver jumped out of the window. A pedestrian attempted to alert her of the fire. The vehicle exploded after exiting the vehicle. The contact sustained an injury to her leg, but no medical attention was provided. The fire department extinguished the fire. A police report was filed. There was no report of a crash or airbag deployment. The vehicle was towed to a tow lot. The local dealer was contacted, but the vehicle was not diagnosed or repaired. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 136,000. The vehicle was auctioned off by the towing company.

The engine in my Hyundai Sonata (replacement engine VIN [XXX] ) experienced a complete internal failure. The component that failed is the 2.4L Theta II GDI engine, which is known for issues related to metal debris, oil restriction, rod bearing wear, and resulting piston and compression failure. The failed engine is currently at the dealership (Carolina Hyundai) and is available for inspection upon request. My safety was put at risk because the engine lost power unexpectedly, ran extremely rough, and became inoperable. A sudden loss of power while driving could have caused a crash, especially in traffic situations. The problem has been reproduced and confirmed by the dealership. They performed a compression test and found all cylinders at extremely low PSI (35–45 psi). The dealer stated the engine cannot perform the required bearing clearance test due to the level of internal damage. Hyundai Corporate initially declined assistance, calling it a...

My 2012 Hyundai Sonata (VIN: [XXX] ) experienced complete engine failure at 241,433 miles on August 7, 2025. The failure aligns with known safety defect symptoms described under NHTSA Recall Campaign 15V568000 and 17V226000, which cite premature bearing wear due to metal debris during engine manufacturing. My vehicle had previously received the knock sensor update under Campaign T3G and failed the BCT (bearing clearance test), confirming bearing damage. Despite this, Hyundai denied my engine replacement claim, stating the issue was related to a fuel pipe and not a rod bearing issue—this is contrary to their own recall documentation and dealer diagnosis. Hyundai continues to deny engine replacement, in violation of their federal recall obligations under 49 U.S.C. §30120. Their refusal endangers public safety by ignoring engine failures that can lead to stalling and crashes. I request NHTSA intervention to compel Hyundai Motor America to comply with federal law and perform...

My 2012 Hyundai Sonata cut off and stopped working! The vehicle locked up in the middle of a main street and would not start back up causing a very unsafe situation. There were no check engine lights on or anything at the time of the incident I immediately had the vehicle towed and inspected it has been determined that the engine is failing! Upon research I found out that these engines have had recalls in the past. Carfax shows that the vehicle has been taken in for routine maintenance and oil changes when needed. I am looking to see if the engine replacement could be covered for this vehicle.

My engine seized on the highway on my way home from work. The service department has been horrid. They lied about who the manager is. They lied about the reason behind not wanting to honor the recall. They are rude - threatened to tow my car today after I waited 6 days to hear back from them about the issue with my car and determination. Was extremely rude. Stated that they were not honoring the recall because there was obvious signs of my engine being tampered with or certain parts on my engine, but could not provide a name of the part or a serial or model number so that this could be verified. I need this addressed immediately.

Vehicle loses power while driving making it unsafe to drive, it can cause an accident in certain conditions like when passing another vehicle or crossing a street. There is a recall for this issue.

Driving came to a stop ,light turned green made a U-turn to go to the gas station heard a pop noise smoke came from inside the car tried stopping it but the brake pedal sunk into the ground pressed my emergency brake it was seized wouldn’t go down (never had that issue my brakes always work ) I smelled brake fluid and seen the abs light on the dash then the power started to go out and my girlfriend almost got trapped in the car

The contact owns a 2012 Hyundai Sonata. The contact received notification of NHTSA Campaign Number: 18V934000 (Engine, Fuel System, Gasoline). The contact stated that while driving 20 MPH, the vehicle stalled. There was an abnormal knocking sound coming from the vehicle. While driving at an undisclosed speed, the vehicle stalled after five minutes. The engine and the ABS warning lights were illuminated. The vehicle was towed to the residence. The contact called the local dealer and was informed that the maintenance records were needed. The contact was using an independent mechanic for maintenance and did not have the records. The vehicle was not diagnosed or repaired. The manufacturer was contacted and opened a case. The failure mileage was approximately 100,000.

