p1326, rod bearing failure and seizure of motor without warning.
2012 Hyundai Sonata engine complaints
Page 2 of 20: complaints 11 to 40 of 578, newest first, as owners wrote them.
I am reporting a pattern of systemic failures on a 2012 Hyundai Sonata Hybrid with approximately 131,000 miles. This is my second the federal safety agency complaint regarding this vehicle and manufacturer. Primary Safety Concern — Engine Wiring Harness: During a recent engine replacement at an authorized Hyundai dealership, technicians identified damage to the engine wiring harness and documented in writing that the owner “might have issues with drive ability.” The dealership declined to repair it under the same goodwill program used to replace the engine and returned the vehicle with this known defect unresolved. The harness directly controls engine operation, hybrid system communication, and overall vehicle control. On a hybrid vehicle, a compromised harness presents a serious and ongoing safety risk. This component is available for inspection upon request. Engine Failure: The hybrid system warning light appeared prior to failure. The vehicle was towed to an authorized dealership where diagnostic code P1326 confirmed engine failure. The manufacturer acknowledged this and replaced the engine under goodwill. Additional System Failures: A pre-scan diagnostic revealed simultaneous fault codes across six systems — engine, transmission, ABS, active hydraulic booster, battery management, and motor control unit — including codes U0293 and U1004 indicating lost communication with the hybrid powertrain control module across multiple systems simultaneously. Independent Safety Advisory: A separate independent repair facility documented in writing that the vehicle presented a severe wheel hub bearing noise and formally advised of an extremely dangerous driving condition. Prior the federal safety agency Complaint: My first complaint to the federal safety agency involved this same vehicle when the manufacturer refused to provide a loaner during an extended recall-related repair hold, requiring formal escalation before they complied. The wiring harness defect remains unrepaired. The vehicle is driven daily out of necessity.
The contact owns a 2012 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, there was an abnormal burning odor coming from the vehicle. While depressing the accelerator pedal, the vehicle hesitated and stalled. The contact stated that the rear driver’s side brake light was inoperative. The failure occurred on several occasions. No warning lights were illuminated. The contact researched and was made aware of an undisclosed recall; however, the VIN was not included in the recall. The vehicle was taken back to the residence. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 168,000.
Vehicle: 2012 Hyundai Sonata Incident Date: August 14, 2024 Location: [XXX] Description of the Problem: The vehicle experienced a sudden and catastrophic fire without warning while in normal use. There were no prior warning lights, messages, or symptoms before the incident. The failure appears to have originated from the electrical system and/or engine (exact cause UNKNOWN), which resulted in the vehicle igniting unexpectedly. Safety Risk: This failure created an immediate and life-threatening safety hazard to all occupants. The vehicle caught fire suddenly, leaving no time to react or prevent injury. There was no crash or external cause associated with this fire. The incident required emergency response from Butts County Fire and Emergency Services, who generated an official report. Injuries and Trauma: My son suffered burn injuries to his fingers, requiring emergency medical treatment. There is neurological damage to the fingertips, indicating lasting physical injury. In addition, my son experienced significant psychological trauma due to sudden exposure to a life-threatening vehicle fire, including acute emotional distress during the incident and ongoing fear associated with vehicle safety. This demonstrates the extreme danger posed by a sudden, unpreventable vehicle fire. Inspection / Confirmation: The incident was documented by Butts County Fire and Emergency Services. At this time, manufacturer inspection is UNKNOWN, dealer inspection is UNKNOWN, and insurance inspection is UNKNOWN. Warning Signs Prior to Failure: There were no warning lights, messages, or symptoms prior to the fire. The failure occurred suddenly and without notice. Defect Pattern Concern: This incident is consistent with known issues involving Hyundai Sonata vehicles, including engine and electrical system failures and reports of vehicle fires. This complaint is submitted to request a formal investigation. Prior Hyundai fire defects reported for this model. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FO
I purchased a used 2012 Hyundai Sonata. Within about 2 weeks it broke down while I was in the far left lane of the freeway. The car suddenly stopped accelerating and made a very loud knocking noise. Thankfully I was able to put on my hazards and make it to the right shoulder without getting into an accident but as soon as I pulled over it shut off and the panel lights all came on. Evidently there was a recall on an engine rod and the previous owners advised they were not aware of it. Hyundai has declined the repair on the recalled engine several times and their reasons keep changing. First they said I was missing records (admittedly I was missing one record but then provided it to them), then they stated excessive neglect due to the condition of the valve train (I saw pics of the valve train and is in good condition), and now they state because the KSDS wasn't installed. From what I understand, being the second owner, if I can prove the upkeep of the vehicle the extended waranty should cover the repair. I even have the letter from the car mechanic stating the vehicle was maintained and in good condition. It seems a lot of good people are getting declined for repairs on these faulty engines. I have many more documents I could provide showing all of the services done and communications with the company. Due to the size limit I included these ones for your review. Thank you so much for any help you can provide.
