NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
384 reportsClear category filterMileage unknown · Sep 5, 2026
Engine
In early July, my vehicle's check engine light turned on. I took it to a reputable local mechanic in Sachse, Texas, who had the vehicle for approximately two weeks. He was unable to determine the cause of the issue but informed me that there was an existing recall and that the dealership should be able to address the problem at …
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In early July, my vehicle's check engine light turned on. I took it to a reputable local mechanic in Sachse, Texas, who had the vehicle for approximately two weeks. He was unable to determine the cause of the issue but informed me that there was an existing recall and that the dealership should be able to address the problem at no cost to me. I then took the vehicle to the Kia dealership. The dealership informed me that there was an extended warranty for the engine and that if their diagnosis determined that the issue was covered under the warranty extension, they would repair it. This is what they texted me: Tech performed Compression test 1 .205psi, 2. 220psi, 3. 260psi, 4. 255psi all cylinders have excessive reading for dry compression test. Tech performed leak down test on all cylinders 1. 21% leak down coming from exhaust side, 2.61% leak down coming from exhaust side, 3. 10% normal, 4. 10% normal. Air leakage from exhaust system defective exhaust valves. Tech performed Cooling system pressure test for 20 minutes with no pressure loss. Ruling out head gasket. Tech evaluated Intake/Exhaust CVVT current and setpoints. Tech determined timing is jumping from back pressure of Clogged Catalyst Converter. Recommending replacing engine due to mileage and exhaust manifold. The dealership's recommended solution was to replace the entire engine. Currently, there is a recall concerning 2017 Kia Sorentos involving engine crankshaft issues. See NHTSA Recall No. 17V586000. I contacted the manufacturer, and they stated that they do not believe my vehicle is covered by the recall. However, I believe the issues identified with my vehicle may be related to the same underlying engine problems addressed by the recall, and I am concerned that the manufacturer is denying coverage rather than properly addressing the issue under the applicable recall or warranty. My engine is experiencing issues that appear similar to those described in the current NHTSA.
NHTSA ODI #11762293
100,000 miles · Sep 1, 2026
EngineEngine And Engine Cooling
The contact owns a 2017 Kia Sorento. The contact stated that the vehicle experienced excessive oil consumption. The vehicle was inspected several times; however, no oil leaks were found. The contact stated that while driving 30 MPH, the vehicle shuddered, and the check engine warning light illuminated and flashed on the instrume…
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The contact owns a 2017 Kia Sorento. The contact stated that the vehicle experienced excessive oil consumption. The vehicle was inspected several times; however, no oil leaks were found. The contact stated that while driving 30 MPH, the vehicle shuddered, and the check engine warning light illuminated and flashed on the instrument panel. The vehicle was taken to an independent mechanic, where it was determined that there was a hole in a valve and a piston was fractured. The vehicle was then towed to a dealer, where the failure was confirmed. The dealer determined that the engine needed to be replaced and the repair was not covered under warranty. The vehicle was not repaired due to the cost. The contact notified the manufacturer via telephone and was referred to the NHTSA Hotline for assistance. The failure mileage was approximately 100,000.
NHTSA ODI #11761315
Mileage unknown · Aug 22, 2026
Engine
My kids and I were driving when my engine started making a loud noise. I pulled over and turned it off for a few minutes then I turned it back on. It worked for another mile or so then started making the noise again and died while I was driving at about 55-60 miles an hr. I was able to pull over, put it in park and turned the ke…
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My kids and I were driving when my engine started making a loud noise. I pulled over and turned it off for a few minutes then I turned it back on. It worked for another mile or so then started making the noise again and died while I was driving at about 55-60 miles an hr. I was able to pull over, put it in park and turned the key off....it wouldn't turn back on and the check engine light came on. When I had someone check it out for me it was about 4 quarts low on oil (it never gave me a warning about the oil and the oil light never came on) and the check engine code was P0024. Oil was added and the camshaft position sensor has been replaced. It starts now but it won't stay on and when it is on it makes a loud screeching sound that isn't coming from the serpentine belt and a loud knocking sound.
