NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
693 reportsClear category filterMileage unknown · Jun 9, 2022
EngineFire
My 2016 KIA SORRENTO caught fire. I was driving off of the highway, with no issues, when i heard a tapping noise. I stopped at the light, turned right, and as I started turning it suddenly sputtered and stopped. I tried to accelerate to get the car out of the lane of traffic, when smoke started coming out from under the hood. …
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My 2016 KIA SORRENTO caught fire. I was driving off of the highway, with no issues, when i heard a tapping noise. I stopped at the light, turned right, and as I started turning it suddenly sputtered and stopped. I tried to accelerate to get the car out of the lane of traffic, when smoke started coming out from under the hood. People next to me started yelling that my car was on fire and that I should get out. At this point I got out of the car, and within minutes the entire undercarriage and front part of car was engulfed in flames. The fire dept put the fire out, and the fire marshal and my insurance is investigating.
NHTSA ODI #11468493
Mileage unknown · Jun 6, 2022
Engine
The one cylinder went before 100,000 miles…..wasn’t too much longer till the next cylinder went and she was done….going through putting a quart of oil in it every single day for over 6 months……JUNK
NHTSA ODI #11467732
Mileage unknown · Jun 6, 2022
Engine
Vehicle cranked but didn't start after sitting for a few hours. Vehicle was towed to kia dealership. Dealer advised piston ring failed and engine lost compression. New engine was needed but was not covered by dealership nor the lifetime engine warranty. The repair cost almost 6000 dollars.
NHTSA ODI #11467721
Mileage unknown · Jun 3, 2022
Engine
I was driving entering a highway accelerating and my car just died; the engine and oil light came on and there was no power. There were NO warning lights or indication that there was any problem. I managed to get over and off the busy highway by coasting and was in fear for my safety. Took the car to Kia dealership and was told…
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I was driving entering a highway accelerating and my car just died; the engine and oil light came on and there was no power. There were NO warning lights or indication that there was any problem. I managed to get over and off the busy highway by coasting and was in fear for my safety. Took the car to Kia dealership and was told after waiting for two weeks for the required diagnostic service. They told me there was internal engine damage due to a bearing failure. This is not covered by warranty unless I had the software upgrade that was available since 4/18. I never received that notification; I have received several other notifications, but not the one about the software upgrade. Now they state it's outside the warranty with zero coverage.
NHTSA ODI #11467295
Mileage unknown · Jun 2, 2022
Engine
After only six months, my 2016 Kia Sorento suddenly lost power while I was driving on the freeway, after my trusted, local mechanic ran a diagnostic, he told me that my car was done for but Kia would stand behind their product, they have a 100,000 mile or ten year warranty for their vehicles. It was a frightening and frustrating…
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After only six months, my 2016 Kia Sorento suddenly lost power while I was driving on the freeway, after my trusted, local mechanic ran a diagnostic, he told me that my car was done for but Kia would stand behind their product, they have a 100,000 mile or ten year warranty for their vehicles. It was a frightening and frustrating experience but at least I was comforted when he told me Kia would take care of it. Kia is not honorable, they are not standing behind their products. Two days ago, I was told that Kia is denying my claim. How disappointing. I will pursue this matter to the end. Kia knows that their engines are prone to catastrophic failures. I was told by a Kia employee that I didn't maintain my vehicle adequately, I have records to the contrary. This is wrong.
NHTSA ODI #11467185
135,000 miles · Jun 1, 2022
Engine
The contact owns a 2016 Kia Sorento. The contact stated while driving 55 MPH, the vehicle lost motive power and stalled. There was no warning light illuminated. The contact pulled over to the side of the roadway and noticed that several unknown warning lights were illuminated. The contact was unable to restart the vehicle. The v…
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The contact owns a 2016 Kia Sorento. The contact stated while driving 55 MPH, the vehicle lost motive power and stalled. There was no warning light illuminated. The contact pulled over to the side of the roadway and noticed that several unknown warning lights were illuminated. The contact was unable to restart the vehicle. The vehicle was towed to an independent mechanic and then towed to an authorized dealer. The vehicle was not repaired. The manufacturer was informed of the failure. The approximate failure mileage was 135,000.
