NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
693 reportsClear category filterMileage unknown · Apr 25, 2024
Engine
I purchased this vehicle in 2021, with about 82k miles on it. No problems were reported to me at that time and I did purchase the vehicle from an auto dealer. I have driven the vehicle approx. 23k miles; my current mileage is 105k. That's an average of about 700 miles per month. I have taken this vehicle for numerous oil change…
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I purchased this vehicle in 2021, with about 82k miles on it. No problems were reported to me at that time and I did purchase the vehicle from an auto dealer. I have driven the vehicle approx. 23k miles; my current mileage is 105k. That's an average of about 700 miles per month. I have taken this vehicle for numerous oil changes as I have noticed my oil light will start flashing but it is no where near time for an oil change. There are no leaks, I have had that checked by 3 separate mechanics and myself. It is simply burning through oil. My most recent oil change was at 103k and, at around 104,500 miles, I had to take it in the shop because the engine began knocking. Due to the way the oil flows within the engine it "spills" onto the spark plugs, shorting them out. That repair cost me $300 and that was just 1 spark plug. I was told to expect this to be recurring due to the defect of the motor and how it consumes oil. The oil was 3 quarts low, meaning the engine had burned through 3 qts in 1500 miles. I am going to be taking it to a local Kia dealership so that they can do a "marker test" with a $90 oil change. This whole oil issue is starting to cost more than the car and if I don't keep pouring oil into the motor it will blow. The Kia engine is basically a money pit of problems all related to oil consumption. Reports are that Kia MAY cover the cost of a replacement motor but only after the motor blows, and only if it meets certain "breakdown" criteria. They cover that repair at about a 2-3% average. Kia KNOWS this problem exists but they refuse to place a recall to fix the issue. They did change the motor oil system around 2019/20 because there were so many complaints about oil consumption but they refuse to acknowledge the existing problem in those 2016-2020 motors hat are still on the roads. My fear is a blown motor at 70mph on the interstate. Kia needs to be more responsible.
NHTSA ODI #11585160
Mileage unknown · Apr 18, 2024
Engine
Engine Failure. The vehicle is available for inspection. Engine Failure while driving put my own and children's lives at risk. The problem has been confirmed by both the dealer and independent service center. No warning lights prior to the problem appearing. Symptoms included rattling sound from engine on start up and accelerati…
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Engine Failure. The vehicle is available for inspection. Engine Failure while driving put my own and children's lives at risk. The problem has been confirmed by both the dealer and independent service center. No warning lights prior to the problem appearing. Symptoms included rattling sound from engine on start up and acceleration as well as coolant leak from engine. Dealership told us the engine seized due to no lubrication despite vehicle receiving timely service for oil change. Kia is denying all responsibility for a fix.
NHTSA ODI #11583858
Mileage unknown · Apr 15, 2024
Engine
On 4/14/24 I was turning the corner and my car cut off on me in the middle of the turn. I coasted to the nearest store. My engine light, oil light and battery light came on upon trying to restart the vehicle. The vehicle will not start and those lights still remain on. I had to have the vehicle towed home. As of today the vehicl…
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On 4/14/24 I was turning the corner and my car cut off on me in the middle of the turn. I coasted to the nearest store. My engine light, oil light and battery light came on upon trying to restart the vehicle. The vehicle will not start and those lights still remain on. I had to have the vehicle towed home. As of today the vehicle still won't start. I am traumatized as this could of ended very badly. I could of been killed and or collided with another vehicle. When my car cut off I was unable to really steer the vehicle luckily there was a nearby gas station I was able to just sharply Coast into and slam on brakes. I believe this is a major safety concern and needs to be addressed as I'm pretty sure I am not the only one with this issue. Upon trying to restart the car
NHTSA ODI #11583180
Mileage unknown · Apr 12, 2024
Engine
I took my vehicle into the Kia dealership here in Visalia, California. The first time I took my vehicle in, it was due to oil consumption. I was burning off over 1qt of oil every 700-1000 miles. This being a concern I asked what should I do next. When this happens the dealership recommends a fresh oil change by them, then they t…
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I took my vehicle into the Kia dealership here in Visalia, California. The first time I took my vehicle in, it was due to oil consumption. I was burning off over 1qt of oil every 700-1000 miles. This being a concern I asked what should I do next. When this happens the dealership recommends a fresh oil change by them, then they tag your oil cap, dip stick, and drian plug so its not to be tampered with. We drove the care as told and took it back. Upon return the motor was then confirmed that it was burning off almost 2 qt of oil. The dealership stated that I needed to do an engine "clean out". The service costs $500 dollars to have done. As suggested I did the service in hope that it would rectify the problem. We did the service, drove the car as instructed, brought it back, and I was told it was still burning oil. Now, according to KIA this is a well known issue and that the next step was an engine replacement. Now this is typically covered under the original warranty and a replacement motor is usually done by kia, BUT since I am the second owner of said vehicle this service doesn't apply to me. On the other had, kia also has a known issue with the rod bearings! Now, from what I was told is that rod bearings tend to fail due to lack of lubrication. Kia then proceeds to tell me that unless my rod bearing fails, they will not replace my motor at no cost, but the service manager told me on a recorded phone call "off the record" that I should drive my car until the motor ceases. Please tell me how this is safe and fair practice by the company? Kia has knowingly sold vehicles with faulty engines and they are not held responsible. I'm supposed to allow my wife to drive this car until the motor ceases and hope she doesn't get into an accident. I have filed claims with Kia North America and with my local dealership. The local dealership has denied my claim twice. Once by the service manager, and again by their DSM (district service manager). I have yet to hear from Kia HQ.
