2012 KIA Sorento
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › KIA › Sorento › 2012
These records cover every 2012 KIA Sorento. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
5 recalls name the 2012 KIA Sorento. Newest first.
Kia America, Inc. (Kia) is recalling certain 2010-2019 Borrego, 2014-2016 Cadenza, 2010-2013 Forte, Forte Koup, Sportage, 2015-2018 K900, 2011-2015 Optima, 2011-2013 Optima Hybrid, Soul, 2012-2017 Rio, 2011-2014 Sorento, and 2010-2011 Rondo vehicles. The Hydraulic Electronic Control Unit (HECU) may experience an electrical short, which can result in an…
Risk and remedy
Risk
An engine compartment 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 replace the HECU fuse, free of charge. Interim notification letters, notifying owners of the safety risk, were mailed November 14, 2023. Owner notification letters were mailed March 29, 2024 through June 18, 2024. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC284.
Kia Motors America (Kia) is recalling certain 2012-2013 Sorento, 2012-2015 Forte and Forte Koup, 2011-2013 Optima Hybrid, 2014-2015 Soul, and 2012 Sportage vehicles. An engine compartment fire can occur while driving.
Risk and remedy
Risk
An engine compartment fire increases the risk of injury.
Remedy
Kia will notify owners, and dealers will inspect the engine compartment for fuel and/or engine oil leaks, perform an engine test and make any repairs, including engine replacement, as necessary, free of charge. In addition, Kia dealers will update the Knock Sensor Detection System (KSDS) software, free of charge. The recall began January 27, 2021. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC200.
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…
Risk and remedy
Risk
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.
Kia Motor Company (Kia) is recalling certain 2011-2014 Optima, 2012-2014 Sorento and 2011-2013 Sportage vehicles. Machining errors during the engine manufacturing process may cause premature bearing wear within the engine.
Risk and remedy
Risk
Bearing wear may result in the engine seizing, increasing the risk of a crash.
Remedy
Kia will notify owners, and dealers will inspect the engine assembly, and replace the engine if necessary, free of charge. The recall began June 20, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC147.
Kia Motors America (Kia) is recalling certain model year 2011-2013 Kia Sorento vehicles manufactured October 19, 2009, to January 31, 2013. In the affected vehicles, if excessive force is applied to the gear shift lever, the brake-shift interlock mechanism may chip or crack allowing the transmission being able to be shifted out of "Park" without the brakes…
Risk and remedy
Risk
Without requiring the brake to be pressed, the vehicle may be unintentionally shifted out of Park, allowing it to roll, which may result in a crash.
Remedy
Kia will notify owners, and dealers will replace the brake-shift interlock mechanism, free of charge. The recall began on November 9, 2015. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC124.
Owner complaints
880 complaints21 involved a crash77 involved a fire36 injuries
What owners report most
Latest complaints
- Steering · Suspension
Unknown
- Air bags
The contact owns a 2012 Kia Sorento. The contact stated that while the vehicle was parked, the air bag warning light was illuminated. The vehicle was taken to a service center, where it was diagnosed and DTC: V1481 was retrieved. The vehicle was then taken to the dealer. The failure mileage was approximately 156,000.
- Fuel/propulsion system
While driving I smelled gas, a few minutes later I saw smoke coming from the hood of the car. I stopped, turned the car off, got my dog, exited the car, which then exploded into flames. I saw that I was not safe the minute I saw the smoke. I was unsure that the gas smell was coming from my car…
While driving I smelled gas, a few minutes later I saw smoke coming from the hood of the car. I stopped, turned the car off, got my dog, exited the car, which then exploded into flames. I saw that I was not safe the minute I saw the smoke. I was unsure that the gas smell was coming from my car until I saw that my gas needle was on E when I had filled up 3 hours prior. The police and the fire department was on scene. No warnings came up on the dash board other than the gas light.
- Air bags · Service brakes, hydraulic
The contact owns a 2012 Kia Sorento. The contact stated that while driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that the vehicle failed to exceed 20 MPH. There were several unknown warning lights…
The contact owns a 2012 Kia Sorento. The contact stated that while driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that the vehicle failed to exceed 20 MPH. There were several unknown warning lights illuminated, and the air bag warning light was also illuminated. The contact received notification of NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic). The vehicle was taken to the dealer, and the recall repair was performed. The failure reoccurred six months later. The vehicle was towed to the dealer. The contact was informed that the failure was caused by wiring issues with the front passenger's seat. The vehicle was not yet repaired. The vehicle was towed to an alternate dealer. The vehicle had not been diagnosed. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 227,079.
