NHTSA owner reports · September 18, 2026 snapshot.
Unknown Or Other complaints
103 reportsClear category filterMileage unknown · May 24, 2021
EngineFuel/propulsion SystemUnknown Or OtherFireInjury
On May 18,2021 my Kia Sorento SXL AWD V6 caught on fire for unknown reason. I was driving with windows open sunroof open and cruise set. Not a single warning light or any weird sounds at all. A car pulled up yelling at me that my car was on fire to pull over off the interstate. I saw nor smelled any smoke anywhere but then I saw…
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On May 18,2021 my Kia Sorento SXL AWD V6 caught on fire for unknown reason. I was driving with windows open sunroof open and cruise set. Not a single warning light or any weird sounds at all. A car pulled up yelling at me that my car was on fire to pull over off the interstate. I saw nor smelled any smoke anywhere but then I saw a cop had someone pulled over so I figured it would be safe since I was an alone female and it was car of males yelling at me to pull over. As soon as I got out and walked to the front of the car there was still no smoke but flames and what I assumed was plastic dripping from the entire underneath. At this time flames shot out from all around the hood and up the windshield as it instantly shattered. As I ran for my life as stuff kept exploding the state trooper had already called for help so fire department arrived in less then 3 min but my car was gone in less than 45 seconds after I stepped out. I am mentally and physically hurt but luckily only a burn the size of a quarter on my wrist but due to shock while watching my car burn and explode my legs gave out and I sat down hard so 5 days after the fire my legs have recovered from running up an incline for my life but my back pain has only increased. But insurance only covers injuries from the car so running from exploding cars and getting injured is not their problem. Just like Kia allowing all of us Sorento owners to drive our family and loved ones around on a bomb waiting to blow at any moment isn’t their problem either. I have now seen at least 8 2017 Sorento sxl unexplained fire complaints all ending in total loss while only looking on this site and one other site. I have pictures and videos of the fire and how close I was to being in the car as u can see my hoodie laying in front of the car on fire too. Fire started on passenger side of motor just like the defect they supposedly fixed in 2014. If anyone else especially the grandchildren that can’t get themselves out of would have died
NHTSA ODI #11418407
48,100 miles · Mar 22, 2021
Unknown Or Other
DRIVING AT ABOUT 75 MILES PER HOUR AND SUDDENLY THE HOOD POP OPEN FORTUNATELY I WAS ABLE TO STOP ON TIME AND PREVENT SOMETHING MAJOR HAVE TO NOTE THAT THERE WAS NO TOO MUCH TRAFFIC.
NHTSA ODI #11404342
40,000 miles · Feb 25, 2021
EngineStructureUnknown Or Other
WHITE SMOKE IN EXHAUST AND LOUD GRIND WHEN COLD START. PAINT IS PEELING IN THE BACK
NHTSA ODI #11397934
43,843 miles · Dec 31, 2020
Unknown Or Other
VEHICLE WAS STATIONARY PARKED IN DRIVEWAY. REAR LIFT GATE WAS ACTIVATED BY OWNER WITH KEY FOB. GRANDCHILD RAN UNDER THE LIFT GATE. OWNER PULLED CHILD FROM REAR LIFT. GATE BRUSHED CHILD'S BACK AND CONTINUED TO CLOSE . OWNER THEN PLACED SEVERAL INAMINATE OBJECTS UNDER REAR OF CAR PROTRUDING FROM CARGO HOLD AND ENGAGED THE LIFT …
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VEHICLE WAS STATIONARY PARKED IN DRIVEWAY. REAR LIFT GATE WAS ACTIVATED BY OWNER WITH KEY FOB. GRANDCHILD RAN UNDER THE LIFT GATE. OWNER PULLED CHILD FROM REAR LIFT. GATE BRUSHED CHILD'S BACK AND CONTINUED TO CLOSE . OWNER THEN PLACED SEVERAL INAMINATE OBJECTS UNDER REAR OF CAR PROTRUDING FROM CARGO HOLD AND ENGAGED THE LIFT GATE. GATE CLOSED EACH TIME UNRESTRICTED TRAPPING THE OBJECT. CALLED KIA REPORTED PROBLEM.