NHTSA ODI #11582710
Mileage unknown · Apr 11, 2024
Engine
I was driving down the road in a 45. My car started to have no power. I no warning came on. Literally Cruising down the road it sounded like the motor blew. Had it towed to my local mechanic and he said it wasn’t good. Never had any faulty components prior to. No warning lamps have come on still and when started you get smoke an…
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I was driving down the road in a 45. My car started to have no power. I no warning came on. Literally Cruising down the road it sounded like the motor blew. Had it towed to my local mechanic and he said it wasn’t good. Never had any faulty components prior to. No warning lamps have come on still and when started you get smoke and a loud knock. When driving I could’ve been hurt or hurt another driver. I contacted Kia and was told that their is no coverage on this motor but when you call the dealerships (called 4) this particular motor that isn’t covered by an extended warranty is back ordered in PA alone an estimated 4-6 months
NHTSA ODI #11582366
Mileage unknown · Apr 7, 2024
Engine
I have been the first owner of my Kia Sorento car and it has always been well maintained. The oil change has always been done on time. I was driving on the highway going 65mph when out of nowhere the check engine started flashing, a rattling noise started, and I noticed it wouldn’t accelerate. There was never any warning lights …
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I have been the first owner of my Kia Sorento car and it has always been well maintained. The oil change has always been done on time. I was driving on the highway going 65mph when out of nowhere the check engine started flashing, a rattling noise started, and I noticed it wouldn’t accelerate. There was never any warning lights of any kind to warn me of something malfunctioning. I had a mechanic check it and said there was an oil loss and affected the engine and I would have to replace it. He mentioned that there has been a lot of issues about the engine failing in Kias but that there is still no recall for it. I have read so many articles of this being true and Kia should fix this! It is definitely a hazard driving a Kia car that does not warn you of the oil loss causing a failed engine.
NHTSA ODI #11581616
Mileage unknown · Apr 5, 2024
Engine
The engine gave out while driving on the highway going 65-70 mph on the left lane ,vehicle started shaking and slowing down really loud cars started going around luckily I was able to get to the right breakdown lane as it stalled. I could have caused a major accident on the highway, I restarted the car it shakes as I drove it sl…
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The engine gave out while driving on the highway going 65-70 mph on the left lane ,vehicle started shaking and slowing down really loud cars started going around luckily I was able to get to the right breakdown lane as it stalled. I could have caused a major accident on the highway, I restarted the car it shakes as I drove it slowly to the exit at every light the car stalled when I stopped. Brought to the dealer they confirmed the engine is gone , no prior warning of any issue. Car isn’t even paid off til next month! They state only option is to put a new engine which is lots of money.