- Engine
I am filing this complaint regarding a sudden and unexpected engine failure in my 2012 Kia Sorento LX equipped with the 2.4L Theta II engine. Vehicle Information: Year: 2012 Make/Model: Kia Sorento LX Engine: 2.4L Theta II VIN: [XXX] While driving, my vehicle experienced a sudden engine failure…
I am filing this complaint regarding a sudden and unexpected engine failure in my 2012 Kia Sorento LX equipped with the 2.4L Theta II engine. Vehicle Information: Year: 2012 Make/Model: Kia Sorento LX Engine: 2.4L Theta II VIN: [XXX] While driving, my vehicle experienced a sudden engine failure and lost power, leaving the vehicle inoperable. This occurred without warning. The vehicle received routine maintenance, including regular oil changes, and the failure was not due to intentional neglect or misuse. I am concerned because this vehicle is equipped with the Kia Theta II 2.4L engine family, which has been associated with previous recalls, investigations, settlements, and numerous consumer complaints involving engine seizure, premature failure, stalling, and safety concerns. I understand my specific VIN may not currently fall within an active recall; however, my vehicle has experienced the same type of catastrophic engine failure reported by other Kia owners with similar engines. I am concerned that vehicles outside current recall VIN ranges may still be experiencing the same defect. An unexpected engine failure while driving creates a serious safety concern due to the potential for sudden loss of power and increased risk to occupants. I am requesting that NHTSA review whether additional 2012 Kia Sorento vehicles equipped with the 2.4L Theta II engine may be affected and whether Kia's current recall population adequately addresses the known engine failure concerns. I have also contacted Kia requesting that they review my vehicle, authorize a no-cost diagnostic evaluation, and determine whether the engine failure is related to known Theta II engine defects. [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
- Service brakes · Suspension
I had taken the Kia Sorrento to a local shop to get an oil change, and Mavis tire had discovered that the rear suspension and rear subframe were severely corroded with rust and I was told that the car is unsafe to drive. I had noticed as well that my brakes would not normally stop when I go to…
I had taken the Kia Sorrento to a local shop to get an oil change, and Mavis tire had discovered that the rear suspension and rear subframe were severely corroded with rust and I was told that the car is unsafe to drive. I had noticed as well that my brakes would not normally stop when I go to press them as a bit of a kickback and the traction sensors and ABS sensors and emergency brake sensors would go off and on for no reason.
- Fuel/propulsion system
On June 6, 2026, while driving home, the vehicle suddenly began smelling strongly of gasoline and burnt rubber. Within seconds, thick black smoke became visible in the side mirrors, followed immediately by white smoke pouring from the front hood and into the passenger cabin through the air vents.…
On June 6, 2026, while driving home, the vehicle suddenly began smelling strongly of gasoline and burnt rubber. Within seconds, thick black smoke became visible in the side mirrors, followed immediately by white smoke pouring from the front hood and into the passenger cabin through the air vents. As I attempted to pull over to safety, the vehicle completely stopped responding. The brakes failed to operate, the engine stalled, and the steering wheel locked completely. We were barely able to bring the vehicle to a stop. Immediately upon exiting, visible flames erupted from underneath the driver's side of the vehicle and out of the front hood. The engine compartment and motor burnt completely.The safety of the driver and front passenger was put at extreme risk of death or severe injury. Because the brakes and steering locked up simultaneously while the cabin filled with smoke, we almost lost the ability to safely exit a moving vehicle that was actively catching fire. Furthermore, at no moment prior to or during the failure did any warning lamps, check engine lights, or diagnostic messages illuminate on the dashboard. There was absolutely zero advance warning from the vehicle's safety systems.The fire originated from a catastrophic fuel system failure, specifically matching the known issues of the high-pressure fuel pump leak.The vehicle is a total loss and is currently located at a tow yard. It is fully available for inspection upon request.Local police responded to the scene and generated an incident log number. A corporate claim has been opened directly with KIA but as of today, no inspector from the manufacturer or insurance has been sent out.
- Engine
The contact owned a 2012 Kia Sorento. The contact’s spouse stated that while driving at an undisclosed speed, the vehicle suddenly lost motive power with no warning lights illuminated. The contact's spouse noticed smoke coming from the front of the vehicle, prompting the contact’s spouse to pull…
The contact owned a 2012 Kia Sorento. The contact’s spouse stated that while driving at an undisclosed speed, the vehicle suddenly lost motive power with no warning lights illuminated. The contact's spouse noticed smoke coming from the front of the vehicle, prompting the contact’s spouse to pull over to the side of the roadway. Moments later, the front of the vehicle caught fire. The local fire department responded to the scene and extinguished the fire; however, the cause of the fire had not yet been determined. The vehicle was completely consumed by the fire and deemed destroyed. No police report was filed, The manufacturer was not notified of the failure. The contact’s spouse stated that the incident was extremely traumatic and believed the vehicle posed a serious safety hazard. The failure mileage was not available.