came off the highway to a stop sign went turn and the engine just seized and would not start no matter what I did. had to have it towed to my house. safety risk was just off the road so i did not get hit. police stop and told me to get a tow truck. and no warning signs at all

My 2012 Hyundai Sonata originally had its engine replaced under Hyundai’s recall (NHTSA Recall #17V226000) due to the Theta II GDI engine defect. The replacement engine was installed by the dealership as part of the recall. However, the replacement engine has now failed after only ~50,000 miles, exhibiting the same issues (engine knocking, stalling, and eventual failure). This occurred despite proper maintenance and care. The dealership contacted Hyundai, and I also contacted Hyundai Consumer Affairs directly. Both refused to replace or assist with the failed replacement engine. It is unacceptable that a recall replacement engine would fail so soon and that Hyundai will not stand behind the part they used to correct a safety defect. The issue remains a serious safety concern, especially since engine failure can lead to fire. I request that NHTSA investigate the durability and safety of replacement engines and Hyundai’s refusal to support affected owners when...

With no warning my car left me sit on the side of the road and when started the engine made an awful knocking noise. Hyundai denied to replace the engine despite there being at least 2 engine recalls. When I asked why they said it was due to no maintenance records so I provided them with maintenance records like they requested and then they deny it again and say they aren’t replacing the engine because the problem with my engine had nothing to do with the 2 engine recalls my vehicle IS affected by.

This is the first time I have an engine failure. I drove my car 3 min before merging into the route 1 highway. In approximately 800 feet, my car went haywire, all lights in the dashboard went ON, the steering wheel got stiff, and the car speed dropped off, I almost got rear-ended. I made an effort to pull over to the break lane. The car shut off and I could not get it to start. I opened the hood, a light smoke was coming out of the engine. I left it open to make sure it doesn't get worse. After 10 min, a State trooper stopped by to check on my safety, I informed him that I called the insurance to report the incident and request a tow truck. After the tow truck dropped off my car in front of my house, I called a mechanic to check it,...

I bought car octv230th little after month as driving engine failure occurred had towed to dealership and they sent to authorized hyndai dealership for the extended warranty campaign. That garage acknowledged problems with the cars engine stating rod bearing clearance and the engine had to be replaced then charged me denied the extended warranty they initially said would classify for. I couldn't keep up with traffic and was very busy almost cause a crash.

I was driving I seen smoke then full flames on my windshield and I tried to stop and put my car in park to get out but my brakes stopped working and I couldn’t get the gear in park so I opened the driver door and had to jump out of the car .I had an engine replacement a year before for it being recalled and police and firefighters were on scene after incident

Engine seized due to extremely low oil despite more than regular oil changes.

It first started when the engine needed to be replaced, I spent thousands trying to get it repaired, soon after they fixed the engine everything started going wrong ( I truly think they put in a faulty or wrong engine @ Hyundai) the car was overheating, I would take it in they would say it’s one thing pay thousands and it wasn’t it, changed the coolant that goes into the cabin, there’s always been a chemical smell since…still overheats, they said maybe it’s the thermostat, spent more money still didn’t fix it, the battery now won’t stay charged(trunk battery) not sure if they hooked it up wrong…the seatbelt hasn’t worked in years, I take it in they say it’s fine, it never clicks, I have to click it in to the passenger seat for safety. They always say it’s fine! I will never ever buy another Hyundai in life due...

On [XXX] while driving approximately 1.5 hours away from home, a warning message appeared on my dashboard stating: “Hybrid System Warning. Stop and Do Not Drive.” I immediately pulled over and contacted my insurance company, who arranged for the vehicle to be towed to the nearest authorized Hyundai dealership (Thomas Hyundai in Cumberland). The warning clearly indicated that it was not safe to continue driving. Later, I found out that the issue reported (recall 198) have presented cases ending with fire of the engine. It is critical to mention that in January 2025, I attended the official manufacturer recall for this vehicle, which was supposed to ensure safety and reliability. Despite this, the vehicle failed and left me stranded in an unsafe area. Since then, I have been without my vehicle for over three weeks. I contacted Hyundai customer care and opened a case. I was repeatedly told a case...

