2020 Kia Sorento

My 2020 Kia Sorento stalled and shut off while driving and eventually stopped working completely, requiring it to be towed to a Kia dealership. The dealership first replaced the starter and then the high-pressure fuel pump, but the vehicle still would not operate. After further diagnosis, I was informed that the timing chain had failed/broken and the engine needed to be replaced, with a new engine quoted at approximately $12,000. I am concerned that this type of sudden engine failure and shutdown could create a serious safety hazard, especially if it occurs while driving in traffic or at highway speeds. I am requesting that NHTSA document and review this incident for similar failures involving 2020 Kia Sorento vehicles.

The vehicle suffered a sudden, severe engine malfunction/misfire while in operation, presenting a serious safety hazard on the road. Following the incident, the vehicle was taken to an authorized dealership service center (Repair Order #XXX), where technicians verbally confirmed that the engine requires a complete replacement due to internal mechanical failure. The catastrophic mechanical failure of the engine directly caused consequential damage to the emissions system, entirely clogging the catalytic converter with unburned fuel/debris. Despite the clear link to the known, systemic defects inherent to the Theta II engine line—which is subject to active federal consent orders, safety recalls, and lifetime warranty extensions—both the dealership and Kia Corporate are refusing to honor the 8-year/80,000-mile Federal Emissions Defect Warranty. The manufacturer is attempting to use the catastrophic failure of their own defective, recalled engine line to evade their legal environmental and safety warranty obligations, leaving the consumer stranded without alternative transportation. This represents a systemic effort by the manufacturer to deflect liability for documented powertrain safety failures onto individual consumers. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

2020 Kia Sorento consuming 1.5 or more quarts of oil every 1,000 miles. Completing oil consumption testing with Kia dealer, which requires I take the car back to the dealer every 1k miles, times, so they can verify the oil levels. Last check, when issue was discovered, vehicle was down to only 1qt of oil after driving only 2k miles from previous oil change. Note: the lambda engine was initially included in the latest Kia class action settlement but was dismissed per the plaintiff’s attorney in that case. However there are numerous reports from a large number of 2020 Kia Sorento owners now with the same issue and running into complete roadblocks in terms of recourse as for most the issue does not begin until they exceed the powertrain warranty. Especially if they’re secondary owners and not the original owner.

I own a 2020 Kia Sorento. There is currently a class action lawsuit settlement ongoing. I have been informed that my 2020 Kia Sorento is not eligible while the settlement clearly states the 2020 Kia Sorento is included as part of the settlement. My Kia’s engine did not fail until after the settlement was finalized because I don’t drive a lot anymore and my mileage was just over a 100,000 miles when it started showing problems. It seems to be a new timeline for new claims and I’m still not allowed to file a claim for the same reason. I bought my car new in 2020. If you need additional information, please advise.

Office of Defects Investigation National Highway Traffic Safety Administration (NHTSA) 1200 New Jersey Avenue SE Washington, DC 20590 Subject: Safety Complaint – Premature Engine Failure Risk Due to Excessive Oil Consumption and Confirmed Cylinder Scoring – 2020 Kia Sorento Dear Sir or Madam, I am submitting a formal safety complaint regarding a 2020 Kia Sorento that is experiencing severe and abnormal engine oil consumption along with confirmed cylinder wall scoring. These conditions indicate progressive internal engine damage and present a significant risk of premature engine failure. The vehicle has been regularly maintained in accordance with manufacturer service recommendations. Despite proper maintenance, the engine began consuming excessive amounts of oil between normal service intervals. During inspection by the servicing dealership, visible cylinder wall scoring was identified within the engine. Cylinder scoring is a clear indication of internal engine wear and deterioration and can lead to rapid progression toward engine failure. Despite the confirmed presence of internal engine damage, the manufacturer has refused to authorize an engine replacement under the extended warranty program unless the engine experiences complete mechanical failure. The dealership has indicated that the vehicle must continue to be operated and monitored until catastrophic breakdown occurs before replacement will be approved. Requiring the continued operation of a vehicle with confirmed cylinder wall damage and abnormal oil consumption raises serious safety concerns. Progressive internal engine damage can lead to sudden engine seizure, stalling, or loss of power while driving, which creates a potential hazard for the driver, passengers, and surrounding traffic. Given the confirmed cylinder scoring and ongoing excessive oil consumption, I respectfully request that the National Highway Traffic Safety Administration investigate.