- Air bags · Engine · Steering
The clock spring needs fixed no features including the horn is working in my airbag light is staying on. Also I now have a loud knock in my motor I understand this should fall under the extended 15 yr 150k warranty; 2012 Kia vehicles (specifically the Sorento) with V6 engines are covered under…
The clock spring needs fixed no features including the horn is working in my airbag light is staying on. Also I now have a loud knock in my motor I understand this should fall under the extended 15 yr 150k warranty; 2012 Kia vehicles (specifically the Sorento) with V6 engines are covered under major safety recalls for engine failure and fire risks. The primary issue involves metal debris from manufacturing that can cause premature engine bearing wear, stalling, and fire. You should check your VIN on the NHTSA site or Kia's recall page to confirm, as these recalls are still active.
- Unknown or other
In September 2025, an authorized Kia dealership performed recall SC284XM (HECU electrical short fire risk) on this 2012 Kia Sorento. During the repair, the dealership disconnected the battery, resetting the PCM/ECU and clearing all OBD-II readiness monitors including the oxygen sensor monitor.…
In September 2025, an authorized Kia dealership performed recall SC284XM (HECU electrical short fire risk) on this 2012 Kia Sorento. During the repair, the dealership disconnected the battery, resetting the PCM/ECU and clearing all OBD-II readiness monitors including the oxygen sensor monitor. Despite driving hundreds of miles afterward, the O2 sensor monitor has not reached a Ready state. A malfunctioning or unmonitored oxygen sensor creates a direct safety risk — the PCM cannot properly regulate the fuel-air mixture, increasing the risk of catalytic converter overheating, engine damage, and potential fire. The vehicle cannot pass California's mandatory smog inspection and the registration has lapsed, forcing the owner to operate an unregistered vehicle or go without transportation entirely. The dealership has verbally confirmed this is a known model-year defect — the root cause is a software condition requiring a PCM reflash, not achievable through normal drive cycles. This is the second occurrence; the identical failure happened in 2022 after a prior battery disconnect on this vehicle. The vehicle is now held at the dealership 11+ days with no update, no loaner, and an ~$460 estimate for repairs caused entirely by Kia's own recall service. A vehicle actively subject to a fire-risk recall (SC284) was returned to an owner in a condition where the engine management system cannot be properly monitored — compounding the original safety risk rather than resolving it. All this an yet a no no-cost remedy has been issued. This vehicle has been subject to five NHTSA recalls: SC200 (engine fire), SC147 (engine bearing), SC284 (HECU fire), SC172 (fuel pipe fire), and brake-shift interlock defect. Simultaneous complaints filed with Kia Consumer Affairs and CA Bureau of Automotive Repair (Ref: XXX). INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
- Engine
Engine warning lamp illuminated as the engine lost some power. Code was diagnosed as the knock sensor issue. Unit taken to mechanic to evaluate and diagnose. Repair shop notified us that based on the sensor, the engine could succumb to a failure at any time. Engine oil was flushed, cleaned, and…
Engine warning lamp illuminated as the engine lost some power. Code was diagnosed as the knock sensor issue. Unit taken to mechanic to evaluate and diagnose. Repair shop notified us that based on the sensor, the engine could succumb to a failure at any time. Engine oil was flushed, cleaned, and replaced. Code was addressed currently. This is similar to the failures observed by other engines in this class, however, it does not appear this engine is part of the lifetime warranty or recall.
- Engine
The contact owns a 2012 Kia Sorento. The contact stated that while driving 75 MPH, the check engine warning light was flashing on the instrument panel. There was a misfire coming from the engine. The contact stated that the vehicle was sputtering while depressing the accelerator pedal and…
The contact owns a 2012 Kia Sorento. The contact stated that while driving 75 MPH, the check engine warning light was flashing on the instrument panel. There was a misfire coming from the engine. The contact stated that the vehicle was sputtering while depressing the accelerator pedal and cautiously drove to the nearest independent mechanic. The mechanic used a code scanner and retrieved a fault code for an inoperable knock sensor and wiring harness. The vehicle was also taken to another independent mechanic who provided the same information. The dealer was notified of the failure, and the contact was informed that there were no recalls on the vehicle. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was unknown.