NHTSA ODI #11466956
Mileage unknown · May 27, 2022
Engine
A month after an oil change, I learned that the engine was extremely low on oil. I had to put 4 quarts in it. Check engine light barely came on. I’m at 79,000 miles and next oil change should be at 82,000 miles
NHTSA ODI #11466452
Mileage unknown · May 22, 2022
Engine
My car started making a knocking and squeaking sound and was shaking really hard and the check engine light started flashing and it just shut off and when I cranked it back up if wouldn’t stay cranked
NHTSA ODI #11465648
Mileage unknown · May 20, 2022
Engine
This car repeatedly has had issues with using oil on a weekly basis and many times it has stalled in heavy traffic, one of which almost caused a collision. I have taken this in for numerous repairs. My most recent incident I was informed by my garage that my engine was now junk.
NHTSA ODI #11465400
Mileage unknown · May 15, 2022
Engine
Driving 60mph, car seemed to be stalling under acceleration. Car was making a knocking sound from the engine. I was in a construction zone, with no shoulder/no pulloff. I managed to crawl to the end of construction and pull off to the side. How I didn't die that day only God knows...Was traveling to see my mom Mother's Day weeke…
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Driving 60mph, car seemed to be stalling under acceleration. Car was making a knocking sound from the engine. I was in a construction zone, with no shoulder/no pulloff. I managed to crawl to the end of construction and pull off to the side. How I didn't die that day only God knows...Was traveling to see my mom Mother's Day weekend, had my 170lb Great Dane and 60 lb Labradoodle with me. No tow company could help with transporting my dogs; only the car and me. I ended up stranded waiting for a ride for hours. Car was towed to dealer; dealer confirms the engine and all components were a total loss (Theta II engine, 2.4 liter, GDI). Repair estimate at $8,360.00!!! That is more than half of what the car is worth!! Multiple attempts to have KIA acknowledge the problem, only to be told by them that it's my fault I didn't have the recall repairs made in 2018. That's funny (in an awful way), because I never received ANYTHING about a recall. EVER. Had oil change the week prior; oil lamp never came on, I was just going by the Valvoline sticker as to time to change. They told me it was bone-dry, not a drop of oil. I wish someone could help me. This will ruin me financially.
NHTSA ODI #11464718
Official recalls
8Sep 19, 2022
Kia America, Inc. (Kia) is recalling certain 2016-2022 Sorento, 2021-2022 Sorento Hybrid (HEV), 2022-2023 Sorento Plug-In Hybrid (PHEV), and 2017-2022 Sportage vehicles equipped with a tow hitch harness installed as original equipment, or purchased as an accessory through a Kia dealership. Debris and moisture accumulation on the tow hitch harness module printed circuit board (PCB) may cause an electrical short, which can result in a fire.
Consequence & remedy
Consequence: A fire while parked or driving can increase the risk of injury.
Remedy: Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will inspect the vehicle, and, as necessary, replace the fuse and/or tow hitch harness module, free of charge. Owner notification letters were mailed August 11, 2023. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC249.
Aug 10, 2022
Kia America, Inc. (Kia) is recalling certain 2016 Sedona and Sorento vehicles. The vehicles may have been manufactured with faulty automatic transmission shift lever assembly components, preventing the shift lever from locking, which can allow the vehicle to rollaway.
Consequence & remedy
Consequence: A vehicle rollaway increases the risk of a crash and injury.
Remedy: Dealers will inspect and replace the automatic transmission shift lever assembly components, as necessary, free of charge. Owner notification letters were mailed October 7, 2022. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC246.
Dec 19, 2018
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence & remedy
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Additional source detail variants (2)
Engine
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.
Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.
