2018 Hyundai Sonata Engine Problems

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.

NHTSA ID

11751641

Incident

Jul 13, 2026

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)

NHTSA ID

11748511

Incident

Jun 9, 2026

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.

NHTSA ID

11745212

Incident

Jul 10, 2025

Check engine light solid/engine failure while driving. 2018 Sonata SE purchased new in fall 2018. Around 50,000 miles started noticing oil level drop and had to add more before next scheduled change. Dealership service center said I just had to shorten the mileage between changes which didn't seem appropriate for a vehicle with 50,000 miles but I did. Continued to have oil consumption problem with no signs of leak, no burning oil smell or exhaust issues. Dashboard display would go off and when I immediately checked dipstick there was barely any oil so I'd add more then go in for full change. At 67,000 or so miles in June 2026, without oil display going off the engine light was now solid. Got to reputable service center near my home and oil was under a quart left yet the warning lamp hadn't gone off. They ran the engine error code P0304 and was misfire #4 cylinder and after compression test, #3 was very low and #4 very high. NOT drivable at that point then towed to dealership so yes, available for inspection by NHTSA at the dealership. For now they claim a 'tune up' is needed for spark plug replacement, valve cover gasket replace and fuel induction service that's my cost to incur which seems to just be fixing the damage of an engine oil consumption problem not fixing the issue that caused the damage. The engine seized/stalled without warning while I was driving the vehicle (granted at low speed in my neighborhood when the engine light turned on). I would not say the engine warning lamp occurred prior to the engine fail, it happed at the same time. This should not happen for a vehicle with my mileage and regular maintenance. I looked up NHTSA for potential recall or other helpful information and started to see extremely similar scenarios to mine and wanted to add complaint as well. This is getting very expensive outside of whatever cost the dealer wants as a fix with rental car needed and tow services. Thank you for your consideration of this engine safety issue.

NHTSA ID

11744559

Incident

Jun 14, 2026

Following completion of Service Campaign 9C2 (ECU software update, TSB 25-01-087H) at a Hyundai dealership, my 2018 Sonata immediately exhibited drivability changes that were not present before the service. Symptoms include altered shift timing, hesitation, and rougher throttle response — particularly noticeable during the first several minutes of driving. These symptoms began on the first drive after the recall update was applied and have been consistent since. The vehicle was returned to the dealership for inspection. No underlying mechanical issue was found, confirming the drivability change is directly attributable to the ECU software update. The vehicle has been maintained strictly per Hyundai's manufacturer-recommended schedule and had no prior drivability issues. I am aware that numerous other owners of Theta II-equipped vehicles (Sonata, Santa Fe, Tucson) have reported identical symptoms following 9C2. At least one dealership has reportedly acknowledged this as a known post-update issue that Hyundai is working to resolve. The altered throttle and shift behavior poses a safety concern, as unexpected hesitation during acceleration affects predictable vehicle control in traffic. The vehicle is available for inspection upon request.

NHTSA ID

11743622

Incident

Mar 14, 2026

The contact The contact stated that when taken the vehicle for a service campaign repair and shortly after went for recall r The vehicle does not run properly on cold starts, the RPMs increase rapidly and slow down, vehicle jerks forward once beginning to drive.. The vehicle does not have this issue once the vehicle is warm. The manufacturer was not notified of the issue. The approximate. Failure mileage was 47,575.

NHTSA ID

11740030

Incident

May 14, 2026

Mileage

47,575 mi

Engine blown out malfunction took two dealer Hyundai Folsom Lake stated rings are bad sludge buildup in engine and stayed at Hyundai motor America denied engine replacement due to knowledge under Theta two engine extended warranty settlement of 150,000 MI 15 years I'm still within warranty but are still being denied had numerous of issues with vehicle oil consumption knock knock sensor replace and other maintenance done since purchase vehicle brand new in 2018

NHTSA ID

11737468

Incident

Apr 4, 2026

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.

NHTSA ID

11736185

Incident

Sep 23, 2024

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.