- Engine
Engine Knocking - Car enters limp mode and has a known recall. KSDS was updated in prior recall and engine has failed at 118k Miles. Car has been well maintained. Kia asks for maintenance records, records were provided and they will not take action. KIA avoided fixing the engine and just updated…
Engine Knocking - Car enters limp mode and has a known recall. KSDS was updated in prior recall and engine has failed at 118k Miles. Car has been well maintained. Kia asks for maintenance records, records were provided and they will not take action. KIA avoided fixing the engine and just updated software to tell you when this happens and now that the engine is failing will not honor their warranty or do work on the car despite sending maintenance records of over 10 years
- Electrical system · Suspension · Unknown or other
My kia Sorento shocks are really bad seems like it bounces Alot More than normal and heard a squeak coming from the shocks also hard to get the to turn when Im park and electric seems to glitch with bulbs going out faster and radio acting like it shorting out since the wiring was replaced it does this
- Engine
The contact owns a 2012 Kia Sorento. The contact stated that after parking and turning off the vehicle, she entered the post office; after 3 to 4 minutes, she was alerted by a consumer that the vehicle had caught fire. The contact noticed fire emerging from the undercarriage. The TPMS warning light…
The contact owns a 2012 Kia Sorento. The contact stated that after parking and turning off the vehicle, she entered the post office; after 3 to 4 minutes, she was alerted by a consumer that the vehicle had caught fire. The contact noticed fire emerging from the undercarriage. The TPMS warning light had been illuminated prior to the incident. Post office employees attempted to extinguish the fire. The fire department was called and successfully extinguished the fire. There were no reported injuries. Police were also present at the scene. The contact related the failure to NHTSA Campaign Number 23V-652000 (Service Brakes, Hydraulic). The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted; however, no assistance was provided. The failure mileage was approximately 200,000.
- Air bags
The contact owns a 2012 Kia Sorento. The contact stated that the air bag warning light illuminated. The vehicle was not taken to the dealer or an independent mechanic to be diagnosed or repaired. The contact stated that the air bag warning light was permanently illuminated. The manufacturer was notified of the failure. The failure mileage was approximately 97,000.
- Suspension
Rear subframe is completely rusted out on one side makes it completely undrivable especially with my young children.
- Engine · Service brakes, hydraulic
The contact owns a 2012 Kia Sorento. The contact received notifications of NHTSA Campaign Numbers: 20V750000 (Engine) and 23V652000 (Service Brakes, Hydraulic); however, the parts to do the recall repairs were unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of…
The contact owns a 2012 Kia Sorento. The contact received notifications of NHTSA Campaign Numbers: 20V750000 (Engine) and 23V652000 (Service Brakes, Hydraulic); however, the parts to do the recall repairs were unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The contact stated that while driving into a parking spot, the vehicle suddenly lost power and stalled. The contact later replaced the battery, but the vehicle failed to start. The vehicle was towed to a certified mechanic, who diagnosed the vehicle with engine failure. The vehicle was not repaired. The manufacturer was informed of the failure and informed the contact that, due to the vehicle not having the sensor changed before the failure, the engine could not be replaced. The dealer informed the contact tha,t due to the mileage, the vehicle would not be covered and would not qualify for the extended warranty coverage for the engine replacement. The failure mileage was approximately 250,000.
- Engine · Power train · Service brakes, hydraulic
The contact owns a 2012 Kia Sorento. The contact stated that the rod bearings were knocking, and the check engine warning light was illuminated. The contact received notification of NHTSA Campaign Numbers: 15V626000 (Power Train), 23V652000 (Service Brakes, Hydraulic), and 20V750000 (Engine). The…
The contact owns a 2012 Kia Sorento. The contact stated that the rod bearings were knocking, and the check engine warning light was illuminated. The contact received notification of NHTSA Campaign Numbers: 15V626000 (Power Train), 23V652000 (Service Brakes, Hydraulic), and 20V750000 (Engine). The local dealer was contacted, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The contact called the warranty company which declined the repairs. The failure mileage was approximately 106,000.
- Unknown or other
The check engine light came on 12/29 and was driven approximately 50 miles. On Jan 3, 2026 vehicle was driven app. 5 miles and left parked at a friends. There was a little smoke coming out from under the hood, but this is not unusual as car had small oil leak for at least 3 years that no one could…
The check engine light came on 12/29 and was driven approximately 50 miles. On Jan 3, 2026 vehicle was driven app. 5 miles and left parked at a friends. There was a little smoke coming out from under the hood, but this is not unusual as car had small oil leak for at least 3 years that no one could find to fix but burned off on engine and gave constant oily smell. Under 10 minutes later driver was notified that neighbors heard 3 explosions, car was on fire and fire department was coming. When driver went back to where vehicle was parked, fire was out and vehicle was almost totally destroyed. Vehicle was towed to a scrap yard.