Nov 30, 2016
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence & remedy
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Additional source detail variants (2)
Trailer Hitches
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Electrical System
Kia Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result in the trailer brake lights being constantly illuminated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, " Lamps, Reflective Devices, and Associated Equipment."
Consequence: If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Oct 24, 2016
Kia Motors America (Kia) is recalling certain model year 2016 Kia Sorento vehicles manufactured March 3, 2016 to March 21, 2016. The driver's seatback frame may have been produced with inadequate weld joints and, as a result, the seatback may not function as designed in the event of a rear-end collision.
Consequence & remedy
Consequence: In the event of a crash, the driver seatback frame could break and fail to restrain a seat occupant, increasing the risk of injury.
Remedy: Kia will notify owners, and dealers will inspect the welds and replace the driver seatback frame, as necessary, free of charge. The recall began on December 9, 2016. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC140.
Jun 29, 2016
Kia Motors America (Kia) is recalling certain model year 2016 Sorento vehicles. A component of the rear suspension may not be properly welded.
Consequence & remedy
Consequence: The improper weld may break, affecting the rear suspension alignment, thereby increasing the risk of a crash.
Remedy: Kia will notify owners, and dealers will inspect the welds at the rear suspension cross-member, replacing the rear cross-member assembly, as necessary, free of charge. The recall began July 27, 2016. Owners may contact Kia Customer Service Department at 1-800-333-4542. Kia's number for this recall is SC137.
Jul 14, 2015
Kia Motors America (Kia) is recalling certain model year 2016 Kia Sorento vehicles manufactured October 23, 2014, to December 10, 2014. The affected vehicles have a front passenger seat belt whose buckle latch assembly may prevent the front passenger from fastening the seat belt.
Consequence & remedy
Consequence: If the front passenger seat belt cannot be latched, an occupant sitting in the front passenger seat has an increased risk of injury in the event of a crash.
Remedy: Kia will notify owners, and dealers will replace the front passenger seat belt buckle cover, free of charge. The recall began on August 18, 2015. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC123.
Feb 13, 2015
Kia Motors America (Kia) is recalling certain model year 2016 Sorento vehicles manufactured October 27, 2014, to January 29, 2015. Due to an improperly soldered component in the accelerator pedal assembly, the driver may not be able to accelerate the vehicle.
Consequence & remedy
Consequence: If the vehicle is unable to be accelerated, there is an increased risk of a crash.
Remedy: Kia will notify owners, and dealers will replace the accelerator assembly, free of charge. The recall began on February 19, 2015. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC115.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3PE23019 · Loss Of Motive Power
Opened Nov 13, 2023 · Closed Jul 23, 2024
Status: closed (inferred from source dates) · Engine; Engine And Engine Cooling:engine:oil/lubrication:seals/gaskets
On November 13, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-019) to investigate allegations of loss of motive power relating to head gasket and/or head bolt failure in Model Year (MY) 2016-2017 Kia Sorento vehicles equipped with the 3.3 L Lambda II engine. When the investigation was opened, ODI had received 13 Vehicle Owner Questionnaires (VOQs) related to reports of loss of motive power. In an information request letter dated November 30, 2023, ODI requested technical information and failure data relating to the alleged defect in the subject MY 2016-2017 Kia Sorento as well as several peer vehicle populations which share the 3.3 L engine. In its February 26, 2024, response to ODI’s information request, Kia provided 2022 customer complaints (including techline and field reports) and 1738 warranty claims representing 2411 unique vehicles within the subject vehicle population. Of the customer complaints provided by Kia, they identified only 53 unique allegations of a loss of motive power resulting from the alleged defect. Kia determined that the remaining reports were minor vehicle drivability or engine performance issues. ODI reviewed the information provided by Kia, along with additional VOQs submitted to NHTSA following the opening of the investigation. When eliminating duplicative reports across the data sources, the total number