NHTSA ID

11735867

Incident

Nov 1, 2025

Had an oil change, then 2 weeks later car making noise, checked the oil and it was completely empty, so we refilled the oil. Then a month after again same issue no oil, refilled it again and now a week later it's 2 quarts low already. Also when I come to a complete stop when it is time to go again it's very slow at going or if I try to excel it takes it a very long time to actually excel I think something's wrong with the fuel pump

NHTSA ID

11728690

Incident

Mar 2, 2026

The vehicle developed a progressive engine failure beginning in early 2024, including loud knocking noises at cold start and visible white/gray/black exhaust smoke. The condition worsened over time. In February 2026, the failure escalated to active oil discharge from the exhaust pipe while the engine was running. Oil exiting through the exhaust indicates internal engine failure (such as piston rings, cylinder walls, or valve seal failure), not an external leak. This creates a safety risk including potential loss of power while driving, risk of engine seizure, and possible fire hazard due to oil in the exhaust system. The condition has been documented on video multiple times and was shown to dealership personnel. The vehicle was taken to a Hyundai dealership for evaluation and remains available for inspection. Despite this, no written diagnostic findings or repair determination have been provided. The issue has been persistent, progressive, and reproducible, and represents a potential defect affecting engine integrity and safe operation of the vehicle.

NHTSA ID

11726107

Incident

Jan 31, 2026

I bought a 2018 Hyundai Sonata a few years back. No warranty. Used. 110,000 miles. A few short months after I purchased it, it stopped working. I took it back to the same dealership where I purchased it and they said they had to replace the coil packs and spark plugs and clean something in the engine out because there's a defect in the engine. I paid $500. Fast forward a few months later. Same thing happens. I take it to an auto repair shop because it's cheaper and the mechanic says he deals with these same issues with other customers who have similar year, make, and models. This pattern continues to this very day. It broke down while I was working my 2nd job. I have a daughter. She plays sports. I have a second job. I need this problem completely alleviated as quickly as possible. Like a lot of the American public, I don't have extra money to keep up with anything beyond the normal maintenance of my vehicle. I keep it up to date with all oil changes. What can you do to get me a vehicle I can trust and it not break down every couple months and cost $300-$600 each time? I don't have good credit (I'm working on that) I have medical issues that I have to visit my doctor for every 3 months. I have the loan through Capital One and they don't offer refinancing. My father who has passed was a car salesman his entire career. I just need reliable transportation and if it's a motor problem like they say then I shouldn't be liable to fix it. The manufacturer should. Please let me know if you need any service records from me. Oh and I also have to put about $20 worth of oil in it every week or so between oil changes. My local oil change guys unfortunately know me very well.

NHTSA ID

11726097

Incident

Mar 21, 2026

2018 Hyundai Sonata 2.4L Theta II engine experiencing severe oil consumption and loss of oil pressure. Oil pressure warning light actively blinking and dipstick completely dry. This is consistent with the known Theta II engine defect subject to prior NHTSA investigations and class action settlements. Mission Hills Hyundai documented low oil concern in service notes during December 2025 visit but failed to take any action and returned the vehicle without repair. Hyundai Consumer Affairs has been unresponsive and provided conflicting information regarding recall completion on this vehicle. This is a serious safety defect that puts the driver at risk of engine failure while operating the vehicle.

NHTSA ID

11724419

Incident

Dec 27, 2025

The vehicle had safety and mechanical problems shortly after purchase, even with low mileage. The issues included warning lights, abnormal noises, repeated mechanical failures, and poor performance that affected the safe operation of the vehicle. These problems started early and continued over time despite repairs and maintenance. Before the incident, the vehicle showed signs of malfunction, including instability while driving and loss of normal performance. These symptoms created an unsafe driving condition and increased the risk of a crash. I believe the vehicle had defects from the beginning that affected safety. The failure contributed to the accident that occurred while driving on the highway, putting my life and my family at risk.

NHTSA ID

11724392

Incident

Mar 16, 2023

Excessive Oil Burning and Oil Consumption. Oil turns black abnormally quickly (within the first 500-1000 miles) even though recommended Full-Synthetic Oil is used. Engine has intermittent rough idle once engine is warm. Occasionally engine experiences "near-stall" and "misfire event", causing the battery light to flash on dashboard. >>>Oil consumption rate is approximately 3-4 quarts per 1,000 miles<<< ***Maintenance completed since purchase*** Coolant Flush - Replaced PCV Valve (NEW) - Replaced Valve cover Gasket + Oil Pan / Oil Pan Gasket (recommended by dealer) (NEW) - Replaced Spark Plugs (recommended by dealer) (NEW) - Replaced Battery (NEW) - Replaced Alternator (NEW) - Replaced both engine accessory belts (NEW) - Replaced 150A main fuse (located on positive battery terminal) (NEW) - Used Hyundai brand oil filters - Used Chevron/Techron Complete Fuel system cleaner twice, between and at oil change (as recommended by "Twin City Hyundai" dealer in Alcoa, TN) ***Had dealership inspect it for approval of known Federal Recall on GDI Engines for excessive oil consumption / engine seizing issues; dealership claimed it did not pass re-call approval*** SYMPTOMS STILL PERSIST Mileage is now approx. 80K