- Engine
The contact owns a 2012 Kia Sorento. The contact stated that her son had reported that the vehicle was losing motive power and had failed to exceed 15 MPH while driving. The check engine warning illuminated. The contact advised the driver to pull over and to stop the vehicle. The vehicle was towed…
The contact owns a 2012 Kia Sorento. The contact stated that her son had reported that the vehicle was losing motive power and had failed to exceed 15 MPH while driving. The check engine warning illuminated. The contact advised the driver to pull over and to stop the vehicle. The vehicle was towed to a local dealer, who diagnosed the vehicle and advised that the engine had failed the engine bearing test and several other engine tests. The contact was advised that the vehicle could not be driven. The contact advised the dealer that in 2024, the same dealer had performed the recall of NHTSA Campaign Number: 20V750000(Engine) on the vehicle. The dealer informed the contact that the vehicle qualified for a manufacturer program for engine replacement. The manufacturer was informed of the failure and advised the contact that the dealer would be contacted, but no further action was taken. The failure mileage was approximately 160,000.
- Service brakes, hydraulic
The contact owns a 2012 Kia Sorento. The contact stated the vehicle was serviced at the local dealer for the NHTSA Campaign Number: 23V652000(SERVICE BRAKES, HYDRAULIC) regarding a safety fire hazard. Days later, while the vehicle was idling, smoke was suddenly present coming from under the hood.…
The contact owns a 2012 Kia Sorento. The contact stated the vehicle was serviced at the local dealer for the NHTSA Campaign Number: 23V652000(SERVICE BRAKES, HYDRAULIC) regarding a safety fire hazard. Days later, while the vehicle was idling, smoke was suddenly present coming from under the hood. The contact opened the hood of the vehicle and discovered flames and smoke coming from the fuse box located in the front of the engine bay. The contact, who was a local fire investigator, retrieved a fire extinguisher and extinguished the flames. The fire department was called to the scene, and a fire report was filed. The vehicle was later towed to the home, and the manufacturer and local dealer were notified of the incident. The manufacturer sent an investigator to the home to examine the vehicle. The investigator determined that the fire had originated at the front of the engine compartment, but did not determine the cause of the fire. No injuries were reported. The contact was concerned that the fire was related to the recall service previously performed. The failure mileage was 212,000.
- Engine
Engine Intake gasket oil leak.
- Engine
The contact owns a 2012 Kia Sorento. The contact stated that, while driving at 60 MPH, she observed smoke emanating from the engine compartment, prompting her to attempt to pull to the shoulder of the roadway. During the attempt, the contact stated that she then heard an abnormal pop, after which…
The contact owns a 2012 Kia Sorento. The contact stated that, while driving at 60 MPH, she observed smoke emanating from the engine compartment, prompting her to attempt to pull to the shoulder of the roadway. During the attempt, the contact stated that she then heard an abnormal pop, after which the vehicle lost motive power, and within a moment, the entire front end of the vehicle was engulfed in flames. Upon exiting the vehicle and being assisted by bystanders, the contact was informed that the bystanders had attempted to alert her on the road as they had observed flames emanating from underneath the vehicle. No warning lights were illuminated. The vehicle was towed to a storage facility but had yet to be deemed a total loss by the contact's insurance provider. A fire report was filed. A police report was not filed, and injuries were not reported. The manufacturer was not notified of the failure. The failure mileage was 106,334.
- Power train
The contact owns a 2012 Kia Sorento. While the contact's son was driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that the traction control and ABS warning lights were illuminated. In addition, the…
The contact owns a 2012 Kia Sorento. While the contact's son was driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that the traction control and ABS warning lights were illuminated. In addition, the contact stated that the vehicle stalled and went into LIMP Mode. The vehicle was driven to the residence. The contact used a portable diagnostic machine and retrieved DTC: C1613,C1205, C1206, C1207, C1208, C1210 and C1211. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The manufacturer was made aware of the failure. The failure mileage was approximately 204,000.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Hyundai and Kia ABS Module Fires
The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by…
The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.
- Loss of Motive Power
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…
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.
- Engine Fires
On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles. During the PE…
On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles. During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types. The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement. Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia. The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio. The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires. In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines. The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS. It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension. For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied. Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates. To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years. In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires. Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis. Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023). 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.
- Throttle control system vulnerabilities
The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003.…
The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.