While driving, the vehicle experienced sudden engine malfunction. The car entered limp mode, lost power, and produced a loud knocking noise from the engine. The failure occurred without warning and created a safety risk because the vehicle could not accelerate properly in traffic. This increased the risk of being rear-ended or unable to move out of dangerous situations. The issue appears to involve the engine (possible internal failure). The vehicle is currently at an authorized dealership and is available for inspection upon request. The problem has been confirmed by the dealership during inspection. The vehicle has been under diagnosis for over three weeks. There were no prior major warning signs before the failure. At the time of the incident, the vehicle suddenly lost performance, entered limp mode, and began making abnormal engine noise. This issue is consistent with widely reported engine defects in similar vehicles. Despite this, the manufacturer has denied coverage and attributed the issue to maintenance, even though regular maintenance was performed. This is a serious safety concern due to sudden loss of power while driving.
While I was driving my car wouldn’t go no higher than 60mph and kept dropping speed but I came to a stop and when I stopped the car was smoking. I heard knocking noise and rumbling noise on the passenger side. It wouldn’t start again
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 investigated.
The contact owns a 2012 Hyundai Sonata. The contact stated that the vehicle was experiencing excessive oil consumption, which required the oil reservoir to be refilled after 3-4 weeks. Additionally, there was no warning light illuminated. The contact stated that upon taking the vehicle to Jiffy Lube for a top off, the mechanic would inform the contact that the oil reservoir was empty and needed to be refilled. The vehicle was not taken to the dealer. The vehicle was not repaired. The manufacturer was informed of the failure. The failure mileage was approximately 158,000.
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 piston failure, but the symptoms and damage are consistent with the known Theta II recall issues. The vehicle has been inspected by the dealership, and all diagnostic information has been submitted to Hyundai under PA Reference #XXX. Hyundai Corporate has not yet responded to me with a case manager. Before the engine failure, the vehicle had rough running and loss of power, but no warning lights or messages illuminated on the dashboard. Symptoms appeared shortly before the engine became undriveable. Based on the dealer’s findings and the engine’s known defect history, it is my assessment that the failure is related to the same issues described in Hyundai’s Theta II engine recall (Campaign 132). INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
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 the federal safety agency 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 the federal safety agency intervention to compel Hyundai Motor America to comply with federal law and perform the necessary recall repairs on my vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
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 the federal safety agency 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 (the federal safety agency 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 the federal safety agency investigate the durability and safety of replacement engines and Hyundai’s refusal to support affected owners when these replacement engines fail prematurely. I have case number with Hyundai 41436693
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, he informed me that the engine is seized.
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 to all of the issues I’ve experienced with mainly Hyundai dealership service mechanics and dealerships, I’m now dealing with a faulty car that could still be a great car if they didn’t mess it up, I thought I was doing right by always only taking my car to Hyundai and goodness I was wrong! There are no “recalls” currently on my car but honestly, did they even do the recalls correctly?! I disagree! They have literally lied, drained my wallet and disappointed me all while making my car worse, it’s like dr’s take these meds that might fix the issue but it’s going to mess up something else, it’s a guessing game all while killing you or in this case my car!!! I don’t know dates, all I know is Hyundai has all the records! Oh and the last straw was them driving my car without my permission mint you, they took it to a totally different shop without my knowledge & had someone else repair the frame which I was unaware of & drive it with ZERO oil in my car which now my car has been sitting for the most part since they repaired my car(or lack there of) because they broke my car! yes I turned it in when it happened, I just never heard anything from anyone now I’m carless
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 manager would call me within three business days, but I never received any follow-up until I insisted. I was eventually assigned a case manager named Snowy, and also remained in contact with the dealership. On several occasions, both Snowy and the dealership assured me that the vehicle would be ready by Thursday, July 10 and that It was not until then that I could start to request a reimbursement for my rental expenses. I repeatedly asked for confirmation because I am renting a car at my own expense in order to go to work and manage my life. However, on Thursday, July 10, I called again and was told the vehicle would instead be ready by Tuesday, July 15. Then, on Friday, July 11, I received an email stating that the engine had just arrived, and that the dealership was only now able to begin repairs. After that, and only once the car is finished, Hyundai will “review” the case and determine whether I qualify for reimbursement. This is unacceptable. I have been without a vehicle for over three weeks, forced to rent a car entirely at my own expense. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA),
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 to be addressed as a safety issue.
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.
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