2006 Hyundai Sonata Engine issues
 

At around 65k miles, my 2006 Hyundai Sonata had it's short engine block replaced. Of course, this was covered under warranty but about 30k miles later (I am just under 95k miles now), my intake gasket went bad and needed to be replaced. Looking at the service papers, it appears the intake gasket was indeed replaced with the engine block at 65k so it's puzzling to me that it needed replacement *again* so soon. And this second time around, I had to pay full price for it (the labor costs put it over $500).

Looking again at the service papers, the original reason why the short engine block had to replace was a knocking sound coming from cylinder #2 (my model is a 4-cyl model). I also recall they also told me that there was a "bent rod" (I believe for the piston in cylinder #2). Well, just yesterday when they replaced the intake gasket -- the noticed that the #2 cylinder was leaning far out -- hence causing a bad fuel/air mixture (which triggered the check engine light). Could there still be a problem that will continue eating up intake gaskets and eventually kill the engine block ... again!? I should point out that I am not a car mechanic so I'm not sure if I am missing something obvious here -- or if there is indeed something screwy going on with my car.

You shouldn't have had to pay for the intake gasket to be replaced the second time. If you are the original owner, it was still covered under the 100k miles warranty. Plus, the only reason the intake gasket failed was probably because it was installed incorrectly.

A lean fuel mixture won't cause a bad intake gasket but a leaking intake gasket will cause a lean fuel condition. So if the intake gasket was replaced correctly, the lean condition should be fixed now.

Cracked - leaking intake gasket on the 2006/2007 2.4 THETA is quite common... I just did one here recently at 83,000 I think it was..

Fella states he had short block.. no reason to remove intake... unbolt head from block and lift head as package deal. They may have never even touched it.

If they installed long block, then moving of intake be require to new engine.. I did a long block on a 2006 back in 2006 early on, the car was a rental wiith hole in block.

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