2016 Kia Sedona

I brought my 2016 Kia Sedona into a mechanic to get checked over and get some new front tires put on on 8/19/24. I was informed that the oil needed changing. So, I changed it as I have always done for years. We took off on a ~2600 mile round trip out east. Once there, I noticed that when I would travel close to a cement divider, a noise was coming from the vehicle that got louder as I accelerated. Thought is was the muffler (sounded like I was hot rodding). There were no engine lights on the dash, so I didn't think there were any major issues. A muffler could wait till I got back. This trip was end of August. There were no other issues, so I put it off. I figured a small hole in muffler or loose. We were called to go back out to New York for 11 days the end of November, and after another 2600 miles, the noise was significantly louder, but mostly noticeable when accelerating. Still idled fairly well. Still no engine lights. On 11/27/24 we took a 600+ mile trip. As of 12/2/2024, I brought the vehicle in to get the spark pugs changed and check the noise. The mechanic said that I was 4.5 quarts low and the noise was knocking in the motor itself. I had replaced the engine oil (synthetic) end of August and now find this Dec. 3rd after bringing it in. It has never burned oil, and there is no evidence of leakage on the floor or anywhere in the engine compartment or oil pan (mine and mechanics observations). Loss of 4.5 quarts in just over 2 months, when never an issue before? And no low oil engine light coming on? This was just taken on 5800 miles of primarily highways. From what I have been reading, knocking prior to engine failure has been popping up, and my family and I could have had a major problem had I gone any longer without checking it out. It is a major issue not having the low oil sensor go off, and suddenly being without 4.5 quarts in such a short time without prior issues, or warning.

Regularly serviced vehicle (2016 Kia Sedona SXL 3.3L) within recommended intervals; most recently on 9/10/2024 at ~117k miles. Invoice indicates dealer put in full capacity of oil (6qt). Vehicle also received multipoint inspection including checking all fluids; non were reported low or in need of flush/replacement. Vehicle had begun to make extra engine noise (rattle/growl) on startup, not sure precisely when; I estimate just in the last few months, maybe September or October. Took 220 (one way, ~440 total) mile trip on 11/5-11/7/2024; vehicle performed well other than aforementioned startup noise. [XXX], vehicle noise had increased significantly and "engine control system" message with CEL was present on the dashboard which was later extinguished after an engine restart. No other warning/error indications were present before or since. Onboard vehicle diagnostics run by the owner (Kia "eServices" app) on 11/12 did not indicate any issues. It was decided we better not drive it and service was scheduled for 11/22. On the same day (11/12) we found the oil to be low by 4.5 qts. Filling the oil to "full" removed a significant amount of the engine noise but (layman's) inspection did not reveal any oil leakage and no other signs of oil burning had been noted previously. One additional trip of ~16 miles made on 11/19 and 6 miles to service on 11/22 (now at 121k miles). Dealer upon inspection stated rod bearings were bad and engine needed replaced. Retrieving the vehicle from service and driving home, it catastrophically failed losing all power in highway traffic and could not be restarted. I'm reporting this because I saw DP24-001 and PE23-019 which seem to be very similar to my issue. I see no reason why a regularly serviced engine could fail so quickly other than a possible manufacturing defect. The engine/components have not been touched since the dealer appointment on 11/22. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Description of Incident: What component or system failed or malfunctioned, and is it available for inspection upon request? The engine of my 2016 Kia Sedona seized due to a lack of oil. The oil pressure warning light, which is designed to alert the driver to low oil pressure or oil-related issues, did not illuminate to indicate any problem. The engine is still available for inspection upon request. How was your safety or the safety of others put at risk? While the engine seizure did not occur while driving, it created a potential hazard for future operation of the vehicle. Had the issue occurred during the 20-mile drive home or on future trips, it could have led to a sudden loss of power, putting the driver, passengers, and others on the road at risk. Has the problem been reproduced or confirmed by a dealer or independent service center? The Kia dealership confirmed that the engine seized due to a lack of oil. However, they have not provided a detailed diagnostic report or explanation for why the oil pressure warning light failed to illuminate. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives, or others? The vehicle has been inspected by Kia but has not been examined by third parties such as insurance representatives or law enforcement. Were there any warning lamps, messages, or other symptoms of the problem prior to the failure, and when did they first appear? There were no warning lamps, messages, or other symptoms prior to the failure. The oil pressure warning light, which should have alerted us to the issue, did not illuminate at any point. Best assessment: My assessment is that the oil pressure warning system failed to function as designed, leading to the engine seizing without warning. This malfunction prevented us from addressing the oil issue in time to avoid catastrophic engine damage.

Thursday, October 31, 2024, the engine blew on our Sedona. Approximately 164,000 miles on the engine. We maintained regular maintenance on the engine and oil changes. Left us stranded on a main highway. State Department of Natural Resources Conservation Officer protected us until county sheriff could respond. The engine light warning was on.

Air conditioning became less cool over the summer. Early October 2024, slight rattling noise heard in engine on acceleration. Approximately a week later, the battery died and was replaced. In the following days, rattling noise became louder and also heard a tapping sound. No warning lights, check engine light, etc. Taken to a local mechanic who inspected and informed us the timing chain is nearly completely worn and it has rubbed a hole in the side of the engine. A complete engine replacement is needed!

Car would not accelerate while driving, while this did not cause an accident in this incident there was definitely the potential for that outcome. Upon inspecting the vehicle, found the vehicle was low on oil by 4 quarts, and no warning lights were on indicating there was a problem with the vehicle. Monitored the vehicle over the next several days to determine if there were any visible oil leaks and there was not. Further inspection by the dealership confirmed there was no visible oil leak and was followed by an oil consumption test by the dealership. Dealership determine that 2 quarts of oil were consumed by the engine over the course of 1,000 mile which is indicates a failure of the test and problems within the engine.