NHTSA ODI #11758822
Mileage unknown · Jul 31, 2026
EnginePower Train
2017 Kia Sorento 2.4L GDI engine seized due to connecting rod bearing failure confirmed by P1326 diagnostic code multiple times. Vehicle entered limp mode limiting RPMs to 1800-2000 exactly as described in PI1802 campaign. Engine subsequently fully seized. Battery tested 98% healthy ruling out electrical cause. Vehicle towed to …
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2017 Kia Sorento 2.4L GDI engine seized due to connecting rod bearing failure confirmed by P1326 diagnostic code multiple times. Vehicle entered limp mode limiting RPMs to 1800-2000 exactly as described in PI1802 campaign. Engine subsequently fully seized. Battery tested 98% healthy ruling out electrical cause. Vehicle towed to [XXX] Kia Avon Indiana. Kia Techline and Consumer Affairs denied PI1802 lifetime warranty claim citing used vehicle reconditioning despite PI1802 explicitly stating coverage applies to both new AND used vehicle owners per official Kia corporate document dated XXX. Consumer Affairs appeal case XXX opened but Kia states no further appeals possible. Kia is wrongfully denying lifetime warranty coverage guaranteed under PI1802 Product Improvement Campaign. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11754083
Mileage unknown · Jul 29, 2026
Engine
My 2017 Kia Sorento experienced a catastrophic, sudden engine lockup on the roadway due to a known manufacturing defect involving rod bearing failure. This defect caused complete loss of motive power and stalled the vehicle on the road, creating an extreme safety hazard for myself, my passengers, and surrounding motorists.Prior …
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My 2017 Kia Sorento experienced a catastrophic, sudden engine lockup on the roadway due to a known manufacturing defect involving rod bearing failure. This defect caused complete loss of motive power and stalled the vehicle on the road, creating an extreme safety hazard for myself, my passengers, and surrounding motorists.Prior to the failure, the vehicle heavily consumed its own motor oil at a dangerous rate of nearly 5 quarts every 1,000 miles. I repeatedly attempted to address this with Kia, completing three separate official oil consumption and combustion tests. The vehicle failed all three tests. Despite documented failures of these critical safety components, Kia Corporate and the local dealership, court Kia, issued bad-faith warranty denials. As a direct result, I was forced to drive a dangerously unstable vehicle for 8,148 additional miles until the engine permanently and violently seized on the road.After being towed, the engine was confirmed to be completely locked up. My husband subsequently dropped the engine's oil pan and discovered a pieces of physical rod bearing debris and pieces of a snapped timing chain floating inside. The vehicle had full engine oil at the time of failure, as we were constantly topping it off to counteract the severe consumption defect.Manufacturer and Dealer Misconduct / Safety Cover-Up:The servicing dealer, Regal Kia, and Kia Corporate Case Manager Jennifer (who previously denied the vehicle after the consumption test failures) have actively colluded to falsify safety records to escape their lifetime warranty obligations under the federal engine class action settlement.The dealership deliberately withheld the vehicle's diagnostic trouble codes (specifically camshaft codes triggered when the timing chain snapped), falsely telling Kia Corporate that "no codes" existed. They fabricated a false history, claiming I stated the vehicle "stalled and the oil light flickered" prior to arrival, despite the vehicle being towed in with a p
NHTSA ODI #11753403
Mileage unknown · Jul 6, 2026
EngineService Brakes
On XXX, the oil warning light was illuminated in our 2017 Kia Sorento SXL and that the vehicle was leaking oil. We brought the vehicle to an independent repair facility (Tire Kingdom, Cairo, NY) for diagnosis on XXX. The repair facility provided an oral assessment with photographs indicating a suspected rear main seal leak. The…
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On XXX, the oil warning light was illuminated in our 2017 Kia Sorento SXL and that the vehicle was leaking oil. We brought the vehicle to an independent repair facility (Tire Kingdom, Cairo, NY) for diagnosis on XXX. The repair facility provided an oral assessment with photographs indicating a suspected rear main seal leak. The engine was dry on the top but excessively wet between the engine and transmission, consistent with a significant oil leak in that area. We were advised that the vehicle could be driven in short intervals of approximately 25 minutes, provided that oil levels were closely monitored and topped off as needed. On XXX, we began driving the vehicle to transport our daughter to a train station 25 minutes away. Halfway through the trip, the vehicle began producing a metallic noise from the engine compartment. We immediately pulled over safely and turned off the engine. After stopping, we discussed next steps and then attempted to restart the vehicle. The engine started but immediately produced a severe mechanical rattling noise. It was shut off within approximately one second of startup. The vehicle was not driven further. The vehicle was then towed to Romeo Kia in [XXX]. Kia performed a diagnostic assessment and determined that the engine required complete replacement, with an estimated repair cost of approximately $10,000. This vehicle previously had a remanufactured engine installed in 2023 following a prior catastrophic engine failure. Between installations, the vehicle was maintained in normal service and was not overdue for scheduled oil changes at the time of this incident (27 days to go). At no point prior to the failure event was there clear indication of immediate catastrophic engine failure beyond the initial oil warning and leak condition. The failure progressed from a diagnosed external oil leak to immediate mechanical failure upon restart, requiring towing and full engine replacement. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11748442
Mileage unknown · Jul 6, 2026
Engine
On February 16, 2023, the engine in our 2017 Kia Sorento SXL developed a sudden, loud knocking noise while driving. No dashboard warning lights illuminated at any time, including no oil pressure warning, check engine light, or other engine-related alerts. The vehicle remained fully operable and did not lose power or seize. I co…
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On February 16, 2023, the engine in our 2017 Kia Sorento SXL developed a sudden, loud knocking noise while driving. No dashboard warning lights illuminated at any time, including no oil pressure warning, check engine light, or other engine-related alerts. The vehicle remained fully operable and did not lose power or seize. I continued driving approximately 20 minutes home, including highway speeds up to ~75 mph. The following day, with the knocking noise worsening but still no warning indicators present, I drove approximately 25 minutes to an independent repair facility. The vehicle was then diagnosed with catastrophic engine failure attributed to oil starvation and was towed. Because the vehicle had fewer than 100,000 miles and was within the expected powertrain warranty period, we pursued a warranty review through Kia. Kia requested maintenance records, which we provided in full after gathering documentation from all service providers over a two-week period. Despite this, the warranty claim was denied, first citing gaps in initial records and later questioning oil type based on older receipts that did not explicitly state “synthetic oil.” At Kia’s recommendation, we authorized an oil pan inspection at our expense. Kia concluded that the oil filter appeared to be more than two years old, which conflicted with our documented maintenance history showing multiple oil changes during that period. Kia denied warranty coverage and quoted approximately $10,500 for engine replacement. We were advised that the replacement engine would be a remanufactured unit and that it was on backorder with no estimated delivery timeline. After approximately ten weeks without resolution, we located a compatible replacement engine at another Kia dealership and arranged transport of the vehicle there. The engine was replaced within three days for approximately $9,000. The repair included installation of a replacement engine, new spark plugs, and a passed state inspection.
