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Sounds like you are outside the 120k mile warranty that they extended from 100k miles. I would contact Hyundai and just maybe they will work with you since it is exactly the issue the engine was recalled about. I had a Taurus that uses a quart every 1000 miles but hard to believe three quarts in 200 miles and no smell or smoke even with the catalytic converter scrubbing it out. I Seafoamed a few cars and could always see smoke out the tailpipe.
 

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Discussion Starter #104
Sounds like you are outside the 120k mile warranty that they extended from 100k miles. I would contact Hyundai and just maybe they will work with you since it is exactly the issue the engine was recalled about. I had a Taurus that uses a quart every 1000 miles but hard to believe three quarts in 200 miles and no smell or smoke even with the catalytic converter scrubbing it out. I Seafoamed a few cars and could always see smoke out the tailpipe.
My wife does a lot of highway driving so it's not really unheard of that she wouldn't see it smoking. I looked it over yesterday and it's grim.... there's NO oil leaks on that car. I've already filed a complaint to Hyundai Corp and they are having one of their Regional Directors reaching out to me, so we'll see what the ultimate plan is. If they don't do anything(and I'll fight them to the end) maybe I'll pick up an insurance wreck with a good engine and do a swap. Either way, I have to do something cause eventhough I'm working fron home for the foreseeable future, I need 2 cars. Anywho, here's what i found....

 

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Sorry to hear about your problem with the Sonata. Engine failures are something you should never see in a modern vehicle, short of outright negligence. I hope you can get it resolved.
 
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Unfortunately, Hyundai corp wants nothing to do with it. I got the run around from the rep and got zero answers other than "I can't tell you that without it going to the dealer". So I asked for a supervisor or someone that CAN give me answers to call me back. The person who called me actually knew cars and I can talk to her on the level. The problem is if it goes to the dealer, I have to tow it(roughly $100), then the dealer charges a $155 diagnostic fee which is basically going to consist of them running codes and looking at the oil. I know damn well that they are going to want to crack the oil pan off which is going to be $$$. I asked for Hyundai to comp me the $155, and they wouldn't even do that...…. So basically I'm screwed with this car. The total cost is on me. That's the absolute LAST Hyundai I'll ever buy!
I'm debating on what to do but I need a car in the meantime. I've been looking at some Bull wagons lately to keep as a 3rd car which will bridge the gap till I can figure out what I'm doing with the Hyundai. I've been debating on getting a wreck with a good motor, or seeing if I can get a good replacement engine somewhere on the cheap. Time will tell, but the payments don't stop because the engine decided to grenade itself...…
 

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Unfortunately, Hyundai corp wants nothing to do with it. I got the run around from the rep and got zero answers other than "I can't tell you that without it going to the dealer". So I asked for a supervisor or someone that CAN give me answers to call me back. The person who called me actually knew cars and I can talk to her on the level. The problem is if it goes to the dealer, I have to tow it(roughly $100), then the dealer charges a $155 diagnostic fee which is basically going to consist of them running codes and looking at the oil. I know damn well that they are going to want to crack the oil pan off which is going to be $$$. I asked for Hyundai to comp me the $155, and they wouldn't even do that...…. So basically I'm screwed with this car. The total cost is on me. That's the absolute LAST Hyundai I'll ever buy!
I'm debating on what to do but I need a car in the meantime. I've been looking at some Bull wagons lately to keep as a 3rd car which will bridge the gap till I can figure out what I'm doing with the Hyundai. I've been debating on getting a wreck with a good motor, or seeing if I can get a good replacement engine somewhere on the cheap. Time will tell, but the payments don't stop because the engine decided to grenade itself...…
I hate to say I told you so, but I predicted your fate almost exactly a year ago, haha. Not that I'm really laughing at your situation, because it's truly awful. The issue with the junkyard route too is that unless you're pulling from a 2015+, you can't guarantee the replacement engine won't have the same problem. To me, the best situation is to do some more research and find a shortblock from a wrecked car that's post fix, drop it in yourself, and then run the car till the wheels fall off.

That's a bummer about Hyundai and the payments make in worst. Are there good engines out there if this is a design issue?
Yes, 2015+ cars had a revision to the oiling system if I remember correctly which solved the issue.
 

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Discussion Starter #109
Oh trust me I didn't expect Hyundai to do anything for me, but anything was worth a shot :)
The issue with the engine isn't with the actual oiling system. It was a defect in the casting process that left metal shavings in the oil passages. Over time, the shavings went through the engine and wore down bearings causing spun bearings. They have extended the warranties of any cars with the Theta II engine till MY 2019 so obviously there's more than they thought was out there.
 

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Discussion Starter #110
LONG overdue update...… I've been working on everyone elses cars but my own. Hyundai refused to do anything for me. They said being that it's 15k over the extended warranty period, and with the limited resources because of the pandemic, they won't even comp me 1 hour of labor in diagnosis..... NOTHING. A multi billion dollar company, and they won't even eat $155. Pathetic!
I've been borrowing my brother's Jeep Patriot for a while and after coming out of 14 day quarantine cause my wife caught covid at her work (REALLY pissed off at that, but she is ok and symptoms were fairly mild due to catching this before they had a name, or knowledge about it back in November) I'm tired of looking at the car sitting in my yard. So, today, I cracked it open and made a video for my YouTube channel. Check it out guys and gals! I'm repairing this myself, damn Hyundai!
 

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I admire your determination!
 