NHTSA ODI #11581297
Mileage unknown · Mar 29, 2024
Engine
I have filed a complaint with the South Carolina Attorney General which is pending and spoke with KIA Consumer Affairs twice about the failure of the Knock Sensor device which has caused engine failure in my 2016 KIA Sorento. I was told by KIA Consumer Affairs that the Upgrade Knock Sensor Campaign was mailed to the first owner …
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I have filed a complaint with the South Carolina Attorney General which is pending and spoke with KIA Consumer Affairs twice about the failure of the Knock Sensor device which has caused engine failure in my 2016 KIA Sorento. I was told by KIA Consumer Affairs that the Upgrade Knock Sensor Campaign was mailed to the first owner of the vehicle in 2018 and was not replaced. I bought the SUV in November 2019 from Carvana. I have the original carfax report which states No Recalls on my SUV. I had no knowledge of the knock sensor upgrade Campaign and of course didn't receive a Recall notice. The only Recall notice I have received, just recently, is for a wiring harness for tow hitch, however, I don't have the tow pkg./hitch on my SUV. Until my engine failed due to the knock sensor, I had no indication of anything being wrong with the SUV. KIA refuses to pay for the engine replacement. My SUV is still at the dealership service dept. until this is resolved. I am a [XXX] lady with 32 years Federal Service with the Veterans Administration in SC. I do not have the money nor should I have to pay for the engine replacement. It's a lot of money! I am appealing for your help to force KIA to take responsibility and replace the engine. When the engine died without warning, I was in a dangerous intersection, during rush hour. An off duty police officer assisted me with directing traffic & obtaining a tow truck to pull me safety until AAA could come tow it. I called the dealership the next day, on [XXX], & was told why they thought the engine died & that warranties on the motor had been extended to 100,000 miles to cover it. I was told to have it towed there. A couple days later a technician called & said he did not think KIA would cover it because the knock sensor was not replaced during the "Recall." Any assistance you can provide is appreciated. Thank you. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11580170
Mileage unknown · Mar 29, 2024
EngineUnknown Or Other
The engine (I think engine) stalls out, and several times the engine has completely died. Almost causing me and the other car involved a very serious accident. The vehicle stalls when sitting at the traffic light and I go to turn to accelerate and it stalls and after pushing/tapping the gas pedal repeatedly it will eventually s…
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The engine (I think engine) stalls out, and several times the engine has completely died. Almost causing me and the other car involved a very serious accident. The vehicle stalls when sitting at the traffic light and I go to turn to accelerate and it stalls and after pushing/tapping the gas pedal repeatedly it will eventually stop and I'm able to then drive on. Also the car does not shift properly at all, it winds up and seems the get stuck and have to try accelerate before it shift. I keep getting errors on my dash saying "possible engine condition, please press schedule service" and then I run the diagnostic report and this is what it says CATEGORY (2) PowerTrain P0456 Evaporative Emission System - Leak Detected (Very Small Leak) Possible condition(s) with your Engine Control System has been detected. KlA recommends a full system check when convenient. To schedule an appointment with a KIA dealer, select Schedule Service on the screen. P0303 Cylinder 3 - Misfire Detected Possible condition(s) with your Engine Control System has been detected. KIA recommends a full system check soon. To schedule an appointment with a KIA dealer, select Schedule Service on the screen. Request Appointment I have taken my vehicle in the KIA Service Center twice and have given them the errors and described the issues I am having along with several other issues. The Kia service department has failed to provide me with a resolution to the problem stated above or any other issues I reported. They didn't even check oil as I requested. They advised me the oil levels were "fine" but once I checked it myself it was actually low, proofing they did not do any type inspection on the vehicle as requested. The advised me that there was nothing they could do about the stalling of the vehicle or the engine shutting down because they couldn't duplicate it. I'm not sure exactly what they are meaning by the statement. I then called KIA corporate number and the representative submitted a case onveh
NHTSA ODI #11580029
119,000 miles · Mar 22, 2024
Engine
The contact owns a 2016 Kia Sorento. The contact stated that while driving at approximately 55-60 MPH, a loud explosion was heard coming from the vehicle. The vehicle then lost motive power. No warning light was illuminated. The contact pulled over the side of the road. The vehicle was towed to an independent mechanic, who diagn…
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The contact owns a 2016 Kia Sorento. The contact stated that while driving at approximately 55-60 MPH, a loud explosion was heard coming from the vehicle. The vehicle then lost motive power. No warning light was illuminated. The contact pulled over the side of the road. The vehicle was towed to an independent mechanic, who diagnosed that there was a hole in the bottom part of the engine, causing oil to leak from the engine. The dealer informed the contact that the engine, starter, and exhaust manifold needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure, and a case was opened. The manufacturer denied the engine replacement. The failure mileage was approximately 119,000. The contact stated the safety issue of the vehicle losing all power without warning while driving is due to a specific engine that Kia installed in several of its cars/suvs. It is called a Theta II engine that was used in 2.0 and 2.4 liter cars.
NHTSA ODI #11578903
Official recalls
8Sep 19, 2022
Kia America, Inc. (Kia) is recalling certain 2016-2022 Sorento, 2021-2022 Sorento Hybrid (HEV), 2022-2023 Sorento Plug-In Hybrid (PHEV), and 2017-2022 Sportage vehicles equipped with a tow hitch harness installed as original equipment, or purchased as an accessory through a Kia dealership. Debris and moisture accumulation on the tow hitch harness module printed circuit board (PCB) may cause an electrical short, which can result in a fire.
Consequence & remedy
Consequence: A fire while parked or driving can increase the risk of injury.
Remedy: Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will inspect the vehicle, and, as necessary, replace the fuse and/or tow hitch harness module, free of charge. Owner notification letters were mailed August 11, 2023. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC249.
Aug 10, 2022
Kia America, Inc. (Kia) is recalling certain 2016 Sedona and Sorento vehicles. The vehicles may have been manufactured with faulty automatic transmission shift lever assembly components, preventing the shift lever from locking, which can allow the vehicle to rollaway.