NHTSA ODI #11748438
Mileage unknown · Jun 25, 2026
Engine
bought car from carmax. engine knock sensor went bad and engine is knocking. kia states engine is not origional and was taken from a junk yard, both kia and carmax are refusing to fix eventhough I am doing payments and it is a known kia issue for this car. Kia charged me 350$ to run test and cleared the light but informed me my …
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bought car from carmax. engine knock sensor went bad and engine is knocking. kia states engine is not origional and was taken from a junk yard, both kia and carmax are refusing to fix eventhough I am doing payments and it is a known kia issue for this car. Kia charged me 350$ to run test and cleared the light but informed me my engine is going to blow. carmax is refusing to do anything but still wants us to pay the 9k we owe on the car eventhough its broke.
NHTSA ODI #11746572
Mileage unknown · Jun 11, 2026
Engine
While driving on the highway on Mother’s Day weekend with my wife and daughter, the vehicle suddenly lost acceleration and engine power while traveling on a 5-lane beltway. The vehicle would not accelerate and I was unable to maintain normal highway speed. I had to coast to the side of the road with the hazard lights activated b…
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While driving on the highway on Mother’s Day weekend with my wife and daughter, the vehicle suddenly lost acceleration and engine power while traveling on a 5-lane beltway. The vehicle would not accelerate and I was unable to maintain normal highway speed. I had to coast to the side of the road with the hazard lights activated because of the safety risk. The vehicle was eventually restarted after being towed to a dealership, but it continued to have severe loss of power and could not safely travel above approximately 45 mph. The suspected failure involves the engine and emissions system. The vehicle has a history of engine-related issues and previously received engine-related repairs. The current engine has developed excessive oil consumption. This condition has resulted in fouled spark plugs and a catalytic converter becoming severely restricted/clogged from oil contamination, causing significant loss of engine performance. A dealership inspected the vehicle and documented the oil-burning complaint and catalytic converter-related fault. The dealership performed diagnostic work, including spark plug replacement, but the problem continued. An independent repair facility also inspected the vehicle and confirmed excessive oil consumption and catalytic converter restriction. The vehicle remains available for inspection. This condition presents a safety concern because the vehicle experienced a sudden loss of power while traveling at highway speeds and was unable to maintain normal traffic speed.
NHTSA ODI #11743629
Mileage unknown · Jun 1, 2026
EnginePower Train
Vehicle has a recurring P0018 fault code (Crankshaft Position - Camshaft Position Correlation Bank 2 Sensor A). Dealer diagnosed loose cam pins on Bank 2 requiring major engine repair. This fault creates a safety risk as improper camshaft timing can cause unexpected engine stalling while driving, resulting in sudden loss of powe…
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Vehicle has a recurring P0018 fault code (Crankshaft Position - Camshaft Position Correlation Bank 2 Sensor A). Dealer diagnosed loose cam pins on Bank 2 requiring major engine repair. This fault creates a safety risk as improper camshaft timing can cause unexpected engine stalling while driving, resulting in sudden loss of power, power steering, and brake assist. The manufacturer has denied warranty coverage despite the vehicle being within the 10-year/100,000-mile powertrain warranty. This appears to be a known widespread issue on the 3.3L V6 engine. Vehicle has 96,000 miles and is still within warranty coverage period.
NHTSA ODI #11741308
Official recalls
4Sep 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.
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.
Sep 21, 2017
Kia Motors America (Kia) is recalling certain 2017 Sorento vehicles equipped with 3.3L engines. The engine crankshaft may have been improperly heat treated and may fail.
Consequence & remedy
Consequence: If the crankshaft fails, the engine will stall, increasing the risk of a crash. A failed crankshaft also increases the risk of a fire.
Remedy: Kia will notify owners, and dealers will inspect the crankshaft, and, as necessary, replace the engine sub assembly, free of charge. The recall began November 6, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC153.
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.
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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