NHTSA ID

11723170

Incident

Dec 1, 2025

The component involved is the engine (2.4L Theta II gasoline engine) in my 2018 Hyundai Sonata. The malfunction involves excessive internal engine oil consumption between oil changes. The vehicle consumes oil at an abnormal rate, requiring frequent top-offs to prevent low oil levels. The vehicle is available for inspection upon request. This condition creates a safety risk because excessive oil consumption can lead to critically low oil levels, engine seizure, sudden engine stall, or loss of propulsion while driving. A sudden engine stall or loss of power while operating at highway speeds could increase the risk of a crash. The problem has been inspected and documented by an authorized Hyundai dealership. During service, the dealership recorded that the customer reported oil burning between oil changes and noted evidence of engine oil consumption. No permanent repair has been performed. The issue remains unresolved. Hyundai Motor America has not physically inspected the vehicle directly but has reviewed the case through customer care. The manufacturer has required additional diagnostic testing at the owner’s expense as a condition of further evaluation and declined to authorize testing at no cost or provide assurance of reimbursement. No crash, fire, or injury has occurred to date. The vehicle has not been inspected by police or insurance representatives. There were no warning lamps illuminated at the time the oil consumption was first observed. The condition was first noticed when oil levels were found to be significantly low between scheduled oil changes. The issue has been ongoing and progressive. Given the known history of engine-related issues involving Hyundai Theta II engines, I am submitting this complaint due to concerns that continued oil consumption may result in engine failure, sudden stall, or loss of propulsion while driving, creating a potential safety hazard. The vehicle remains in service but the condition has not been corrected.

NHTSA ID

11719276

Incident

Jun 25, 2025

The oil pan is starting to crack, a small drip is now happening but dealership says it could spilt and cause the engine to seize while driving. The pan looks very flimsy compared to my Ford and Toyota.

NHTSA ID

11719179

Incident

Nov 18, 2025

To Whom It May Concern, My name is [XXX] , and I am formally escalating serious ongoing issues with my 2018 Hyundai Sonata. Despite repeated attempts to resolve these concerns through the dealership, my vehicle continues to experience excessive oil consumption, engine failures, and additional mechanical issues, all while under warranty. I am now seeking immediate corporate intervention. Timeline of Events and Mismanagement: •2024(~62000 miles): First reported oil leak and excessive oil consumption. Directed to complete multiple 1,000-mile oil consumption tests. I complied fully. •2024: Repeatedly redirected between service advisors, received conflicting instructions, misleading guidance, and poor communication. No effective resolution was provided. •2025: Completed extensive additional diagnostic testing as requested. Despite full compliance, no clear corrective action was taken. •2024–Present: Vehicle brought to Hyundai on US 19 in New Port Richey approximately 13–15 times for engine-related concerns. Each visit demonstrated neglect, miscommunication, and failure to properly address documented issues. •February 11, 2026: After proper diagnostics, vehicle found to have two additional oil leaks, including a head gasket and valve cover requiring replacement, with total estimated repair costs exceeding $3,000. I was advised I must repeat all testing already completed in 2024 before final determination. •Vehicle is currently at 71,332 miles. Impact: •Delays and repeated unnecessary testing pushed my vehicle beyond warranty limits. •Mismanagement caused significant financial burden, emotional stress, and frustration. •If initial oil consumption issues had been properly addressed under warranty, the current extensive engine failures could likely have been avoided. Immediate Requests: 1Full review of my complete service and diagnostic history. 2Warranty or goodwill coverage for all necessary engine repairs, including head gasket and valve cover INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.

NHTSA ID

11718006

Incident

Oct 12, 2024

While driving the vehicle, I repeatedly must check and put oil in. (On average once per week) I took the car to an auto shop where I was told that the engine was bad and I must get a new one. I kept driving, putting oil in as needed, then the car in the middle of driving started to shudder and the check engine light came on. I parked the car and haven't driven it since

NHTSA ID

11715822

Incident

Jun 13, 2025

Unknown what system failed. The vehicle is at an impound lot and can be inspected on request. Police and fire department were on the scene. Police did provide a report # , and fire department provided a fire rescue case number. Safety of driver was put at risk due to the fire and potential for burning or even death. Other drivers could have been at risk if traffic had not allowed for quick movement to side of the road. No warning lamps had been on prior to the drive and none prior to fire. First indication was a burning smell while driving. As pulling over, another driver honked to alert to fire he could see from rear of ca,. before I noticed the flames. Upon getting out of car first flames I saw appeared to be coming from under passenger side of car. The fire department arrived about 15 minutes after pulling to side of the road. The car was fully engulfed in flames. They then extinguished the fire. Police saw vehicle and insurance will examine. Apparently this is a known issue in Hyundai of which this vehicle had no open recalls pertaining to such.

