2016 Kia Soul

I am reporting a safety concern related to NHTSA Recall 19V120 involving my Kia Soul. The recall identifies a defect related to catalytic converter overheating, which can lead to engine damage, stalling, and increased risk of fire. My vehicle is currently experiencing an illuminated check engine light and unsafe driving conditions. During service evaluation at Kia of Columbus, I was informed that my vehicle has a catalytic converter blockage contributing to these issues. However, I was also told that my vehicle does not qualify for recall repair because no engine code was detected during diagnostics. This is concerning, as the vehicle is actively exhibiting symptoms consistent with the recall condition, including a confirmed catalytic converter issue and an illuminated malfunction indicator lamp. Despite this, I was denied full recall coverage and instead offered a goodwill repair requiring me to pay 50% of the cost. I believe this situation represents a failure to properly apply recall criteria and raises concerns regarding customer safety, as the vehicle may be at risk for engine failure or fire. I am requesting further review of this matter and investigation into the handling of this recall by the servicing dealership.

The contact owns a 2016 Kia Soul. The contact stated that while driving at 55 MPH, the check engine warning light illuminated, and the vehicle stalled. Upon further research, the contact associated the failure with NHTSA Campaign Number: 19V120000 (Engine, Engine and Engine Cooling). The vehicle was taken to an independent mechanic who determined that the catalytic converter needed to be replaced. The mechanic informed the contact that the inside of the catalytic converter had melted, but there was no fire. The vehicle was repaired, but the failure reoccurred. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 105,000.

I had the oil changed on my car at a local tire and lube shop. Two weeks later I drove to Vegas (7 hrs one way). While in Vegas I started to hear a super faint clicking noise coming from under my hood, but no lights came on inside, so I assumed maybe it was nothing serious and would have it checked when I returned home 3 days later. On the way home (2 hrs from home) the clicking got louder. I attempted to pass some cars and, as I accelerated, the clicking got much louder and then I heard a loud clank and the car shuttered. I proceeded to pull over and got out of the car and saw small flames and smoke coming from under my car. A couple had pulled over with me and had a fire extinguisher which they used to put the fire out. Upon towing the car home I found a piece of metal hanging from a melted piece of plastic. I inspected it and discovered that it was a piece of a piston from my engine. There was also a puddle of oil and a streak of gasoline on the trailer that had come from my car. I experienced catastrophic engine failure. When the engine broke it punched a hole in my oil pan which caused a fire and burned a hole in my fuel line. I am unsure of what caused the engine to fail, but in seeing the recalls for the exact same thing happening to previously recalled Kia Souls I figured i'd check it out to see if I may be included in that. No lights came on alerting me to any problems. There were no signs of leaking oil. Just clicking that got louder and then a loud noise and shudder and fire.

I just bought the car one month ago, and While driving my 2016 Kia Soul on a high-speed highway at approximately 98,000 miles, the vehicle suddenly lost power without warning. The engine stopped responding and the car could not accelerate. This created a very dangerous situation because traffic was moving at high speed and I was at risk of being hit from behind. I was driving with my son, who has a disability, and I was taking him to his therapy appointment. The sudden loss of power made the situation even more stressful and unsafe because I was responsible for his safety while the vehicle was failing in traffic. Fortunately, I was able to carefully move out of the main highway and exit the road to avoid a crash. I managed to reach a nearby auto mechanic shop, where the vehicle had to remain because the engine had failed and the car could no longer be driven safely. This incident represents a serious safety concern because the vehicle lost power suddenly while driving on a fast highway, which could easily have resulted in a serious accident.

