Engine owner reports: Hyundai Sonata years in the records

The records describe a possible crash, fire, injury, or loss of control.

“The lower aluminum engine oil pan developed a structural hairline fracture ("micro-crack") directly along the factory casting ridge adjacent to the drain plug. The component failed without any external impact, road hazard, scraping, or underbody damage. The failure was officially confirmed and documented by Eckert Hyundai during a service visit on July 13, 2026 (Case #42971835). Following the dealer oil service, the fracture degraded into an active, worsening oil drip that requires a catch tray under the vehicle to capture leaking fluid. The vehicle is currently available for inspection. Safety Risk: An active engine oil leak poses a significant safety hazard. Rapid or continuous loss of engine oil can cause sudden oil starvation, severe engine seizure, or total power loss without warning while driving at highway speeds, increasing the risk of a crash. Furthermore, dripping oil contacting hot exhaust or engine components presents a potential fire hazard. Prior Symptoms / History: This vehicle has a well-documented history of severe internal engine issues and thermal stress, including excessive oil consumption (running 1.2 quarts low in 1,127 miles), valve cover gasket failure, and severe drivetrain vibrations from failing front axles. The excessive internal crankcase pressure and thermal stress from these underlying defects contributed directly to the material fatigue and structural failure of this aluminum oil pan.”

The records describe a possible crash, fire, injury, or loss of control.

“I purchased my vehical at Car Culture in Warren, Oh. The dealer said to only take it there for maintenance, so I did as required. Whenever the check engine light came on I would bring it there and they would say it was a sensor and they fixed it. And one day it started miss firing and the light came on again. When I took it to the dealership, they said it needed oil to bring it in every 2 weeks to top the oil off. And so I did that and finally the car was getting worse at 122,000 miles. When I took it there they said it needed a new motor!!!. They NEVER told me of a recall or a sensor replacement needing done by hyundai. Iam now stuck with a $13,000 loan on a car worth nothing without paying $5,000 on a "possible" fix for their negligence. I have a [XXX] old son, fiancee, morgage and a job im struggling to get to, because I was never notified of a possible recall on my year, make and model of car. Please help me. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)”

The records describe a possible crash, fire, injury, or loss of control.

“Vehicle caught fire after repeatedly taking it to Hyundai for service . I complained about the oil consumption and knocking noises while the vehicle was still under warranty and it was denied.”

The records describe a possible crash, fire, injury, or loss of control.

“I am submitting this complaint to report a serious and ongoing safety defect involving the engine of my 2018 Hyundai Sonata Sport equipped with the 2.4L Theta II engine. The vehicle has been officially tested and documented by Hyundai as consuming more than two (2) quarts of engine oil per 1,000 miles, which Hyundai has acknowledged following completion of its oil consumption test procedure. Despite this confirmation, Hyundai has declined to fully correct the defect. As the condition has progressed, the engine now fouls spark plugs every 350–500 miles, resulting in: •Engine misfires •Loss of power during operation •Rough running and hesitation •Risk of sudden engine stalls while driving This condition occurs without warning and requires repeated roadside or emergency repairs simply to keep the vehicle operable. The condition has deteriorated further, requiring replacement of fouled spark plugs every 350-500 miles. Loss of power and engine shaking can occur at any time, presenting a safety hazard for me and other drivers.”

The records describe a possible crash, fire, injury, or loss of control.

“Despite proper maintenance, the vehicle is burning oil at an excessive rate. I have already replaced the oil pan, but the issue persists. I now have to add oil frequently between oil changes. This creates a serious safety concern, as low oil levels can cause engine failure while driving, leading to sudden loss of power or stalling in traffic. This puts me, my passengers, and other drivers at risk. There are no visible leaks, which suggests the oil is being burned internally. This appears to be a potential defect rather than normal wear and tear. I am requesting that this issue be investigated as it may affect other vehicles of the same make and model. This is becoming very expensive having to refill oil as the dipstick shows nothing. This has been confirmed by technicians that there has been no oil in my car despite coming in on time or before the recommended miles. The oil light will come on a few weeks after having the oil changed. It seems this is an issue with this engine type.”