of allegations of loss of motive power relating to the alleged defect in the subject vehicles is 77, representing an incident report rate of 59 per 100,000 vehicles. The MY 2016 Kia Sorento exhibited both the highest overall complaint rate and loss of motive power report rate across all subject and peer vehicle populations, representing an incident report rate of 102 per 100,000 vehicles. Across all data sources, there are no allegations of crashes or fires relating to the alleged defect. The one injury incident reflected in the failure summary table above is related to a consumer who was reportedly burned (minor burn requiring medical attention) while attempting to remove the coolant reservoir cap following a loss of motive power event. In their response to ODI, Kia described that if the threads of a head bolt hole in the subject engine becomes damaged, the clamping force between the cylinder head and engine block can decrease in the area of the affected head bolt. Kia’s assessment of the alleged defect is that when the failure occurs, drivers are provided with numerous warning signs prior to a potential loss of motive power event. According to Kia, potential warning signs associated with this failure include coolant leak/consumption or noticeable coolant odor, engine oil leak/consumption, engine temperature gauge rising to “H” (hot), check engine light illuminating, engine cooling fan remaining on following the engine being shut off, HVAC system not functioning properly, unusual engine noise, difficulty starting the vehicle, and smoke/condensation emitting from the engine compartment or exhaust. Through both its review of the information provided by Kia and outreach to consumers, ODI confirmed that there is reasonable detectability present in the vast majority of occurrences of the alleged defect. To mitigate the alleged defect, Kia increased the engagement depth of the head bolt threads for all subject engines, beginning in May 2017. ODI’s analysis of the failure data demonstrates that this corrective action correlates with a much lower incident report rate for engines produced following the change (8 per 100,000 vehicles for the MY 2018-2020 Kia Sorento). In December 2023, Kia launched extended warranty campaign WTY035 covering failures associated with the alleged defect in the subject vehicle population through 15 years or 180,000 miles, whichever comes first. Through its investigation, ODI identified the following peer vehicle populations, which were produced prior to the corrective action and exhibit failure rates comparable to the subject vehicles: MY 2014-2015 Kia Sorento, MY 2015-2016 Kia Sedona, and MY 2014-2017 Kia Cadenza equipped with the 3.3 L engine. Through discussions with ODI during the investigation, Kia decided to launch extended warranty campaign WTY039 in May 2024, which covers these peer vehicle populations through 15 years or 180,000 miles, whichever comes first. Based on analysis of the failure data indicating a low incident report rate of loss of motive power for the alleged defect, and in consideration of the warning signs which frequently occur from head gasket and/or head bolt failure in the subject engines, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Additional source detail variants (2)
Engine And Engine Cooling:engine:oil/lubrication:seals/gaskets
On November 13, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-019) to investigate allegations of loss of motive power relating to head gasket and/or head bolt failure in Model Year (MY) 2016-2017 Kia Sorento vehicles equipped with the 3.3 L Lambda II engine. When the investigation was opened, ODI had received 13 Vehicle Owner Questionnaires (VOQs) related to reports of loss of motive power. In an information request letter dated November 30, 2023, ODI requested technical information and failure data relating to the alleged defect in the subject MY 2016-2017 Kia Sorento as well as several peer vehicle populations which share the 3.3 L engine. In its February 26, 2024, response to ODI’s information request, Kia provided 2022 customer complaints (including techline and field reports) and 1738 warranty claims representing 2411 unique vehicles within the subject vehicle population. Of the customer complaints provided by Kia, they identified only 53 unique allegations of a loss of motive power resulting from the alleged defect. Kia determined that the remaining reports were minor vehicle drivability or engine performance issues. ODI reviewed the information provided by Kia, along with additional VOQs submitted to NHTSA following the opening of the investigation. When eliminating duplicative reports across the data sources, the total number of allegations of loss of motive power relating to the alleged defect