NHTSA ID

11714245

Incident

Jan 29, 2026

The contact owns a 2018 Hyundai Sonata. The contact stated that while driving approximately 60 MPH, the vehicle started to vibrate roughly. The contact felt the vibration in the steering wheel. The check engine warning light was illuminated. The contact slowed down and pulled off the roadway. The contact turned off and restarted the vehicle and was able to shift to drive(D); however, the vehicle was hesitating and failed to accelerate as needed. The contact drove the vehicle to an independent mechanic at speeds no greater than 40 MPH. The mechanic scanned the vehicle and retrieved codes for a misfire in the engine. The mechanic advised the contact to take the vehicle to a dealer for assistance. The vehicle was towed to the local dealer. The vehicle was not yet diagnosed or repaired. The manufacturer was informed of the failure. The contact requested an engine replacement that was denied by the manufacturer. The failure mileage was approximately 138,000.

NHTSA ID

11709976

Incident

Dec 18, 2025

Mileage

138,000 mi

Engine oil consumption issues. My 2018 Hyundai Elantra falls within the dates of this issue. I had an oil consumption issue done and the dealership claimed it passed. I have to put oil in my car every 3 weeks and change spark plugs at the same time because of engine leaking oil in to them. My engine light is always on, knocking and pinging sound, poor performance issues, and blue smoke coming out of tail pipe. I have stuck on the side of the highway several times and have misses work because of the ongoing issues with the engine. How can a oil consumption issue pass and i have all these issues. I have spent several hundreds of dollars on oil, spark plugs, frequent oil changes and tows. There was only 85,000 miles when I started to notice the problem and had only owned it for 6 months.

NHTSA ID

11709109

Incident

Jul 10, 2025

The contact owns a 2018 Hyundai Sonata. The contact stated that while receiving an oil change, the technician advised that the oil level was very low. The contact stated that the low oil warning was intermittently illuminated. The contact was advised to take the vehicle to a dealer to be diagnosed. The contact had taken the vehicle to a local dealer, where an oil consumption test was performed. The contact was advised that the vehicle was operating normally. The contact stated that the low oil warning light was illuminated again. The vehicle was taken back to the same dealer, and the oil level was topped off; another oil consumption test was suggested. The contact researched online and related the failure to a known issue of oil consumption that could lead to engine failure. The contact called the manufacturer and asked about an engine replacement because the vehicle was still under warranty. The manufacturer informed the contact that a combustion cleaning had to be performed to determine if the engine needed to be replaced. The contact stated that the vehicle was taken back to the same dealer who performed the combustion cleaning; however, the excessive oil consumption remained, and there was evidence of burned oil coming from the exhaust pipe. The contact called the dealer and was advised that another oil consumption test and combustion cleaning were needed. The vehicle was not repaired. The failure mileage was 103,235.

NHTSA ID

11706599

Incident

Dec 13, 2024

Mileage

103,235 mi

While driving on the highway, my 2018 Hyundai Sonata experienced sudden loss of engine power and became undrivable. The failure occurred without warning at approximately 86,500 miles. At the time of the incident, there were two children in the vehicle, and the breakdown occurred at night in cold temperatures (approximately 20°F). An authorized Hyundai dealership later diagnosed zero compression in cylinder 3 and confirmed a cracked piston, recommending full engine replacement. The sudden loss of power while driving created a safety risk due to traffic conditions and environmental exposure.

NHTSA ID

11705457

Incident

Nov 27, 2025

The contact owns a 2018 Hyundai Sonata. The contact stated that while driving at an undisclosed speed, the low oil warning light illuminated. The vehicle was taken to the dealer, but was not diagnosed or repaired. The dealer advised the contact to have an oil change performed and then return the vehicle after 1,000 miles of driving. The contact stated that after returning the vehicle to the dealer, the vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 99,000.

NHTSA ID

11703258

Incident

Dec 5, 2025

Mileage

99,000 mi