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LONG overdue update...… I've been working on everyone elses cars but my own. Hyundai refused to do anything for me. They said being that it's 15k over the extended warranty period, and with the limited resources because of the pandemic, they won't even comp me 1 hour of labor in diagnosis..... NOTHING. A multi billion dollar company, and they won't even eat $155. Pathetic!
I've been borrowing my brother's Jeep Patriot for a while and after coming out of 14 day quarantine cause my wife caught covid at her work (REALLY pissed off at that, but she is ok and symptoms were fairly mild due to catching this before they had a name, or knowledge about it back in November) I'm tired of looking at the car sitting in my yard. So, today, I cracked it open and made a video for my YouTube channel. Check it out guys and gals! I'm repairing this myself, damn Hyundai!
Keep us informed. You are doing a fine job with communication and sharing your work. You might need -.002" undersized bearings on all. Way back, '55 ford V-8 that had been sludged up and the oil pickup screen plugged so minimum pressure. I took the screen and put gasoline in it and set it on fire. (outside). After is was good. I put undersized bearings all around and it ran for years just fine. I did not polish the shaft as I had nothing to it with. Plastigage is your friend in this
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Are you going to replace the bearing cap since it looked heat damaged and may fail. Also those rod bolts have been beat and stressed, depending on cost it maybe worth changing also.

Have you ever seen the neat way to use a shoelace and emery paper to polish the journal? You wrap the emery paper loosely around the journal and then a shoe lace. You pull back and forth on the shoe lace which spins the paper around the bearing.
 

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Oooh, glitter in the oil! Never a good sign. I've only seen that one once. Thankfully!

That is the strangest oil pump setup I've ever seen. Make sure you flush it out before you reinstall it, if you can.

I'd get some emery cloth for polishing the journal. Easier than sandpaper and less grit. Be sure to flush out the crank oil passage when your done. I'd keep than passage facing down as much as possible when polishing.

Looking forward to the next video!
 

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Been dithering about putting in my 2¢ worth, but I sympathize with John's situation. much to my chagrin, the wife decided my dad's 1990 Volvo 240 was getting long in the tooth - hell, it was just getting broken in! - but she wanted something newer and I went along with it. She and my daughter came home with a 2012 Hyundai Sonata with the 2.4L Theta engine. Startlingly fast for a four-banger, but designed to be virtually impossible for an owner to do his/her own maintenance.That was August 2019.

This February (four months ago) we were half-way home from Waycross, GA visiting the daughter and grandson and coming into Ocala on I-75 the car backfired out the exhaust pipe, lost acceleration and I nursed it to the next exit, nine miles up the road. We only were doing 80mph but ended up doing 35mph in the breakdown lane to the next exit. The guy at the auto-parts store did a diagnostic and said it was dealer-only repair - engine replacement was required. (It was a Sunday, of course.) Thank God, it was under warranty so our repairs, rental car fees and motel room all were covered under extended warranty...but that engine only had 78K on it. Cause of replacement - worn/spun crank bearings. We were provided a rebuilt 2.4L...wonder how long that will last.

She loves the car, but all I see is a time bomb waiting to blow ~
 

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Follow-up to my previous post...the Hyundai seems to be running OK after five months but the wife doesn't quite yet trust it for road trips. Meanwhile, the wagon turned 200K miles, nine days ago (pics to follow in a separate post - it turned zeroes just as I pulled into the driveway last Monday) and...we are going to Waycross to visit the daughter, grandson and granddog...guess which car she's decided we're driving! Having some detail work done on the Brick (Volvo 240, my late father's car, only owned it nine years) and she's dicey about the Hyundai....so, Old Faithful it is. She promised in return that I could spend $3K at the Ford body shop for a full rust repair - two small patches - plus a full sanding and new paint job. It'll end up looking front-line worthy at the dealership. At 30 years old, even the dealership is starting to take interest in our wagon. It's one of two registered 1990 Taurus wagons known to the Florida DMV in SW Fla. if their records are correct. Anyhow, we're ready and rarin' to hit the road.

I rarely drive that Hyundai. It's got all the gadgets and all, but the car was designed for midgets. I'm spoiled....I grew up with Rambler Ambassadors, with full, genuine seat cushions front and rear. Since the 1990s. most cars skimp on the depth of the seat cushions to give the illusion of more front and rear leg room. My Bull has old-fashioned seats which cradle one's butt and thighs all the way to the knees, and since I converted both halves of the split-bench front seat to six-way power, they are sublimely comfy. (Right-side powered seats weren't even an option in the Taurus or Sable for 1990...I had to work some magic to make THAT happen.) Her Hyundai, on the other hand, has these narrow front buckets with seat cushions which end halfway down my legs and the power adjustments are woeful. After 100 miles, my poor back is screaming for relief. Adjusting the radio is almost impossible without turning the hazards on by accident, and the A/C takes forever to come on even in 95° temps and high humidity.

I'll keep my low-tech, 30-year-old Bull any day of the week over that Korean thing. :)
 
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In the 80's and 90's I was on the road ~40 weeks a year. Company when the first front wheel drive banned us from GM after a few wrecks from suspension fails. Avis was the corp supplier and they had to give us rear wheel GM and Ford. Few Lincolns. Company at where I was based got a leased fleet of Taurus '86 for two day or less checkout. First impression and continuing the seat comfort was head and shoulders above any things in rentals. My '11 Buick Lucerne is nice but I still prefer to do my daily driving in my '03 Sable wagon. I do average 9 trips a day, average ~4 miles per. 155K on it and dread the thought of someday it rusts out. Or I get too old to drive.
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