The REAL Reason Why Modern Engines Are FAILING

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Transcript:

Why Are So Many Modern Engines Failing?

That’s what we’re going to find out. Welcome to Car Help Corner, where we help you, the consumer, master the process of car buying and ownership.

Engine failures have become far too common on newer vehicles. Many major automakers are seeing record-high numbers of engine failures, followed by record-setting recalls—sometimes in the millions. In this episode, I’ll cover which companies had the worst engine-failure recalls over the past year, why this is happening, what these failures have in common, and whether things are likely to improve anytime soon.

Let’s get into the worst recalls.

Nissan Engine Recall

First up: Nissan.

In 2025, Nissan recalled around half a million vehicles equipped with the VC Turbo engine family. That includes a turbocharged three-cylinder used in the Nissan Rogue, and a turbocharged four-cylinder used in models like the Murano, Altima, and Infiniti QX50 and QX60.

These are complicated engines built around variable compression technology, and they’ve been linked to bearing failure—a problem that can take out the entire engine and require a full replacement. The real-world failure rate isn’t necessarily massive, but it’s significant enough that these aren’t engines you want to own without a warranty.

Toyota Engine Recall

Next: Toyota.

Toyota’s reputation for reliability is legendary, but the latest-generation Tundra has become a major blemish. The issue centers on Toyota’s 3.4-liter twin-turbo V6, which has been linked to premature engine failures—sometimes even before the first oil change. Again, the commonly cited culprit is bearing wear and bearing failure.

Toyota recalled over 100,000 2022 and 2023 trucks, with the fix being an all-new engine. More recently, Toyota expanded the recall to 2024 models, which suggests the underlying issue wasn’t fully resolved.

The same engine is also used in models like the Lexus LX and GX, although failures appear far more common in the Tundra than in the Lexus applications.

GM V8 Engine Recall

Another major recall involves General Motors and their full-size trucks and SUVs equipped with the 5.3-liter and 6.2-liter V8s—engines found across the GMC Sierra and Yukon, Chevrolet Silverado, Tahoe, Suburban, and Cadillac Escalade.

The problems often start with failing lifters, commonly associated with cylinder deactivation systems. When lifters fail, they can take out the camshaft, and in some cases this happens shockingly early—sometimes even before the first oil change.

GM has been dealing with variations of this issue for over a decade. On top of that, the 6.2-liter has also been linked to rod and main bearing failures, prompting a recall involving more than 700,000 vehicles. NHTSA has expanded its investigation, and it’s possible that over a million vehicles could ultimately be implicated.

Hyundai/Kia Engine Recall

As serious as the recalls above are, they pale in comparison to Hyundai and Kia.

Earlier in 2025, Kia recalled over 130,000 Kia Seltos and Kia Soul models with a 2.0-liter four-cylinder due to the risk of engine failure from bad piston rings. But that’s just the surface.

This story goes back more than a decade. Since 2011, Hyundai and Kia have experienced widespread failures involving their 2.0L and 2.4L engines used across numerous models. Over the span of roughly ten years, close to 10 million Hyundai and Kia vehicles have been recalled, and hundreds of thousands of engines have been replaced.

By scale—total vehicles recalled, engines replaced, lawsuits, regulatory fines, and overall cost—this stands as one of the largest engine-failure crises of the modern era.

Other Notable Recalls

Other manufacturers have faced serious engine-related recalls as well, including:

Ford, with recalls involving certain three-cylinder, four-cylinder, and V6 EcoBoost engines.

Jeep, including plug-in hybrid powertrains in models like the Wrangler and Grand Cherokee, which have been linked not only to engine failures but also engine fires.

Honda, which recalled some vehicles with the 3.5-liter V6 due to the risk of bearing failure.

The worst part is that even when the recall is covered by the manufacturer, it’s often the consumer who pays the real-world price: breakdowns, towing, and being stranded without a vehicle for weeks—or even months—while parts and replacement engines sit backordered. Engine replacements can take 12–18 hours of labor per vehicle, which also overwhelms dealer service departments. Unsurprisingly, multiple automakers—including GM, Toyota, Hyundai, and Kia—have faced class action lawsuits. Hyundai and Kia have also been fined by NHTSA for not reacting quickly enough. Altogether, the cost to automakers is now well into the billions.

Why Engines Are Failing

So why is this happening? Why are so many automakers suddenly struggling to build modern engines that hold up?

There are many factors, but the biggest driver is modern emissions and efficiency requirements.

A recent article in Automotive News explains how the industry’s long push for cleaner, lower-emission, more fuel-efficient engines has created an unintended consequence: today’s engines are smaller, more advanced, and far more highly stressed. That means they’re much less tolerant of small manufacturing issues—machining errors, incomplete cleaning, tiny debris left behind—imperfections that older engines often would have survived.

Aggressive downsizing and efficiency targets have also increased peak cylinder pressures and average loads. That increases stress on bearings and accelerates wear. At the same time, automakers have moved toward thinner oils to reduce friction and improve fuel economy. The combination—higher loads plus thinner oil—means components have to be machined, cleaned, and assembled perfectly.

To support thin oils, manufacturers have also reduced clearances between moving parts like crankshafts and bearings. The downside is that the protective “cushion” of oil between parts is smaller. If even tiny bits of metal or debris get into that space, they can act like sandpaper—chewing up bearings and causing catastrophic failures. In many cases, metal shavings and debris are specifically cited in failure investigations.

Beyond what the article cited, there are other contributing factors that often show up in modern powertrains:

Turbocharging paired with downsized displacement

Cylinder deactivation systems

Direct injection (and the complexity that comes with it)

Longer oil-change intervals

Cost-cutting pressures and manufacturing complexity driven by globalization

Will It Get Better?

There is some good news.

First, these failures are largely isolated to specific engines and models. The majority of modern engines—especially from reputable brands—do not suffer widespread catastrophic failure.

Second, automakers appear to be reacting. For example, the article notes that GM leadership is aware of the severity of the issue and is working to ensure these problems aren’t repeated in the next generation of small-block V8s expected around 2027.

Hyundai has made similar public statements, saying it has improved manufacturing processes based on lessons learned—expanding inspections, adding additional process controls, and strengthening real-time monitoring throughout engine production. These improvements are part of a broader quality push, and Hyundai’s newer Smartstream engines do appear to be holding up better so far.

Hopefully, these companies have learned the hard lessons. After decades of engine development experience, failures at this level are unacceptable—especially given how expensive new vehicles have become. Consumers deserve better.

Let me know your thoughts on this issue in the comments. If you got value out of this, make sure to subscribe, like, and hit the Hype button.

If you’re planning to purchase a vehicle and you live in Ontario, OMVIC is the motor vehicle sales regulator responsible for administering and enforcing the rules dealerships must follow. To learn more about your consumer protection rights, visit OMVIC’s website. For additional car buying advice, recommendations, or help getting a great deal on your next new car purchase, visit carhelpcan.com.

Thanks so much for watching, and see you next time.

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