While driving on the highway with my two minor children, my vehicle suddenly shut off without warning. I lost power in the middle of traffic, which was extremely dangerous — we were nearly rear-ended and had to coast to the shoulder. The check engine light had been on for some time prior to the incident, but there were no other warning messages. After being towed, the car would not start again, even after attempting to jump-start it. A mechanic inspected it and believes the engine is seized. I later discovered that my 2012 Sonata is equipped with the Theta II engine, which is known for sudden failure due to oil starvation or bearing wear. Although there are no current recalls on my VIN, the symptoms are consistent with the known Theta II engine defect. This situation put me and my children at serious risk, and I believe this failure needs...

Butts County Fire and Emergency Services made a report about the car catching on fire. There was an electrical problem and/or the engine caught on fire. My son’s fingers got burned and he was taking to the emergency room. Further neurological damage done to all of his finger tips. No warning car just blew up in fire. My son’s fingers could have died during the car fire.

Hybrid system malfunction Do not Drive warning light comes on while driving and stalls out the car

The contact owns a 2012 Hyundai Sonata. The contact stated while driving 35 MPH, the vehicle was leaking engine oil. There were no warning lights illuminated. The contact towed the vehicle to an independent mechanic who diagnosed the vehicle with engine failure. Due to the oil leak, the vehicle was left with no oil in the engine, causing the engine to seize. The dealer was made aware of the failure; however, the contact was informed the vehicle only had a 60-day warranty. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 105,761.

The contact owns a 2012 Hyundai Sonata. The contact stated that while attempting to start the vehicle, the vehicle briefly hesitated before starting. After starting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed a failure with the engine. The contact was advised to take the vehicle to the dealer for assistance. The vehicle was not repaired. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 137,000.

The contact owns a 2012 Hyundai Sonata. The contact stated that while driving 45 MPH and depressing the accelerator pedal, the vehicle failed to respond as needed, before the engine seized. The contact stated that unknown warning lights were illuminated. The contact pulled over to the right side of the road and attempted to restart the vehicle several times; however, the vehicle failed to respond. The vehicle was towed to dealer, where it was diagnosed and determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 128,000.

On [XXX] at approximately [XXX], my [XXX] Daughter was using my car to go to work. When she called us and informed my husband that the car did not start. At that point he asked to video call him so that he can visually see what was going on. She was directed to turn on the car again at and that point, the car started then smoke was noticed from coming out of the hood. My daughter managed to open the hood where flames emerged from the center of the engine. She then ran in the house to get a fire extinguisher and managed to put it out and it reignited. She then made a second attempt with another fire extinguisher where it briefly subsided and then grew larger. At that point the fire dept arrived and successfully extinguished the fire and deemed the car totaled after the Fire Marshall...

Unknown Cought fire under the hood was engulfed within minutes

Engine oil level goes low very soon after an oil change less than 1000 miles driven and oil becomes black on dip stick when checking the oil level in between oil changes and there is no noticeable oil leaks. At one point the oil level was below the low level indicator on dip stick.

When driving. Slow down to turn or to use round about car goes into EV. When i go to accelerate the gas motor will not re engage and the hybrid alarm system will go off. I lose all power to go any where. I have to pull over shut my car off give it a min then restart so the motor will come back on so i can drive again. I have to do this mulitple time in a 20 mile drive.

Engine suddenly shut off middle of the road while driving and will not restart. No warning lights came on prior to the engine failure. My family safety was put at risk since engine shut off middle of the road and I had to push it to the corner lane. Just imagine if I was on the middle lane on a highway when this happened. Alternator, battery was checked by a mechanic...no issue.

I took the car to the dealer because the codes was reading engine assembly issues. I took it to the dealer and they stated it was the knock sensor and they got it approved to replace it now they saying it's the engine and it was denied. I just got the engine from the dealership in 2020

Oil consumption engine issues

Car engine light is flashing

Received Hyundai recall 251 the end of 2023. Car taken to Hyundai dealer in March 2024 and dealer could not make the repairs on the recall. The end of July, the car caught fire (engine fire) when the car was parked for 10 minutes. Car and adjacent structure was destroyed.