in the subject vehicles is 77, representing an incident report rate of 59 per 100,000 vehicles. The MY 2016 Kia Sorento exhibited both the highest overall complaint rate and loss of motive power report rate across all subject and peer vehicle populations, representing an incident report rate of 102 per 100,000 vehicles. Across all data sources, there are no allegations of crashes or fires relating to the alleged defect. The one injury incident reflected in the failure summary table above is related to a consumer who was reportedly burned (minor burn requiring medical attention) while attempting to remove the coolant reservoir cap following a loss of motive power event. In their response to ODI, Kia described that if the threads of a head bolt hole in the subject engine becomes damaged, the clamping force between the cylinder head and engine block can decrease in the area of the affected head bolt. Kia’s assessment of the alleged defect is that when the failure occurs, drivers are provided with numerous warning signs prior to a potential loss of motive power event. According to Kia, potential warning signs associated with this failure include coolant leak/consumption or noticeable coolant odor, engine oil leak/consumption, engine temperature gauge rising to “H” (hot), check engine light illuminating, engine cooling fan remaining on following the engine being shut off, HVAC system not functioning properly, unusual engine noise, difficulty starting the vehicle, and smoke/condensation emitting from the engine compartment or exhaust. Through both its review of the information provided by Kia and outreach to consumers, ODI confirmed that there is reasonable detectability present in the vast majority of occurrences of the alleged defect. To mitigate the alleged defect, Kia increased the engagement depth of the head bolt threads for all subject engines, beginning in May 2017. ODI’s analysis of the failure data demonstrates that this corrective action correlates with a much lower incident report rate for engines produced following the change (8 per 100,000 vehicles for the MY 2018-2020 Kia Sorento). In December 2023, Kia launched extended warranty campaign WTY035 covering failures associated with the alleged defect in the subject vehicle population through 15 years or 180,000 miles, whichever comes first. Through its investigation, ODI identified the following peer vehicle populations, which were produced prior to the corrective action and exhibit failure rates comparable to the subject vehicles: MY 2014-2015 Kia Sorento, MY 2015-2016 Kia Sedona, and MY 2014-2017 Kia Cadenza equipped with the 3.3 L engine. Through discussions with ODI during the investigation, Kia decided to launch extended warranty campaign WTY039 in May 2024, which covers these peer vehicle populations through 15 years or 180,000 miles, whichever comes first. Based on analysis of the failure data indicating a low incident report rate of loss of motive power for the alleged defect, and in consideration of the warning signs which frequently occur from head gasket and/or head bolt failure in the subject engines, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Engine
On November 13, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-019) to investigate allegations of loss of motive power relating to head gasket and/or head bolt failure in Model Year (MY) 2016-2017 Kia Sorento vehicles equipped with the 3.3 L Lambda II engine. When the investigation was opened, ODI had received 13 Vehicle Owner Questionnaires (VOQs) related to reports of loss of motive power. In an information request letter dated November 30, 2023, ODI requested technical information and failure data relating to the alleged defect in the subject MY 2016-2017 Kia Sorento as well as several peer vehicle populations which share the 3.3 L engine. In its February 26, 2024, response to ODI’s information request, Kia provided 2022 customer complaints (including techline and field reports) and 1738 warranty claims representing 2411 unique vehicles within the subject vehicle population. Of the customer complaints provided by Kia, they identified only 53 unique allegations of a loss of motive power resulting from the alleged defect. Kia determined that the remaining reports were minor vehicle drivability or engine performance issues. ODI reviewed the information provided by Kia, along with additional VOQs submitted to NHTSA following the opening of the investigation. When eliminating duplicative reports across the data sources, the total number of allegations of loss of motive power relating to the alleged defect in the subject vehicles is 77, representing an incident report rate of 59 per 100,000 vehicles. The MY 2016 Kia Sorento exhibited both the highest overall complaint