NHTSA ODI #11385764
50,000 miles · Aug 27, 2020
Unknown Or OtherFire
I WAS DRIVING TO MY HOUSE FROM MY CABIN AFTER TWO HOURS OF DRIVING I WAS AT A STOPLIGHT AND THE OIL LIGHT CAME ON SO I DECIDED TO KEEP GOING AND TAKE THE NEXT EXIT TO SEE IF I NEEDED OIL..BUT I NEVER MADE IT. MY SON THANKFULLY ROLLED HIS WINDOW AND WAS LIKE MOM THE CAR IS ON FIRE, I THEN TRIED TO PUT THE BREAKS ON BUT THEY DIDN'…
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I WAS DRIVING TO MY HOUSE FROM MY CABIN AFTER TWO HOURS OF DRIVING I WAS AT A STOPLIGHT AND THE OIL LIGHT CAME ON SO I DECIDED TO KEEP GOING AND TAKE THE NEXT EXIT TO SEE IF I NEEDED OIL..BUT I NEVER MADE IT. MY SON THANKFULLY ROLLED HIS WINDOW AND WAS LIKE MOM THE CAR IS ON FIRE, I THEN TRIED TO PUT THE BREAKS ON BUT THEY DIDN'T WORK SO WE SLOWLY COASTED DOWN TO ABOUT 10-20 AND I WAS LIKE GET OUT. SO HE JUMPED OUT THE MOVING,ON FIRE CAR. HE SUFFERED FROM ROAD RASH. LONG STORY SHORT BY THE FLAMES WERE SO BIG ON THE DRIVES SIDE THAT MY SENSES FINALLY CAME TOGETHER AND SLAMMED THE CAR IN PARK TO STOP IT AND I CRAWLED OUT THE PASSENGER SIDE DOOR. BY THE TIME THE FIREMEN CAME TO PUT OUT THE FIRE THE CAR WAS BASICALLY TO THE FRAME.
NHTSA ODI #11351492
44,100 miles · Aug 24, 2020
Unknown Or Other
I WAS DRIVING DOWN THE FREEWAY, WHICH WAS WELL PAVED, NO CONSTRUCTION IN THE AREA AND NO SEMI-TRUCKS NEARBY. I WAS IN THE MIDDLE LANE TRAVELING AT 70 MPH, WHEN I HEARD A LOUD EXPLOSION WHICH SOUNDED LIKE A GUN SHOT. THE SOUND WAS SO LOUD, I THOUGHT I WAS REAR ENDED BY ANOTHER VEHICLE TRAVELING AT A HIGH SPEED. FRIGHTENED, I GLAN…
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I WAS DRIVING DOWN THE FREEWAY, WHICH WAS WELL PAVED, NO CONSTRUCTION IN THE AREA AND NO SEMI-TRUCKS NEARBY. I WAS IN THE MIDDLE LANE TRAVELING AT 70 MPH, WHEN I HEARD A LOUD EXPLOSION WHICH SOUNDED LIKE A GUN SHOT. THE SOUND WAS SO LOUD, I THOUGHT I WAS REAR ENDED BY ANOTHER VEHICLE TRAVELING AT A HIGH SPEED. FRIGHTENED, I GLANCED AT MY REARVIEW MIRROR AND SEEN MY REAR WINDOW WAS INTACT. THIS IS WHEN I SEEN PIECES OF GLASS FLYING BACK TOWARDS THE CAR BEHIND ME. I FINALLY REALIZED THAT IT WAS MY SUNROOF THAT HAD EXPLODED. I SLOWED DOWN AND MOVED OVER TO THE SLOW LANE. THE DRIVER THAT WAS BEHIND ME, PULLED ALONGSIDE ME IN DISBELIEF AS TO WHAT HAD JUST OCCURRED. AFTER REALIZING I WAS OK, HE CONTINUED ON HIS WAY. I PULLED OFF AN EXIT AND PARKED ON A STREET AND PHOTOGRAPHED THE SHATTERED SUNROOF. IT WAS IN THAT MOMENT I WAS THANKFUL MY WIFE AND KIDS WERE NOT IN THE CAR WITH ME OR THAT I WAS UTILIZING THE SUNROOF. IF THIS WAS THE CASE, THE GLASS COULD HAVE CAUSED SEVERAL INJURIES OR LED TO A MULTIPLE VEHICLE CRASH ON THE FREEWAY DUE TO THE GLASS FALLING DOWN ON TOP OF ME. AFTER TAKING SEVERAL PHOTOGRAPHS, I CALLED MY INSURANCE COMPANY WHO STATED I COULD FILE A CLAIM OR SEE IF THE DEALERSHIP WOULD TAKE CARE OF THE ISSUE. I DROVE TO THE DEALERSHIP I PURCHASED THE VEHICLE AT, AND EXPLAINED THE TRAUMATIC EVENT THAT HAD JUST OCCURRED. THE KIA DEALERSHIP JUST INFORMED ME THERE WAS NOTHING THEY COULD DO AND COMPARED IT TO ME DRIVING OFF THE LOT AND RUNNING OVER A NAIL WITH MY TIRE. THIS RESPONSE WAS VERY FRUSTRATING AND I EXPLAINED TO THEM THIS WAS AN ISSUE THAT IS COMMONLY REPORTED ONLINE. AGAIN, I WAS TOLD THERE WAS NOTHING THEY COULD DO AND FOR ME TO FILE A CLAIM WITH MY INSURANCE. THIS WAS A SCARY SITUATION TO EXPERIENCE AND I WOULD LIKE TO SEE A RECALL OF THIS VEHICLE TO FIX THE ISSUE OR INFORM CONSUMERS BEFORE IT HAPPENS SO IT DOES NOT CAUSE ANY FUTURE INJURIES OR DEATHS.