My daughter had her car towed to the Hyundai dealership because of engine failure. Upon inspection we learned that there was a recall on the engine. We had to wait a few weeks so that the dealership could get approval and authorization to replace the engine. Finally after 3 or so weeks we got a courtesy car to drive. After about 4 weeks our car was finally ready to pick up so we took the courtesy car back and picked up our car. After about 4 months or so maybe my daughter went to her friends house one afternoon and her and her friend left in the friends car. They had been gone maybe 10 minutes or so and her friends neighbor called her friend and said that her car was on fire and they had already called the fire department but the car was engulfed in flames and before...

connecting rod bearing failed

The contact owned a 2012 Hyundai Sonata. The contact stated while driving at an undisclosed speed the low oil warning light illuminated. The vehicle was taken to an independent mechanic where it was diagnosed that the engine had failed and needed to be replaced. The vehicle was not repaired. The dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 170,000.

The contact owns a 2012 Hyundai Sonata. The contact stated that while driving 30 MPH, the vehicle shut off. The contact restarted the vehicle, and an abnormal knocking sound was coming from the engine compartment with the check engine warning light illuminated. Despite the vehicle repeated engine shut off failure, the contact was able to drive the vehicle to an independent mechanic for service. The vehicle was diagnosed with a rod bearing failure. Neither the dealer nor the manufacturer was notified of the failure. The vehicle was not repaired. The failure mileage was approximately 124,000.

On July 29, 2024, my 2012 Hyundai Sonata Hybrid was parked in our driveway. About 10 minutes later an engine fire started that consumed the car. The local Fire Departmemt put out the fire but the car was totaled. The fire also destroyed a storage shed and some windows were damaged. The car was taken to the Hyundai Dealer for servicing when the engine light came on on March of 2024. The car was left for a few days with the dealer. The NHTSA Recall Number 23V651000 was not repaired during that service call.

Engine stalled in middle of the road while travelling. It put me in danger of getting into an accident. Tried getting appointment with dealership and nonappointments available for next 30 days. No warnings before the failure.

Airbag clock springs module malfunction disabling emergency deployment of the driver’s side airbag in the event of a collision. My 2012 Hyundai Sonata 2.0 Turbo with 93,336 miles on it, ending seized up going at highway speed causing instant and complete loss of power. Smoke started coming out from under the front engine compartment hood making me think the car was on fire. Trying to get the car manuvered off the highway and over to the right side of the road I was almost involved in a collision with other traffic. I was scared almost to death. Hyundai Motor America is now refusing to repair my vehicle even though it is covered under their extend warranty.

On the morning of April 15, 2024, at around 6 a.m., our 2012 Hyundai Sonata Hybrid unexpectedly caught fire and exploded in front of our house. This incident occurred shortly after I started the car and left it to warm up. Smoke and flames emerged from under the hood, quickly escalating until the front of the vehicle exploded, shattering the windows and extensively damaging the driver and passenger sides. Previously, we had noticed a fuel odor emanating from the hood, which we suspected was related to a known fuel recall issue. We brought the vehicle to the manufacturer's attention, hoping for a resolution under the recall. Unfortunately, the manufacturer did not address the fuel smell as part of the recall services and instead billed us for unrelated repairs. This oversight on their part raises serious concerns about the safety and reliability of the recall process and the manufacturer's accountability in...

The engine failed causing my steering and breaks to lock up on the interstate going 70mph surrounded by 18 wheelers, which was a total surprise as my car had no warning lamps on. Fortunately, I was able to guide my Hyundai safely to the side of the highway where I waited 5 hours for a tow truck. After leaving my car at Hyundai for 3 weeks due to an engine recall I was totally unaware of, they informed me they will not approve a new engine due to lack of service history? The only this lacking in my s"service history" are a few oil changes which I did myself due to the engine burning so much oil due to the recall. After eight years in the military as a mechanic I'm pretty sure I can handle an oil change on a sedan. Hyundai also refused to put me in a...