Consequence & remedy
Consequence: A vehicle rollaway increases the risk of a crash and injury.
Remedy: Dealers will inspect and replace the automatic transmission shift lever assembly components, as necessary, free of charge. Owner notification letters were mailed October 7, 2022. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC246.
Dec 19, 2018
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Additional source detail variants (2)
Engine
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Nov 30, 2016
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence & remedy
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Additional source detail variants (2)
Trailer Hitches
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Electrical System
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Oct 24, 2016
Kia Motors America (Kia) is recalling certain model year 2016 Kia Sorento vehicles manufactured March 3, 2016 to March 21, 2016. The driver's seatback frame may have been produced with inadequate weld joints and, as a result, the seatback may not function as designed in the event of a rear-end collision.
Consequence & remedy
Consequence: In the event of a crash, the driver seatback frame could break and fail to restrain a seat occupant, increasing the risk of injury.
Remedy: Kia will notify owners, and dealers will inspect the welds and replace the driver seatback frame, as necessary, free of charge. The recall began on December 9, 2016. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC140.
Jun 29, 2016
Kia Motors America (Kia) is recalling certain model year 2016 Sorento vehicles. A component of the rear suspension may not be properly welded.
Consequence & remedy
Consequence: The improper weld may break, affecting the rear suspension alignment, thereby increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will inspect the welds at the rear suspension cross-member, replacing the rear cross-member assembly, as necessary, free of charge. The recall began July 27, 2016. Owners may contact Kia Customer Service Department at 1-800-333-4542. Kia's number for this recall is SC137.
Jul 14, 2015
Kia Motors America (Kia) is recalling certain model year 2016 Kia Sorento vehicles manufactured October 23, 2014, to December 10, 2014. The affected vehicles have a front passenger seat belt whose buckle latch assembly may prevent the front passenger from fastening the seat belt.
Consequence & remedy
Consequence: If the front passenger seat belt cannot be latched, an occupant sitting in the front passenger seat has an increased risk of injury in the event of a crash.
Remedy: Kia will notify owners, and dealers will replace the front passenger seat belt buckle cover, free of charge. The recall began on August 18, 2015. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC123.
Feb 13, 2015
Kia Motors America (Kia) is recalling certain model year 2016 Sorento vehicles manufactured October 27, 2014, to January 29, 2015. Due to an improperly soldered component in the accelerator pedal assembly, the driver may not be able to accelerate the vehicle.
Consequence & remedy
Consequence: If the vehicle is unable to be accelerated, there is an increased risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the accelerator assembly, free of charge. The recall began on February 19, 2015. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC115.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3PE23019 · Loss Of Motive Power
Opened Nov 13, 2023 · Closed Jul 23, 2024
Status: closed (inferred from source dates) · Engine; Engine And Engine Cooling:engine:oil/lubrication:seals/gaskets
On November 13, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-019) to investigate allegations of loss of motive power relating to head gasket and/or head bolt failure in Model Year (MY) 2016-2017 Kia Sorento vehicles equipped with the 3.3 L Lambda II engine. When the investigation was opened, ODI had received 13 Vehicle Owner Questionnaires (VOQs) related to reports of loss of motive power. In an information request letter dated November 30, 2023, ODI requested technical information and failure data relating to the alleged defect in the subject MY 2016-2017 Kia Sorento as well as several peer vehicle populations which share the 3.3 L engine. In its February 26, 2024, response to ODI’s information request, Kia provided 2022 customer complaints (including techline and field reports) and 1738 warranty claims representing 2411 unique vehicles within the subject vehicle population. Of the customer complaints provided by Kia, they identified only 53 unique allegations of a loss of motive power resulting from the alleged defect. Kia determined that the remaining reports were minor vehicle drivability or engine performance issues. ODI reviewed the information provided by Kia, along with additional VOQs submitted to NHTSA following the opening of the investigation. When eliminating duplicative reports across the data sources, the total number of allegations of loss of motive power relating to the alleged defect in the subject vehicles is 77, representing an incident report rate of 59 per 100,000 vehicles. The MY 2016 Kia Sorento exhibited both the highest overall complaint rate and loss of motive power report rate across all subject and peer vehicle populations, representing an incident report rate of 102 per 100,000 vehicles. Across all data sources, there are no allegations of crashes or fires relating to the alleged defect. The one injury incident reflected in the failure summary table above is related to a consumer who was reportedly burned (minor burn requiring medical attention) while attempting to remove the coolant reservoir cap following a loss of motive power event. In their response to ODI, Kia