- Headlight Failure
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) based on seventy-four Vehicle Owner Questionnaires (VOQs) reporting headlight failures on model year (MY) 2011-2013 KIA Sorento vehicles.In its response to ODI's June 25, 2020, information request letter (portions of which were submitted…
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) based on seventy-four Vehicle Owner Questionnaires (VOQs) reporting headlight failures on model year (MY) 2011-2013 KIA Sorento vehicles.In its response to ODI's June 25, 2020, information request letter (portions of which were submitted under request for confidentiality), Kia Motor America (Kia) provided design details of the headlight system showing that each headlight circuit is independently powered by the Smart Junction Box (SJB), a power control module. Kia claimed that the design minimizes the chance of both headlights failing simultaneously due to a headlight connector defect, a component located downstream of the SJB. Kia also advised that the SJB contains a safety feature designed to monitor power consumption for each headlight circuit; if excessive current is being demanded by either headlight the SJB will open the circuit (i.e., stop supplying current). Lastly Kia presented testing showing that the maximum headlight connector temperature achieved prior to the SJB opening the circuit was below the autoignition temperature of the plastic material the connector housing is made of, which Kia maintains eliminates the potential for a fire originating from an electrically overheated headlight connector. In its review of all available data, ODI determined that the majority of both VOQ and Kia customer complaints (1,339 reports in total) involved the loss or dimming of a single low beam headlight assembly caused primarily by a poor or overheated connector terminal located at the headlight. In some cases the failures were momentary in nature (i.e., flickering) with the headlights coming back on without driver intervention. A minority of VOQs and Kia complaints (the 196 Other reports) alleged simultaneous (and persistent) loss of both low beam headlights, and in most cases the driver was able to take an action (e.g., toggle the headlight switch, or use the ON rather than the AUTO setting on the headlight switch) to reinstate the low beam headlights. The high beam headlights were not seen to be affected and were available for drivers to use as alternate lighting.ODI did not identify any crashes or injuries, nor any fire incidents caused by a headlight related defect. While some VOQ and Kia reports alleged or indicated a fire occurrence, the incidents were found to involve melting or smells/odors due to thermal overheating of the plastic headlight connector housing, rather than an open flame fire.ODI notes that in April 2019, Kia initiated a 10 years/unlimited mileage warranty extension program to replace the headlight connector for MY 2011-2013 Sorento vehicles.Based on this analysis, a safety-related defect has not been identified at this time, and ODI is closing the investigation. This does not constitute a finding by the Agency that a safety-related defect is not present; the Agency will take further action if warranted by additional information received.The reference (ODI) numbers for the VOQs cited above are included in the downloadable version of this closing resume available at NHTSA.gov.
- Non-crash Vehicle Fires
During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Kia Optima, MY 2011-2014 Kia…
During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Kia Optima, MY 2011-2014 Kia Sorento and MY 2010-2015 Kia Soul vehicles equipped with Theta II, Gamma, Nu and Lambda II engines (approximately 1.7 million vehicles). ODI also reviewed field and other data on other Kia vehicles (approximately 3.6 million additional vehicles) equipped with the same engines used in the above-mentioned vehicles.As a result of this PE, Kia has issued NHTSA Recalls 20V-750 and 21V-844 to address potential engine failures and fires in certain Kia vehicles equipped with various engine types.Additional information on these and other related recall actions is available in the downloadable version of this resume available at NHTSA.gov.In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure-related recalls mentioned above and conducted previously.See the EA21-003 Opening Resume available at NHTSA.gov for more information.Also available in the downloadable version of this resume is a list of the reference numbers for the 444 ODI reports, or Vehicle Owner Questionnaires (VOQs), cited above which ODI received through mid-November 2021.Note that the Manufacturer reports cited above are customer complaints received through March 2019.
- Non-crash Vehicle Fires
In a letter dated June 11, 2018, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a safety defect investigation into non-collision related fires on model year (MY) 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles. In a letter…
In a letter dated June 11, 2018, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a safety defect investigation into non-collision related fires on model year (MY) 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles. In a letter dated July 24, 2018, CAS requested that MY 2010-2015 Kia Soul vehicles be added to the petition. CAS stated that there is a higher number of complaints to NHTSA regarding non-crash fires on these vehicles compared to other similar vehicles. The Office of Defects Investigation (ODI) had already opened Recall Queries (RQ17-003 and RQ17-004) on all Kia and Hyundai vehicles equipped with Theta II engines for engine failures that may cause stalling and fires.The queries cover most of the petition subject Optima, Sorento, Sonata, and Santa Fe vehicles but not any of the subject Soul vehicles.On August 21, 2018, ODI opened a Defect Petition (DP18-003) to evaluate whether to grant or deny the CAS petition. ODI sent Information Request letters to Kia and Hyundai (September and October 2018) requesting information on all engine and non-engine related fires in the petition vehicles.ODI performed extensive analysis on the information obtained from Kia and Hyundai. During the DP18-003 analysis, Kia and Hyundai each initiated three additional safety recalls related to engine compartment fires on certain petitioned and non-petitioned vehicles (nearly 740,000 total vehicles: Recalls 18V-907, 18V-934, 19V-101, 19V-063, 19V-120, and 19V-204). Based on ODI?s review of the applicable materials, including responses to Information Requests sent to multiple manufacturers, Vehicle Owner Questionnaires (VOQ), and Early Warning Data, NHTSA decided to grant the petition.The CAS petition was granted on March 29, 2019. Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) have been opened to assess the scope, frequency, and potential safety-related consequences of alleged defects relating to non-collision vehicle fires in the 2011-2014 Kia Optima and Sorento, 2011-2014 Hyundai Sonata and Santa Fe, and 2010-2015 Kia Soul.Attached is a list of the reference numbers for the 404 VOQs cited above.