Complaint Summary: Post recall catalytic converter failure on 2016 Kia Soul with 1.6L GDI engine (SC176 recall previously performed). Complaint Details: I own a 2016 Kia Soul equipped with the 1.6 liter Gamma GDI engine (engine code G4FD, emissions family GKMXV01.6DBE). This engine is part of Kia’s SC176 recall for catalytic converter overheating and thermal damage. My dealer performed the SC176 ECU software update in May 2019, but did not replace the catalytic converter at that time because the P0420 code had not yet appeared. In early 2026, my catalytic converter failed with a P0420 “Catalyst Efficiency Below Threshold” code. My mechanic confirmed the converter was internally damaged. This failure is consistent with the known SC176 defect, where converters can be partially damaged before the ECU update and fail later. Kia and the dealer refused to replace the converter under the recall, stating that because the P0420 code did not appear in 2019, the converter is no longer covered. I was forced to pay $2,781.91 out of pocket for a new catalytic converter, exhaust manifold, and oxygen sensors. The diagnostic test was another $120 plus tax. This appears to be a case where the converter was already compromised by the SC176 defect prior to the software update, but the failure occurred later. I am requesting that NHTSA document this issue, as it suggests the recall remedy may not fully address pre existing catalyst damage and may leave owners with significant repair costs. VIN: [XXX] Mileage at failure: ~90,000 miles Engine: 1.6L Gamma GDI (G4FD) Recall: SC176 (ECU update performed, converter not replaced) INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I kept all of the maintenance records for the oil changes. The engine blew a piston and I will need a new engine. Driving down the road, it just lost power and died. Local mechanic looked at it and said I needed a new engine. When I began looking for a new engine, the cost would have been $3500.00 plus labor. When looking for a used engine, the salvage person said there was a recall on the engines. I took it to the local dealer, said I was over the mileage. and would probably cost the dealer $9000.00. The car is almost 10 years old. It was a good car. It was a standard, which should mad it last longer.

March 22, 2026: driving through town when the engine started making an odd high pitched sound then lost all acceleration and had to get it towed back to my house. No indicator lights on the dashboard came on. March 26, 2026: my mechanic diagnosed it as a catalytic converter clog. 2019: vehicle was serviced at a Kia dealer for SC176 recall relating to catalytic converter failure. December 2022: Kia replaced the engine due to failure from metal shavings from the tie rod getting into the oil. In 2024 kia reimbursed me for the cost of this replacement due to a class action lawsuit for this issue. March 30, 2026: both Kia dealership and Kia phone line advised that my vehicle no longer qualifies for catalytic converter replacement since the recall service was completed in 2019.

The contact owned a 2016 Kia Soul. The contact received notification of NHTSA Campaign Number: 19V120000 (Engine, Engine and Engine Cooling). The contact stated that while driving at an undisclosed speed, the vehicle lost motive power and the engine made an abnormal sound. The contact turned off the vehicle to let it cool down. The vehicle was restarted and taken to an independent mechanic, who determined that the catalytic converter and exhaust pipe had caught fire and melted. The mechanic performed an oil change and drilled a hole in the catalytic converter, and advised the contact to take the vehicle to the dealer for the recall repair. The vehicle was taken to the dealer, who determined that the spark plugs were saturated in engine oil. The dealer flushed the radiator and performed a second oil change; however, the dealer refused to perform the recall repair. The vehicle was taken back to the independent mechanic, who replaced the spark plugs but refused to repair the engine until the recall was repaired. The contact stated that later while coasting downhill in neutral (N) after adding a quart of engine oil due to no oil in the engine, he heard an implosion coming from behind the driver's side front seat. No warning light was illuminated. The contact unbuckled his seat belt and jumped out of the vehicle, fracturing his ribs. The contact suffered burns to his right hand, legs, left side of face, nose, and eyebrows. The contact stated that the vehicle rolled downhill, and there were flames underneath the vehicle on the passenger's side. The contact ran after the vehicle. The vehicle drove into the bushes and came to a stop. Two bystanders alerted the contact that there were flames inside the vehicle. The police were called and arrived, attempting to extinguish the fire with an extinguisher until it was empty, and the fire had restarted. The firefighters arrived and extinguished the fire. A police report was filed and included with the fire department. The contact was transported to the hospital via ambulance an

Safety defect P1326 code is a known indicator of rod bearing wear. When it triggered, the vehicle immediately went into Limp Mode, creating a significant safety hazard. The behavior aligns with the documented defect affecting NU GDI Engines and is not consistent with normal Engine wear. I have confirmed the KSDS software update was performed. I have taken the vehicle to Clay Cooley Kia of Plano and my service advisor has confirmed that the engine is defected per the NU GDI Engine Settlement and related federal safety actions.