described that if the threads of a head bolt hole in the subject engine becomes damaged, the clamping force between the cylinder head and engine block can decrease in the area of the affected head bolt. Kia’s assessment of the alleged defect is that when the failure occurs, drivers are provided with numerous warning signs prior to a potential loss of motive power event. According to Kia, potential warning signs associated with this failure include coolant leak/consumption or noticeable coolant odor, engine oil leak/consumption, engine temperature gauge rising to “H” (hot), check engine light illuminating, engine cooling fan remaining on following the engine being shut off, HVAC system not functioning properly, unusual engine noise, difficulty starting the vehicle, and smoke/condensation emitting from the engine compartment or exhaust. Through both its review of the information provided by Kia and outreach to consumers, ODI confirmed that there is reasonable detectability present in the vast majority of occurrences of the alleged defect. To mitigate the alleged defect, Kia increased the engagement depth of the head bolt threads for all subject engines, beginning in May 2017. ODI’s analysis of the failure data demonstrates that this corrective action correlates with a much lower incident report rate for engines produced following the change (8 per 100,000 vehicles for the MY 2018-2020 Kia Sorento). In December 2023, Kia launched extended warranty campaign WTY035 covering failures associated with the alleged defect in the subject vehicle population through 15 years or 180,000 miles, whichever comes first. Through its investigation, ODI identified the following peer vehicle populations, which were produced prior to the corrective action and exhibit failure rates comparable to the subject vehicles: MY 2014-2015 Kia Sorento, MY 2015-2016 Kia Sedona, and MY 2014-2017 Kia Cadenza equipped with the 3.3 L engine. Through discussions with ODI during the investigation, Kia decided to launch extended warranty campaign WTY039 in May 2024, which covers these peer vehicle populations through 15 years or 180,000 miles, whichever comes first. Based on analysis of the failure data indicating a low incident report rate of loss of motive power for the alleged defect, and in consideration of the warning signs which frequently occur from head gasket and/or head bolt failure in the subject engines, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Additional source detail variants (2)
Engine And Engine Cooling:engine:oil/lubrication:seals/gaskets
On November 13, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-019) to investigate allegations of loss of motive power relating to head gasket and/or head bolt failure in Model Year (MY) 2016-2017 Kia Sorento vehicles equipped with the 3.3 L Lambda II engine. When the investigation was opened, ODI had received 13 Vehicle Owner Questionnaires (VOQs) related to reports of loss of motive power. In an information request letter dated November 30, 2023, ODI requested technical information and failure data relating to the alleged defect in the subject MY 2016-2017 Kia Sorento as well as several peer vehicle populations which share the 3.3 L engine. In its February 26, 2024, response to ODI’s information request, Kia provided 2022 customer complaints (including techline and field reports) and 1738 warranty claims representing 2411 unique vehicles within the subject vehicle population. Of the customer complaints provided by Kia, they identified only 53 unique allegations of a loss of motive power resulting from the alleged defect. Kia determined that the remaining reports were minor vehicle drivability or engine performance issues. ODI reviewed the information provided by Kia, along with additional VOQs submitted to NHTSA following the opening of the investigation. When eliminating duplicative reports across the data sources, the total number of allegations of loss of motive power relating to the alleged defect in the subject vehicles is 77, representing an incident report rate of 59 per 100,000 vehicles. The MY 2016 Kia Sorento exhibited both the highest overall complaint rate and loss of motive power report rate across all subject and peer vehicle populations, representing an incident report rate of 102 per 100,000 vehicles. Across all data sources, there are no allegations of crashes or fires relating to the alleged defect. The one injury incident reflected in the failure summary table above is related to a consumer who was reportedly burned (minor burn requiring medical attention) while attempting to remove the coolant reservoir cap following a loss of motive power event. In their response to ODI, Kia described that if the threads of a head bolt hole in the subject engine becomes damaged, the clamping force between the cylinder head and engine block can decrease in the area of the affected head bolt. Kia’s assessment of the alleged defect is that when the failure occurs, drivers are provided with numerous warning signs prior to a potential loss of motive power event. According to Kia, potential warning signs associated with this failure include coolant leak/consumption or noticeable coolant odor, engine oil leak/consumption, engine temperature gauge rising to “H” (hot), check engine light illuminating, engine cooling fan remaining on following the engine being shut off, HVAC system not functioning properly, unusual engine noise, difficulty starting the vehicle, and smoke/condensation emitting from the engine compartment or exhaust. Through both its review of the information provided by Kia and outreach to consumers, ODI confirmed that there is reasonable detectability present in the vast majority of occurrences of the alleged defect. To mitigate the