- Scope and Timeliness
NHTSA opened Recall Query (RQ) 17-003 to investigate the timeliness and scope of Kia?s Theta II GDI engine recall (Recall No. 17V-224), and Kia?s compliance with reporting requirements. On November 23, 2020, the Agency entered into a Consent Order with Kia to administratively resolve NHTSA?s assertions of violations…
NHTSA opened Recall Query (RQ) 17-003 to investigate the timeliness and scope of Kia?s Theta II GDI engine recall (Recall No. 17V-224), and Kia?s compliance with reporting requirements. On November 23, 2020, the Agency entered into a Consent Order with Kia to administratively resolve NHTSA?s assertions of violations of law in connection with RQ17-003. NHTSA?s assertions included that Kia may be liable for civil penalties on multiple grounds, including that Recall No. 17V-224 was untimely and Kia?s recall report contained certain inaccuracies.Under the Consent Order, Kia agreed to a total civil penalty of $70,000,000. The total civil penalty included a payment of $27,000,000 as a Non-Deferred Amount.Kia also agreed to a sum of $27,000,000 as an Abeyance Amount to be deferred and held in abeyance pending its satisfactory completion, as reasonably determined by NHTSA, of the requirements of the Consent Order.Kia also agreed to a $16,000,000 Performance Obligation Amount to be expended by Kia to fulfill specified Safety Data Analytics Infrastructure obligations. The Consent Order also includes other terms designed to enhance Kia?s safety practices, and requires Kia to retain a Third-Party Auditor who directly reports to NHTSA.Other than RQ17-003, the Consent Order is not intended to affect any other current or future investigation of NHTSA which may involve vehicles equipped with Theta II GDI engines. In particular, Engineering Analysis (EA) 21-003 (which is upgraded from Preliminary Evaluation (PE) 19-004) continues NHTSA?s evaluation of certain performance and design issues relating to the Theta II and other engines.Nothing in the Consent Order discharges Kia from any obligation to comply with the Safety Act or regulations thereunder, including the obligation to carry out recalls in accordance with the law, and to initiate a recall upon any future determination by Kia, or upon any finally adjudicated order from NHTSA, that vehicles equipped with Theta II GDI engines contain a defect related to motor vehicle safety or do not comply with an applicable FMVSS.This RQ is closed. Closure of this RQ has no bearing on the terms of the Consent Order, including Kia's ongoing performance obligations, and does not represent a determination by the agency as to Kia's performance under the Consent Order to date.