rate and loss of motive power report rate across all subject and peer vehicle populations, representing an incident report rate of 102 per 100,000 vehicles. Across all data sources, there are no allegations of crashes or fires relating to the alleged defect. The one injury incident reflected in the failure summary table above is related to a consumer who was reportedly burned (minor burn requiring medical attention) while attempting to remove the coolant reservoir cap following a loss of motive power event. In their response to ODI, Kia described that if the threads of a head bolt hole in the subject engine becomes damaged, the clamping force between the cylinder head and engine block can decrease in the area of the affected head bolt. Kia’s assessment of the alleged defect is that when the failure occurs, drivers are provided with numerous warning signs prior to a potential loss of motive power event. According to Kia, potential warning signs associated with this failure include coolant leak/consumption or noticeable coolant odor, engine oil leak/consumption, engine temperature gauge rising to “H” (hot), check engine light illuminating, engine cooling fan remaining on following the engine being shut off, HVAC system not functioning properly, unusual engine noise, difficulty starting the vehicle, and smoke/condensation emitting from the engine compartment or exhaust. Through both its review of the information provided by Kia and outreach to consumers, ODI confirmed that there is reasonable detectability present in the vast majority of occurrences of the alleged defect. To mitigate the alleged defect, Kia increased the engagement depth of the head bolt threads for all subject engines, beginning in May 2017. ODI’s analysis of the failure data demonstrates that this corrective action correlates with a much lower incident report rate for engines produced following the change (8 per 100,000 vehicles for the MY 2018-2020 Kia Sorento). In December 2023, Kia launched extended warranty campaign WTY035 covering failures associated with the alleged defect in the subject vehicle population through 15 years or 180,000 miles, whichever comes first. Through its investigation, ODI identified the following peer vehicle populations, which were produced prior to the corrective action and exhibit failure rates comparable to the subject vehicles: MY 2014-2015 Kia Sorento, MY 2015-2016 Kia Sedona, and MY 2014-2017 Kia Cadenza equipped with the 3.3 L engine. Through discussions with ODI during the investigation, Kia decided to launch extended warranty campaign WTY039 in May 2024, which covers these peer vehicle populations through 15 years or 180,000 miles, whichever comes first. Based on analysis of the failure data indicating a low incident report rate of loss of motive power for the alleged defect, and in consideration of the warning signs which frequently occur from head gasket and/or head bolt failure in the subject engines, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
DP22003 · Loss Of Motive Power
Opened Sep 12, 2022 · Closed Dec 12, 2023
Status: closed (inferred from source dates) · Engine
The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing. There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
DP21002 · Engine Oil Pressure Switch Leak
Opened Nov 12, 2021 · Closed Jun 26, 2023
Status: closed (inferred from source dates) · Engine; Engine And Engine Cooling:engine:oil/lubrication:pressure/temperature Sensor
In a letter dated September 30, 2021, Mr. Gerald James (the petitioner) requested that NHTSA conduct an investigation of the Model Year (MY) 2015-2017 Kia Sorento equipped with 3.3L V6 ?Lambda? engines for ?severe oil leaks? from the oil pressure switch (OPS) that could ?lead to engine failure? with little warning to the driver. Mr. James based this request on his own experience and data found in NHTSA?s Vehicle Owner Questionnaire (VOQ) database. NHTSA reviewed the material cited by the petitioner, information submitted by Kia, NHTSA?s testing, and other pertinent information in NHTSA databases.On November 12, 2021, ODI opened Defect Petition DP21-002 to evaluate the petitioner?s request. ODI performed an analysis that included evaluation of the petitioner?s vehicle, searches of ODI complaints from vehicle owners, non-dealer field reports, manufacturers? supplemental information relating to design of the component, and component testing performed by ODI.On December 16, 2021, ODI and Kia North America performed a joint inspection on the petitioner?s vehicle. ODI and Kia agreed the OPS was leaking oil and observed oil in the crevices atop the engine block. The vehicle received a new replacement OPS and was delivered back to the petitioner. The original part that was removed from