NHTSA ODI #11351002
12,000 miles · Feb 24, 2020
Unknown Or Other
WE WERE DRIVING ON THE HIGHWAY FROM NC TO VA AND THE SUNROOF EXPLODED. WE PULLED OVER BECAUSE WE WERE UNSURE WHAT CAUSE SUCH A LOUD NOISE ONLY TO SEE THE SUNROOF SHATTERED. IT WAS CLEAR NOTHING HAD CAUSED IT AND IT JUST EXPLODED ON ITS OWN. WE IMMEDIATELY TOOK PICTURES, CONTACTED KIA AND FILED OUR CLAIM WITH THEM. THEY'VE FINALL…
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WE WERE DRIVING ON THE HIGHWAY FROM NC TO VA AND THE SUNROOF EXPLODED. WE PULLED OVER BECAUSE WE WERE UNSURE WHAT CAUSE SUCH A LOUD NOISE ONLY TO SEE THE SUNROOF SHATTERED. IT WAS CLEAR NOTHING HAD CAUSED IT AND IT JUST EXPLODED ON ITS OWN. WE IMMEDIATELY TOOK PICTURES, CONTACTED KIA AND FILED OUR CLAIM WITH THEM. THEY'VE FINALLY COME BACK SAYING THAT SINCE THEY CAN'T ASCERTAIN THE CAUSE OF THE DAMAGE TO THE SUNROOF THEY'RE CAN'T TAKE RESPONSIBILITY.
NHTSA ODI #11311225
Mileage unknown · Jan 23, 2020
EngineUnknown Or Other
JANUARY 17, 2020, I AM STILL UNDER THE EXCESSIVE OIL CONSUMPTION TESTING. I WENT TO THE DEALERSHIP AS THEY TOLD ME TO ON DEC. 30 2019, I MET MY 1000 MILES, IT WAS DOWN 1 QT. OF OIL. THE DIPSTICK IS 'SEALED' TO THE ELECTRIC HARNESS, THEY CLAIM IT WILL NOT CATCH ON FIRE. HOPEFULLY IT WON'T. SO FAR WITH THE TESTING, THE OIL IS D…
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JANUARY 17, 2020, I AM STILL UNDER THE EXCESSIVE OIL CONSUMPTION TESTING. I WENT TO THE DEALERSHIP AS THEY TOLD ME TO ON DEC. 30 2019, I MET MY 1000 MILES, IT WAS DOWN 1 QT. OF OIL. THE DIPSTICK IS 'SEALED' TO THE ELECTRIC HARNESS, THEY CLAIM IT WILL NOT CATCH ON FIRE. HOPEFULLY IT WON'T. SO FAR WITH THE TESTING, THE OIL IS DOWN 1 QUART EVERY 1000 MILES, THE ENGINE ONLY HOLDS ABT. 5 1/4 QUARTS OF OIL. THE MANUFACTURER RECOMMENDS OIL CHANGE EVERY 7500 MILES. THE SERVICE TECH SAID THEY ARE HAVING EXCESSIVE OIL CONSUMPTION PROBLEMS WITH THE 2.0 AND 2.4 ENGINES, I HAVE A 2.4 ENGINE. THIS VEHICLE IS SCARY, I FEEL UNSAFE DRIVING IT, IT MAY CATCH ON FIRE. SERVICE TECH TOLD ME IT WILL TAKE A TOTAL OF 4 SEALED DIPSTICK TESTING, I HAVE TWO MORE TO GO.