alleged defect, Kia increased the engagement depth of the head bolt threads for all subject engines, beginning in May 2017. ODI’s analysis of the failure data demonstrates that this corrective action correlates with a much lower incident report rate for engines produced following the change (8 per 100,000 vehicles for the MY 2018-2020 Kia Sorento). In December 2023, Kia launched extended warranty campaign WTY035 covering failures associated with the alleged defect in the subject vehicle population through 15 years or 180,000 miles, whichever comes first. Through its investigation, ODI identified the following peer vehicle populations, which were produced prior to the corrective action and exhibit failure rates comparable to the subject vehicles: MY 2014-2015 Kia Sorento, MY 2015-2016 Kia Sedona, and MY 2014-2017 Kia Cadenza equipped with the 3.3 L engine. Through discussions with ODI during the investigation, Kia decided to launch extended warranty campaign WTY039 in May 2024, which covers these peer vehicle populations through 15 years or 180,000 miles, whichever comes first. Based on analysis of the failure data indicating a low incident report rate of loss of motive power for the alleged defect, and in consideration of the warning signs which frequently occur from head gasket and/or head bolt failure in the subject engines, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Engine
On November 13, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-019) to investigate allegations of loss of motive power relating to head gasket and/or head bolt failure in Model Year (MY) 2016-2017 Kia Sorento vehicles equipped with the 3.3 L Lambda II engine. When the investigation was opened, ODI had received 13 Vehicle Owner Questionnaires (VOQs) related to reports of loss of motive power. In an information request letter dated November 30, 2023, ODI requested technical information and failure data relating to the alleged defect in the subject MY 2016-2017 Kia Sorento as well as several peer vehicle populations which share the 3.3 L engine. In its February 26, 2024, response to ODI’s information request, Kia provided 2022 customer complaints (including techline and field reports) and 1738 warranty claims representing 2411 unique vehicles within the subject vehicle population. Of the customer complaints provided by Kia, they identified only 53 unique allegations of a loss of motive power resulting from the alleged defect. Kia determined that the remaining reports were minor vehicle drivability or engine performance issues. ODI reviewed the information provided by Kia, along with additional VOQs submitted to NHTSA following the opening of the investigation. When eliminating duplicative reports across the data sources, the total number of allegations of loss of motive power relating to the alleged defect in the subject vehicles is 77, representing an incident report rate of 59 per 100,000 vehicles. The MY 2016 Kia Sorento exhibited both the highest overall complaint rate and loss of motive power report rate across all subject and peer vehicle populations, representing an incident report rate of 102 per 100,000 vehicles. Across all data sources, there are no allegations of crashes or fires relating to the alleged defect. The one injury incident reflected in the failure summary table above is related to a consumer who was reportedly burned (minor burn requiring medical attention) while attempting to remove the coolant reservoir cap following a loss of motive power event. In their response to ODI, Kia described that if the threads of a head bolt hole in the subject engine becomes damaged, the clamping force between the cylinder head and engine block can decrease in the area of the affected head bolt. Kia’s assessment of the alleged defect is that when the failure occurs, drivers are provided with numerous warning signs prior to a potential loss of motive power event. According to Kia, potential warning signs associated with this failure include coolant leak/consumption or noticeable coolant odor, engine oil leak/consumption, engine temperature gauge rising to “H” (hot), check engine light illuminating, engine cooling fan remaining on following the engine being shut off, HVAC system not functioning properly, unusual engine noise, difficulty starting the vehicle, and smoke/condensation emitting from the engine compartment or exhaust. Through both its review of the information provided by Kia and outreach to consumers, ODI confirmed that there is reasonable detectability present in the vast majority of occurrences of the alleged defect. To mitigate the alleged defect, Kia increased the engagement depth of the head bolt threads for all subject engines, beginning in May 2017. ODI’s analysis of the failure data demonstrates that this corrective action correlates with a much lower incident report rate for engines produced following the change (8 per 100,000 vehicles for the MY 2018-2020 Kia Sorento). In December 2023, Kia launched extended warranty campaign WTY035 covering failures associated with the alleged defect in the subject vehicle population through 15 years or 180,000 miles, whichever comes first. Through its investigation, ODI identified the following peer vehicle populations, which were produced prior to the corrective action and exhibit failure rates comparable to the subject vehicles: MY 2014-2015 Kia Sorento, MY 2015-2016 Kia Sedona, and MY 2014-2017 Kia Cadenza equipped with the 3.3 L engine. Through discussions with ODI during the investigation, Kia decided to launch extended warranty campaign WTY039 in May 2024, which covers these peer vehicle populations through 15 years or 180,000 miles, whichever comes first. Based on analysis of the failure data indicating a low incident report rate of loss of motive power for the alleged defect, and in consideration of the warning signs which frequently occur from head gasket and/or head bolt failure in the subject engines, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
