Owners of popular models could be left without an engine—what’s going wrong and who’s at risk
In 2025, major automakers have been hit with large-scale engine problems. Well-known brands are rolling out massive service campaigns, and the root causes of these failures have taken many by surprise.
Several global auto groups have found themselves under intense scrutiny this year due to serious powertrain issues. According to Autonews, hundreds of thousands of vehicles have been affected by recalls, with different brands running into strikingly similar problems.
General Motors was among the first to announce a major recall. The company identified defects in its 6.2-liter gasoline V8 engines used in recent model-year Cadillac Escalade, Chevrolet Silverado, Suburban, and Tahoe vehicles, as well as the GMC Sierra and Yukon. Issues with the crankshaft and connecting rod assembly can lead to power loss and, in some cases, accidents. Some vehicles will require complete engine replacements, while others will be fixed with higher-viscosity engine oil and a new oil filter.
Japanese automakers have not been spared either. Toyota expanded a service campaign due to the risk of failure in its turbocharged 3.5-liter V6 engines. Affected vehicles include the Toyota Tundra pickup and Lexus LX and GX SUVs produced from late 2022 through early 2024. The issue stems from the possibility of manufacturing debris entering the engine, which can cause rough operation, reduced performance, and in the worst cases, total engine failure.
Honda has also come under close regulatory attention. In the U.S., an investigation has been launched into potential engine failures affecting more than one million Honda and Acura vehicles. The list includes Pilot crossovers, Odyssey minivans, TLX sedans, and Ridgeline pickups built between 2016 and 2020. The core issue is excessive wear of the connecting rod bearings, which can result in severe engine damage. Despite earlier service actions, complaints continue to surface, and the scope of the problem appears to be growing.
Hyundai is recalling more than 135,000 Santa Fe SUVs from recent model years. The problem involves an incorrectly installed starter motor cover that, in the event of a crash, could lead to a short circuit or even a fire. The recall affects non-hybrid versions equipped with the turbocharged 2.5-liter engine.
Stellantis has also reported significant issues. In mid-November, the automaker announced a recall covering more than 110,000 hybrid Jeep Grand Cherokee and Wrangler models. During manufacturing, sand may have entered the engine block, potentially causing internal damage, power loss, and an increased risk of fire. Dozens of fire incidents and warranty claims have already been recorded, and owners will begin receiving recall notices for inspections.
According to Auto30.com, all of these cases point to a common trend: modern engines are designed with extremely tight tolerances and rely on ultra-low-viscosity motor oils. While this approach improves fuel efficiency and helps meet emissions standards, it also makes engines highly sensitive to even minor manufacturing flaws. Small amounts of debris or metal shavings can now lead to major failures.
In the past, engines were more forgiving, and minor assembly imperfections rarely caused critical damage. Today, however, tight tolerances and lightweight oils leave little room for error. As a result, even the world’s largest automakers are facing widespread and costly recalls.
Modern engines are undeniably more efficient and powerful than ever, but their reliability depends heavily on manufacturing precision and proper maintenance. Vehicle owners are advised to closely monitor recall notices and contact their dealer at the first sign of trouble.