NHTSA ODI #11301483
44,000 miles · Jan 21, 2020
StructureUnknown Or Other
MY PANORAMIC SUNROOF EXPLODED WHILE I WAS DRIVING ON THE INTERSTATE FOR NO APPARENT REASON. NO IMPACT; I SAW NOTHING, WITNESSES BEHIND ME SAY NOTHING HIT ME, I WASN'T UNDER AN OVERPASS, I WASN'T FOLLOWING ANYONE CLOSELY. DRIVING STRAIGHT AT ABOUT 75MPH.
NHTSA ODI #11300709
Mileage unknown · Dec 30, 2019
EngineUnknown Or Other
I BROUGHT MY VEHICLE TO THE DEALERSHIP DEC 09 2019 (MILEAGE 56176) AS INSTRUCTED BY SERVICE TECH IN ORDER FOR THEM TO CHECK REASON THIS VEHICLE IS USING A LOT OF OIL IN BETWEEN OIL CHANGES. SERVICE TECH CHECKED OIL AND FOUND OIL WAS DOWN 1.25 QTS. SERVICE TECH OPENED TECH LINE CASE AND SENT PICTURES TO KIA. I WAS INSTRUCTED T…
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I BROUGHT MY VEHICLE TO THE DEALERSHIP DEC 09 2019 (MILEAGE 56176) AS INSTRUCTED BY SERVICE TECH IN ORDER FOR THEM TO CHECK REASON THIS VEHICLE IS USING A LOT OF OIL IN BETWEEN OIL CHANGES. SERVICE TECH CHECKED OIL AND FOUND OIL WAS DOWN 1.25 QTS. SERVICE TECH OPENED TECH LINE CASE AND SENT PICTURES TO KIA. I WAS INSTRUCTED TO RETURN TO DEALERSHIP TO RECHECK OIL LEVEL IN 1000 MILES. TODAY, DEC. 30 2019, (MILEAGE 57231) I RETURNED TO DEALERSHIP. OIL WAS DOWN 1 QT. AFTER 1055 MILES. IF YOU DO THE MATH, ENGINE ONLY HOLDS 5.5 QUARTS OF OIL, IF I GO THE ENTIRE 7500 MILES IN BETWEEN OIL CHANGE(AS PER OWNER MANUAL) I WOULD BE OUT OF OIL.SERVICE TECH ADDED 1 QT. OIL AND PUT IN A SEALED DIPSTICK SO I CANNOT CHECK OIL LEVEL. HOW AM I TO KNOW OIL LEVEL? I PARK VEHICLE IN MY GARAGE. WHEN I QUESTIONED TECH ABOUT THIS HE SAID IT WAS ON KIA'S LIABILITY IF SOMETHING WERE TO HAPPEN. I WOULD KNOW WHEN THE ENGINE IS OUT OF OIL, THE ENGINE WILL START KNOCKING, AND HE MADE THE KNOCKING SOUND ON THE COUNTER. THAT IS REALLY HELPING MY HUSBAND AND I COMFORT LEVEL, IF SOMEONE GETS HURT OR KILLED, WHAT DOES IT MATTER? THERE ARE OTHER PEOPLE ON THE ROADS THAT COULD BE INJURED OR KILLED IF SOMETHING HAPPENS TO MY VEHICLE. MY VEHICLE COULD CATCH ON FIRE, CAUSE INJURIES OR DEATH TO US AND / OR OTHERS. SERVICE TECH WOULD NOT SAY WHAT KIA IS DOING ABOUT THIS MATTER WHEN I ASKED HIM. HE JUST SAID KIA IS LOOKING INTO IT. HE GAVE MY HUSBAND AND I THE IMPRESSION HE KNOWS WHAT IS GOING ON, HE SAID HE WAS NOT AT LIBERTY TO DISCUSS ANY FURTHER. THE SERVICE TECH ALSO STATED THAT IT IS UP TO THE OWNERS TO CHECK THEIR OWN OIL LEVELS. NOW I CANNOT CHECK THE OIL LEVEL, IT HAS A SEALED DIPSTICK. HE IS CONTRADICTING HIMSELF, MAKE NO SENSE.
NHTSA ODI #11292186
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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