DP22003 · Loss Of Motive Power
Opened Sep 12, 2022 · Closed Dec 12, 2023
Status: closed (inferred from source dates) · Engine
The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing. There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
DP21002 · Engine Oil Pressure Switch Leak
Opened Nov 12, 2021 · Closed Jun 26, 2023
Status: closed (inferred from source dates) · Engine; Engine And Engine Cooling:engine:oil/lubrication:pressure/temperature Sensor
In a letter dated September 30, 2021, Mr. Gerald James (the petitioner) requested that NHTSA conduct an investigation of the Model Year (MY) 2015-2017 Kia Sorento equipped with 3.3L V6 ?Lambda? engines for ?severe oil leaks? from the oil pressure switch (OPS) that could ?lead to engine failure? with little warning to the driver. Mr. James based this request on his own experience and data found in NHTSA?s Vehicle Owner Questionnaire (VOQ) database. NHTSA reviewed the material cited by the petitioner, information submitted by Kia, NHTSA?s testing, and other pertinent information in NHTSA databases.On November 12, 2021, ODI opened Defect Petition DP21-002 to evaluate the petitioner?s request. ODI performed an analysis that included evaluation of the petitioner?s vehicle, searches of ODI complaints from vehicle owners, non-dealer field reports, manufacturers? supplemental information relating to design of the component, and component testing performed by ODI.On December 16, 2021, ODI and Kia North America performed a joint inspection on the petitioner?s vehicle. ODI and Kia agreed the OPS was leaking oil and observed oil in the crevices atop the engine block. The vehicle received a new replacement OPS and was delivered back to the petitioner. The original part that was removed from the subject vehicle was retained by ODI for further analysis.As of December 30, 2022, for the MY 2015-2017 Kia Sorento population of 161,519 vehicles with 3.3L engine, NHTSA reviewed internal data and has identified no consumer complaints or field reports in its database, with unique Vehicle Identification Numbers (VIN), citing engine failure or stalling related to the petition?s allegation of defective OPS. When combined with the supplemental warranty and technical analysis from the manufacturer, field report and customer complaint data in response to the Information Request letter sent, NHTSA identified no unique VINs alleging engine failure or stalls caused by OPS leaking on the subject vehicles named in the petition.On April 4, 2022, the Vehicle Research and Test Center (VRTC) performed testing of the petitioner?s component (OPS) based on testing protocol consistent with Kia?s specifications for the subject vehicle. The testing involved the petitioner?s original OPS in a controlled system to replicate the subject vehicle?s oil pressure, flow, and temperature. VRTC determined that a vehicle would have to miss more than a dozen oil change intervals to reach low engine oil capacity. Testing also revealed the OPS would operate, as manufacturer intended, illuminating the vehicle?s MIL to alert the driver of lower oil pressure.In April of 2022, Kia North America issued a warranty extension that extended the coverage of the Oil Pressure Switch from 5 years/60,000 miles to 15 years/150,000 miles on MY 2014-2018 Sorento, MY 2014-2016 Cadenza, and MY 2015-2018 Sedona vehicles, all equipped with the 3.3L Lambda engine. The extended warranty coverage includes diagnosis, repair, and applies to customers experiencing engine oil leaking from the engine or if the engine oil pressure warning light stays illuminated after the engine is turned on.After a thorough review of the material submitted by the petitioner, information already in NHTSA's possession, testing performed by VRTC, technical information provided by Kia, the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that an engine failure due to the alleged defect is likely and does not warrant a formal investigation. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be publi
Additional source detail variants (2)
Engine And Engine Cooling:engine:oil/lubrication:pressure/temperature Sensor
In a letter dated September 30, 2021, Mr. Gerald James (the petitioner) requested that NHTSA conduct an investigation of the Model Year (MY) 2015-2017 Kia Sorento equipped with 3.3L V6 ?Lambda? engines for ?severe oil leaks? from the oil pressure switch (OPS) that could ?lead to engine failure? with little warning to the driver. Mr. James based this request on his own experience and data found in NHTSA?s Vehicle Owner Questionnaire (VOQ) database. NHTSA reviewed the material cited by the petitioner, information submitted by Kia, NHTSA?s testing, and other pertinent information in NHTSA databases.On November 12, 2021, ODI opened Defect Petition DP21-002 to evaluate the petitioner?s request. ODI performed an analysis that included evaluation of the petitioner?s vehicle, searches of ODI complaints from vehicle owners, non-dealer field reports, manufacturers? supplemental information relating to design of the component, and component testing performed by ODI.On December 16, 2021, ODI and Kia North America performed a joint inspection on the petitioner?s vehicle. ODI and Kia agreed the OPS was leaking oil and observed oil in the crevices atop the engine block. The vehicle received a new replacement OPS and was delivered back to the petitioner. The original part that was removed from the subject vehicle was retained by ODI for further analysis.As of December 30, 2022, for the MY 2015-2017 