Cars Most Likely to Need an Engine Rebuild and What to Buy Instead

Consumer Reports shows the models most at risk for this expensive problem

Jeff S. Bartlett, Consumer Reports Managing Editor, Autos.

By Jeff S. Bartlett
Managing Editor, Autos

Steven Elek, Consumer Reports Program Leader, Auto Data Analytics.

By Steven Elek

Updated May 14, 2021

A common concern with cars as they age is dependability—not only that they may not get you to work one day but also that a catastrophic failure could cost thousands of dollars. Major problems are rare in general, but they do happen.

To understand how often such problems occur, we analyzed data on older models from our Annual Autos Surveys to see which ones had the highest problem rates for major systems that often required expensive repairs.

Three problems areas stood out: the engine, head gasket, and transmission. With some models, problems occurred with surprising frequency at a certain age and mileage.

Engine problems are among the greatest mechanical nightmares for their inconvenience, expense, and time to repair. We found that there are more than a dozen older models with problems serious enough to require engine rebuilds.

“Engine failure can be caused by many things,” says John Ibbotson, Consumer Reports’ chief mechanic. “Some engine rebuilds are needed due to low compression from worn piston rings, resulting in lack of power, misfiring, or excessive oil consumption, while others suffer from crankshaft or connecting rod bearing failure, signaled by a knocking sound.” Because of the difficulty and time required to rebuild an engine, repair shops will often replace the original engine with one that has been remanufactured.

2014 Kia Optima

2014 Kia Optima 4-cyl.
Typical mileage: 96,000-127,000
Alternatives without this problem: 2013-2015 Honda Accord, 2014-2015 Mazda6

2013 Kia Sorento

2013 Kia Sorento 4-cyl.
Model years affected: 2012-2013
Typical mileage: 69,000-108,000
Alternatives without this problem: 2012-2015 Toyota Highlander, 2012-2015 Toyota 4Runner

2013 Hyundai Santa Fe

2013 Hyundai Santa Fe
Model years affected: 2012-2013
Typical mileage: 97,000-118,000
Alternatives without this problem: 2012-2015 Toyota Highlander, 2012-2015 Toyota 4Runner

2011 Hyundai Sonata

2011 Hyundai Sonata
Model years affected: 2011-2014
Typical mileage: 72,000-142,000
Alternatives without this problem: 2011-2013 Toyota Camry, 2011-2013 Honda Accord

2012 Subaru Forester

2012 Subaru Forester
Typical mileage: 81,000-129,000
Alternatives without this problem: 2011-2014 Honda CR-V, 2011-2014 Toyota RAV4, 2013-2014 Mazda CX-5

2013 Hyundai Santa Fe Sport

2013 Hyundai Santa Fe Sport
Model years affected: 2013-2014
Typical mileage: 74,000-101,000
Alternatives without this problem: 2013-2014 Mazda CX-5, 2011-2014 Honda CR-V, 2011-2014 Toyota RAV4

2011 Audi A4

2011 Audi A4
Typical mileage: 62,000-82,000
Alternative without this problem: 2011-2013 Infiniti G

2011 Chevrolet Equinox/GMC Terrain

2011 Chevrolet Equinox / GMC Terrain
Model years affected: 2011-2012
Typical mileage: 86,000-124,000
Alternatives without this problem: 2011-2014 Toyota RAV4, 2013-2014 Mazda CX-5, 2011-2014 Honda CR-V

2015 Ford Mustang

2015 Ford Mustang 4-cyl.
Typical mileage: 76,000-85,000
Alternatives without this problem: 2015-2016 BMW 2 Series, 2015-2016 Mazda MX-5 Miata

2013 BMW X3

2013 BMW X3
Typical mileage: 83,000-93,000
Alternative without this problem: 2014-2016 Acura RDX

2015 Volvo XC60

2015 Volvo XC60
Typical mileage: 60,000-86,000
Alternative without this problem: 2014-2016 Acura RDX