the subject vehicle was retained by ODI for further analysis.As of December 30, 2022, for the MY 2015-2017 Kia Sorento population of 161,519 vehicles with 3.3L engine, NHTSA reviewed internal data and has identified no consumer complaints or field reports in its database, with unique Vehicle Identification Numbers (VIN), citing engine failure or stalling related to the petition?s allegation of defective OPS. When combined with the supplemental warranty and technical analysis from the manufacturer, field report and customer complaint data in response to the Information Request letter sent, NHTSA identified no unique VINs alleging engine failure or stalls caused by OPS leaking on the subject vehicles named in the petition.On April 4, 2022, the Vehicle Research and Test Center (VRTC) performed testing of the petitioner?s component (OPS) based on testing protocol consistent with Kia?s specifications for the subject vehicle. The testing involved the petitioner?s original OPS in a controlled system to replicate the subject vehicle?s oil pressure, flow, and temperature. VRTC determined that a vehicle would have to miss more than a dozen oil change intervals to reach low engine oil capacity. Testing also revealed the OPS would operate, as manufacturer intended, illuminating the vehicle?s MIL to alert the driver of lower oil pressure.In April of 2022, Kia North America issued a warranty extension that extended the coverage of the Oil Pressure Switch from 5 years/60,000 miles to 15 years/150,000 miles on MY 2014-2018 Sorento, MY 2014-2016 Cadenza, and MY 2015-2018 Sedona vehicles, all equipped with the 3.3L Lambda engine. The extended warranty coverage includes diagnosis, repair, and applies to customers experiencing engine oil leaking from the engine or if the engine oil pressure warning light stays illuminated after the engine is turned on.After a thorough review of the material submitted by the petitioner, information already in NHTSA's possession, testing performed by VRTC, technical information provided by Kia, the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that an engine failure due to the alleged defect is likely and does not warrant a formal investigation. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be publi
Additional source detail variants (2)
Engine And Engine Cooling:engine:oil/lubrication:pressure/temperature Sensor
In a letter dated September 30, 2021, Mr. Gerald James (the petitioner) requested that NHTSA conduct an investigation of the Model Year (MY) 2015-2017 Kia Sorento equipped with 3.3L V6 ?Lambda? engines for ?severe oil leaks? from the oil pressure switch (OPS) that could ?lead to engine failure? with little warning to the driver. Mr. James based this request on his own experience and data found in NHTSA?s Vehicle Owner Questionnaire (VOQ) database. NHTSA reviewed the material cited by the petitioner, information submitted by Kia, NHTSA?s testing, and other pertinent information in NHTSA databases.On November 12, 2021, ODI opened Defect Petition DP21-002 to evaluate the petitioner?s request. ODI performed an analysis that included evaluation of the petitioner?s vehicle, searches of ODI complaints from vehicle owners, non-dealer field reports, manufacturers? supplemental information relating to design of the component, and component testing performed by ODI.On December 16, 2021, ODI and Kia North America performed a joint inspection on the petitioner?s vehicle. ODI and Kia agreed the OPS was leaking oil and observed oil in the crevices atop the engine block. The vehicle received a new replacement OPS and was delivered back to the petitioner. The original part that was removed from the subject vehicle was retained by ODI for further analysis.As of December 30, 2022, for the MY 2015-2017 Kia Sorento population of 161,519 vehicles with 3.3L engine, NHTSA reviewed internal data and has identified no consumer complaints or field reports in its database, with unique Vehicle Identification Numbers (VIN), citing engine failure or stalling related to the petition?s allegation of defective OPS. When combined with the supplemental warranty and technical analysis from the manufacturer, field report and customer complaint data in response to the Information Request letter sent, NHTSA identified no unique VINs alleging engine failure or stalls caused by OPS leaking on the subject vehicles named in the petition.On April 4, 2022, the Vehicle Research and Test Center (VRTC) performed testing of the petitioner?s component (OPS) based on testing protocol consistent with Kia?s specifications for the subject vehicle. The testing involved the petitioner?s original OPS in a controlled system to replicate the subject vehicle?s oil pressure, flow, and temperature. VRTC determined that a