Kia Sorento population of 161,519 vehicles with 3.3L engine, NHTSA reviewed internal data and has identified no consumer complaints or field reports in its database, with unique Vehicle Identification Numbers (VIN), citing engine failure or stalling related to the petition?s allegation of defective OPS. When combined with the supplemental warranty and technical analysis from the manufacturer, field report and customer complaint data in response to the Information Request letter sent, NHTSA identified no unique VINs alleging engine failure or stalls caused by OPS leaking on the subject vehicles named in the petition.On April 4, 2022, the Vehicle Research and Test Center (VRTC) performed testing of the petitioner?s component (OPS) based on testing protocol consistent with Kia?s specifications for the subject vehicle. The testing involved the petitioner?s original OPS in a controlled system to replicate the subject vehicle?s oil pressure, flow, and temperature. VRTC determined that a vehicle would have to miss more than a dozen oil change intervals to reach low engine oil capacity. Testing also revealed the OPS would operate, as manufacturer intended, illuminating the vehicle?s MIL to alert the driver of lower oil pressure.In April of 2022, Kia North America issued a warranty extension that extended the coverage of the Oil Pressure Switch from 5 years/60,000 miles to 15 years/150,000 miles on MY 2014-2018 Sorento, MY 2014-2016 Cadenza, and MY 2015-2018 Sedona vehicles, all equipped with the 3.3L Lambda engine. The extended warranty coverage includes diagnosis, repair, and applies to customers experiencing engine oil leaking from the engine or if the engine oil pressure warning light stays illuminated after the engine is turned on.After a thorough review of the material submitted by the petitioner, information already in NHTSA's possession, testing performed by VRTC, technical information provided by Kia, the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that an engine failure due to the alleged defect is likely and does not warrant a formal investigation. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be publi
Engine
In a letter dated September 30, 2021, Mr. Gerald James (the petitioner) requested that NHTSA conduct an investigation of the Model Year (MY) 2015-2017 Kia Sorento equipped with 3.3L V6 ?Lambda? engines for ?severe oil leaks? from the oil pressure switch (OPS) that could ?lead to engine failure? with little warning to the driver. Mr. James based this request on his own experience and data found in NHTSA?s Vehicle Owner Questionnaire (VOQ) database. NHTSA reviewed the material cited by the petitioner, information submitted by Kia, NHTSA?s testing, and other pertinent information in NHTSA databases.On November 12, 2021, ODI opened Defect Petition DP21-002 to evaluate the petitioner?s request. ODI performed an analysis that included evaluation of the petitioner?s vehicle, searches of ODI complaints from vehicle owners, non-dealer field reports, manufacturers? supplemental information relating to design of the component, and component testing performed by ODI.On December 16, 2021, ODI and Kia North America performed a joint inspection on the petitioner?s vehicle. ODI and Kia agreed the OPS was leaking oil and observed oil in the crevices atop the engine block. The vehicle received a new replacement OPS and was delivered back to the petitioner. The original part that was removed from the subject vehicle was retained by ODI for further analysis.As of December 30, 2022, for the MY 2015-2017 Kia Sorento population of 161,519 vehicles with 3.3L engine, NHTSA reviewed internal data and has identified no consumer complaints or field reports in its database, with unique Vehicle Identification Numbers (VIN), citing engine failure or stalling related to the petition?s allegation of defective OPS. When combined with the supplemental warranty and technical analysis from the manufacturer, field report and customer complaint data in response to the Information Request letter sent, NHTSA identified no unique VINs alleging engine failure or stalls caused by OPS leaking on the subject vehicles named in the petition.On April 4, 2022, the Vehicle Research and Test Center (VRTC) performed testing of the petitioner?s component (OPS) based on testing protocol consistent with Kia?s specifications for the subject vehicle. The testing involved the petitioner?s original OPS in a controlled system to replicate the subject vehicle?s oil pressure, flow, and temperature. VRTC determined that a vehicle would have to miss more than a dozen oil change intervals to reach low engine oil capacity. Testing also revealed the OPS would operate, as manufacturer intended, illuminating the vehicle?s MIL to alert the driver of lower oil pressure.In April of 2022, Kia North America issued a warranty extension that extended the coverage of the Oil Pressure Switch from 5 years/60,000 miles to 15 years/150,000 miles on MY 2014-2018 Sorento, MY 2014-2016 Cadenza, and MY 2015-2018 Sedona vehicles, all equipped with the 3.3L Lambda engine. The extended warranty coverage includes diagnosis, repair, and applies to customers experiencing engine oil leaking from the engine or if the engine oil pressure warning light stays illuminated after the engine is turned on.After a thorough review of the material submitted by the petitioner, information already in NHTSA's possession, testing performed by VRTC, technical information provided by Kia, the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that an engine failure due to the alleged defect is likely and does not warrant a formal investigation. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be publi
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