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We own a 2010 Santa Fe with a 2.4L engine. It currently has roughly 140,000Km on it. The engine was making strange sounds according to my stepdaughter who had borrowed the vehicle one day. At the time, we were on the road ourselves in Mississippi, returning to Canada from a road trip to New Orleans in my 2013 Hyundai Veloster Turbo.

She immediately brought it to our dealership here in Orleans, ON where my wife had purchased the vehicle. There was absolutely no warning lights which appeared on the vehicle's instrumentation gauges. Ne 'check engine' light, no 'oil' light, no 'overheating' indication. Nothing... There has never been any history of engine overheating. The tech told my stepdaughter that had she driven the vehicle another hour or so, it would have suffered a catastrophic engine failure, due to the low level of oil in the engine.

Where had the engine oil gone??? The undercarriage of the car was covered in it (according to the Hyundai tech) and she was later informed (as we were when we returned home) that the engine oil had somehow ended up in the cooling system. To make a long story short, they suspected that a head gasket leak may have been responsible for this, but as a motorcycle mechanic myself, I just can't wrap my head around this happening. I can't think of any engine design where engine oil and coolant fluid would even have a remote chance of meeting up. After stripping down the engine and examining the head and gasket, the head was pronounced sound (no warpage) and there was no failure noted in the engine head gasket either.

How over 3 litres of oil wound up contaminating our cooling system lines and radiator before blowing out on to the road, remains a mystery and will cost us an approximate $4,000.00CDN to have set right. With absolutely no guarantee that it won't happen again... Has anyone else gone through this scenario? If so, what the heck was it? There is a flaw somewhere, but what...???
 

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We own a 2010 Santa Fe with a 2.4L engine. It currently has roughly 140,000Km on it. The engine was making strange sounds according to my stepdaughter who had borrowed the vehicle one day. At the time, we were on the road ourselves in Mississippi, returning to Canada from a road trip to New Orleans in my 2013 Hyundai Veloster Turbo.

She immediately brought it to our dealership here in Orleans, ON where my wife had purchased the vehicle. There was absolutely no warning lights which appeared on the vehicle's instrumentation gauges. Ne 'check engine' light, no 'oil' light, no 'overheating' indication. Nothing... There has never been any history of engine overheating. The tech told my stepdaughter that had she driven the vehicle another hour or so, it would have suffered a catastrophic engine failure, due to the low level of oil in the engine.

Where had the engine oil gone??? The undercarriage of the car was covered in it (according to the Hyundai tech) and she was later informed (as we were when we returned home) that the engine oil had somehow ended up in the cooling system. To make a long story short, they suspected that a head gasket leak may have been responsible for this, but as a motorcycle mechanic myself, I just can't wrap my head around this happening. I can't think of any engine design where engine oil and coolant fluid would even have a remote chance of meeting up. After stripping down the engine and examining the head and gasket, the head was pronounced sound (no warpage) and there was no failure noted in the engine head gasket either.

How over 3 litres of oil wound up contaminating our cooling system lines and radiator before blowing out on to the road, remains a mystery and will cost us an approximate $4,000.00CDN to have set right. With absolutely no guarantee that it won't happen again... Has anyone else gone through this scenario? If so, what the heck was it? There is a flaw somewhere, but what...???

I had the same problem. My car is Santa Fe 2011 2.2L CRDI (Asean version), and at 110k km, I have Engine Oil in radiator. (no coolant in engine). The Hyundai mechanics is unable to find what caused this (they check thru every connections and hose). They open up the engine and told me the head gasket is blown. Was informed a complete engine overhaul is required. This include changing all the hoses, thermostat, and radiator. (kinda ridiculous).

The final bill to me is close to USD 2000.00 after conversion!!! (consider extremely expensive from where I come from)

Also, at 95k km, I had a leak engine oil coolant. This was replaced under warranty. The cost of this is nothing compared to the engine overhaul case.
 

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Ne 'check engine' light, no 'oil' light, no 'overheating' indication. Nothing... There has never been any history of engine overheating. The tech told my stepdaughter that had she driven the vehicle another hour or so, it would have suffered a catastrophic engine failure, due to the low level of oil in the engine
 
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