vehicle would have to miss more than a dozen oil change intervals to reach low engine oil capacity. Testing also revealed the OPS would operate, as manufacturer intended, illuminating the vehicle?s MIL to alert the driver of lower oil pressure.In April of 2022, Kia North America issued a warranty extension that extended the coverage of the Oil Pressure Switch from 5 years/60,000 miles to 15 years/150,000 miles on MY 2014-2018 Sorento, MY 2014-2016 Cadenza, and MY 2015-2018 Sedona vehicles, all equipped with the 3.3L Lambda engine. The extended warranty coverage includes diagnosis, repair, and applies to customers experiencing engine oil leaking from the engine or if the engine oil pressure warning light stays illuminated after the engine is turned on.After a thorough review of the material submitted by the petitioner, information already in NHTSA's possession, testing performed by VRTC, technical information provided by Kia, the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that an engine failure due to the alleged defect is likely and does not warrant a formal investigation. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be publi
Engine
In a letter dated September 30, 2021, Mr. Gerald James (the petitioner) requested that NHTSA conduct an investigation of the Model Year (MY) 2015-2017 Kia Sorento equipped with 3.3L V6 ?Lambda? engines for ?severe oil leaks? from the oil pressure switch (OPS) that could ?lead to engine failure? with little warning to the driver. Mr. James based this request on his own experience and data found in NHTSA?s Vehicle Owner Questionnaire (VOQ) database. NHTSA reviewed the material cited by the petitioner, information submitted by Kia, NHTSA?s testing, and other pertinent information in NHTSA databases.On November 12, 2021, ODI opened Defect Petition DP21-002 to evaluate the petitioner?s request. ODI performed an analysis that included evaluation of the petitioner?s vehicle, searches of ODI complaints from vehicle owners, non-dealer field reports, manufacturers? supplemental information relating to design of the component, and component testing performed by ODI.On December 16, 2021, ODI and Kia North America performed a joint inspection on the petitioner?s vehicle. ODI and Kia agreed the OPS was leaking oil and observed oil in the crevices atop the engine block. The vehicle received a new replacement OPS and was delivered back to the petitioner. The original part that was removed from the subject vehicle was retained by ODI for further analysis.As of December 30, 2022, for the MY 2015-2017 Kia Sorento population of 161,519 vehicles with 3.3L engine, NHTSA reviewed internal data and has identified no consumer complaints or field reports in its database, with unique Vehicle Identification Numbers (VIN), citing engine failure or stalling related to the petition?s allegation of defective OPS. When combined with the supplemental warranty and technical analysis from the manufacturer, field report and customer complaint data in response to the Information Request letter sent, NHTSA identified no unique VINs alleging engine failure or stalls caused by OPS leaking on the subject vehicles named in the petition.On April 4, 2022, the Vehicle Research and Test Center (VRTC) performed testing of the petitioner?s component (OPS) based on testing protocol consistent with Kia?s specifications for the subject vehicle. The testing involved the petitioner?s original OPS in a controlled system to replicate the subject vehicle?s oil pressure, flow, and temperature. VRTC determined that a vehicle would have to miss more than a dozen oil change intervals to reach low engine oil capacity. Testing also revealed the OPS would operate, as manufacturer intended, illuminating the vehicle?s MIL to alert the driver of lower oil pressure.In April of 2022, Kia North America issued a warranty extension that extended the coverage of the Oil Pressure Switch from 5 years/60,000 miles to 15 years/150,000 miles on MY 2014-2018 Sorento, MY 2014-2016 Cadenza, and MY 2015-2018 Sedona vehicles, all equipped with the 3.3L Lambda engine. The extended warranty coverage includes diagnosis, repair, and applies to customers experiencing engine oil leaking from the engine or if the engine oil pressure warning light stays illuminated after the engine is turned on.After a thorough review of the material submitted by the petitioner, information already in NHTSA's possession, testing performed by VRTC, technical information provided by Kia, the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that an engine failure due to the alleged defect is likely and does not warrant a formal investigation. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be publi
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