I was driving. The tailpipes started smoking I checked engine oil and it was almost empty. No check engine light came on. The engine could have locked up on me on a state hwy that has a 60mph limit! No warning light. No low oil light. No lights came on at all ever. The car still doesn't have any light on but has oil consumption like I've never experienced. The engine was replaced in 2019 and only has about 63,000 miles on it.

The contact owns a 2012 Hyundai Sonata. The contact stated while driving approximately 35 MPH, the check engine warning light illuminated, and the vehicle stalled. The vehicle failed to restart. The contact replaced the battery, but the vehicle failed to restart. After numerous attempts, the vehicle was able to restart but the failure recurred, and the vehicle stalled. The vehicle failed to restart. The vehicle was towed to an independent mechanic. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 100,000.

Approx one year post engine replacement, and 2 weeks prior turbo system replacement, I am having major issues with my sonatait struggles to stay started, it always hesitates and doesn't want to move when I press accelerator, shakes jolts and shudders, the smell of burning oil comes thru the vents and even smoke comes out from under the vehicle. The engine is leaking masses amounts of oil that seem to be leaking from all over the under carriage and half way to the back underneath the car, oil is in the wheel wells, and even splashed on the rims, the spark plugs are covered in oil, huge plums of white and dark smoke come out of the tailpipes, literally blinding anyone behind me, press the accelerator to the floor and it just shudders and smokes even more, check engine light is on and states malfunctioning turbo system, boost pressure sensor...

The contact owns a 2012 Hyundai Sonata. The contact stated that while driving approximately 45 MPH, the vehicle started to lose motive power with several unknown warning lights illuminated before the vehicle stalled. The vehicle was towed to the local dealer who determined that the engine had failed and needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure, but no assistance was offered. The contact was informed that the VIN was not included in NHTSA Campaign Number: 15V568000 (Engine). The vehicle had experienced the failure listed in the recall. The failure mileage was 152,000.

The contact owns a 2012 Hyundai Sonata. The contact stated that while his daughter was driving at 65 MPH, an abnormal knocking noise began to emit from the vehicle as the check engine light appeared on the instrument panel. The vehicle began to lose power as the contact's daughter coasted the vehicle into a parking lot. Due to the failure, the vehicle was towed to the contact's residence. Upon investigation, the contact discovered NHTSA Campaign Number: 15V568000 (Engine) which was linked to the failure. Neither the dealer nor the manufacturer had been notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 195,000.

2012 Hyundai Sonata engine ceased on [XXX] heading west away from Dallas, Texas on [XXX] leaving my young daughter stranded in the middle of nowhere on her way to Lubbock Texas. Daughter had car towed by AAA to the closest Hyundai dealer and Hyundai dealer did not advise daughter that recalled engine due to known failures that been replaced in or about 2011 at approx 60,000 miles was an engine known to fail post engine replacement and expected to fail again within approximately 50-60,000 miles oats replacement engine had same issues as original recalled engine. Daughter sold car as junk for $200 to service guy at shop not knowing engine could be replaced. Dealers are not being forthcoming about replacing the engine. In this particular Hyundai Sonata, which, even though was replaced, previously, was known and expected to fail again according to service people. Hyundai needs to be held accountable...

My engine has locked up at 60,000 miles . I got the car when it was only 30,000 miles on it back in Jan 2021. It locked up on me in Oct 2022. I took it to the Carolina Hyundai dealership . Corporate will not help me get the engine fixed because of the first owner not keeping up with the oil changes . But I did my part in keeping up with the vehicle maintenance. I even tried filing this with BBB Auto but it went in their favor . All because I could not get the information for the maintenance of the vehicle that happened 2012-2016. Due to privacy and security reasons . Auto shops will not release what was done on the vehicle and some was not reporting to CarFax then when the car was owned by the first owner . Please help .

My vehicle sometimes stops on the highway. I get the alert hybrid system warning, do not drive. The dealership was charging over $8000 to fix the problem. They even told me they don't know if the problem will be solved after changing my oil pump