- Panoramic Glass Sunroof Breakage
The investigation focused on spontaneous breakage (fracture) of the panoramic sunroof (sunroof) on MY 2011-2013 Kia Sorento vehicles. The sunroof is constructed of tempered glass (often referred to as ?safety glass?), which, when broken, crumbles into granular chunks rather than splintering into jagged shards. The…
The investigation focused on spontaneous breakage (fracture) of the panoramic sunroof (sunroof) on MY 2011-2013 Kia Sorento vehicles. The sunroof is constructed of tempered glass (often referred to as ?safety glass?), which, when broken, crumbles into granular chunks rather than splintering into jagged shards. The failure summary above shows NHTSA reports identified by the Office of Defects Investigation (ODI), and reports submitted by Kia from start of production of the subject MY 2011-2013 Kia Sorento through October 8, 2019, the date of ODI's last request for Kia data.Reports of sunroof failures typically occurred while the vehicle was in motion and often described a loud noise when the fracture occurred. If the sunshade is closed when the sunroof fractures, the particles are contained, otherwise the particles can drop into the passenger compartment.Reported injuries generally were minor in nature, such as nicks and cuts that often occurred when complainants were cleaning-up glass particles post-incident. No crash incidents have been identified, and complaints display a declining trend since 2014.During EA14-002, ODI requested and obtained failure data for the subject vehicles, the MY 2014 Sorento (which used a similar sunroof from a different supplier), and other peer Kia products (Optima and Sportage).ODI also requested and obtained failure data for peer vehicles produced by Hyundai, Ford, Nissan, and Volkswagen and failure reports through a General Order NHTSA issued to 13 OEMs (including Kia) in April 2016.This produced a significant volume of data upon which ODI bases this closing. NHTSA's Vehicle Research and Test Center (VRTC) also conducted testing on the subject sunroofs in an attempt to better understand potential hazards.In its responses to ODI, Kia states it has continuously monitored sunroof failure allegations throughout this investigation, and that the only consistently identified cause is external impact from foreign objects. Kia notes that the sunroof complies with the applicable Federal Motor Vehicle Safety Standards for glazing, and that it has not identified a manufacturing defect or assembly process error despite significant investigative efforts. Kia maintains that the field data supports its conclusion that an unreasonable risk to motor vehicle safety does not exist, citing a comparatively moderate failure rate, low injury risk posed by tempered glass, and the lack of an identified defect mechanism. Kia further notes it has received no reports of crashes due to driver distraction related to roof failure events, nor is NHTSA aware of any such reports.NHTSA's April 2016 General Order requested data on vehicles with panoramic glass sunroofs greater than 0.5 square meters in area. The response identified 97 distinct models produced over 11 model years totaling some 10 million vehicles. Over 4,000 sunroof fractures were reported (none of which alleged a crash due to driver distraction) forming a high to low frequency continuum by model.While the subject vehicles were at the high end of the spectrum, they were not the highest.Through its analysis of the information obtained to date, ODI has not identified sufficient evidence of a safety-related defect in the subject sunroof. This includes the absence of any suggestive trends by region, seasonality, date of production, or vehicle age, together with the minor nature of the alleged injuries and the lack of crash allegations in the subject or any of the peer vehicles. Accordingly, the investigation is closed. ODI will take further actions if warranted by new evidence. The reference numbers for the ODI failure reports cited above, as well as additi
- Panoramic Sunroof Breakage
On October 21, 2013 the Office of Defects Investigation (ODI) opened PE13-035 in order to further examine claims that the sunroof would spontaneously break on 2011-2013 Kia Sorento vehicles.The majority of these claims occurred while the vehicle was in motion.Glass shattering while driving may distract the driver, and…
On October 21, 2013 the Office of Defects Investigation (ODI) opened PE13-035 in order to further examine claims that the sunroof would spontaneously break on 2011-2013 Kia Sorento vehicles.The majority of these claims occurred while the vehicle was in motion.Glass shattering while driving may distract the driver, and the resulting glass particles which enter the passenger compartment may injure occupants.To date, ODI has received a total of 26 reports of sunroof breakage on the subject vehicles. Of those, 24 occurred while the vehicle was in motion.There were also four (4) injury incident reports for minor cuts/scratches. Kia submitted a total of 123 field incidents related to sunroof breakage in response to ODI's information request. Of this number, ODI identified 78 unique vehicle identification numbers (VINs), with 9 matching ODI complaint vehicles.Sixty of the submitted reports occurred while the vehicle was in motion.Fourteen (14) of the submitted reports alleged minor cuts/scratches from falling glass.Kia also submitted a total of 101 warranty and goodwill claims for sunroof replacement, of which 86 unique VINs were identified.Kia stated in its response that their field inspections identified only one potential cause for the sunroof breakage - external impacts from rocks or other foreign objects encountered while the vehicle was in motion.In the other instances, no evidence of a defect was found, however, Kia's inspection results were inconclusive as to a cause for the breakage.Kia advises that the Sorento sunroofs also have a greater surface area than many other vehicles, potentially making them more susceptible to road debris strikes.While ODI recognizes that the Sorento may be more at risk due to its larger impact area, the rate of ODI reported incidents is concerning.Thus, the investigation has been upgraded toan Engineering Analysis (EA14-002) to further analyze the scope, frequency, and consequence of these failures.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10345933, 10410440, 10432904, 10453957, 10466987, 10478778, 10492886, 10502219, 10508983, 10514388, 10531972, 10534883, 10553341, 10555931, 10556212, 10562460, 10562516, 10563779, 10564555, 10567351, 10568629, 10572959, 10575487, 10583122, 10583626, 10584650
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 11010507TECHNICAL SERVICE BULLETIN: PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published in (PI2002A, PI2002B and SC200**1) titled Knock Sensor Detection System - ECU Logic Improvement. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below return to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).
- 11001595TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: ANTI-THEFT S/W LOGIC UPGRADE & DECAL INSTALLATION (CS2304) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides the procedure to upgrade the software logic of the Integrated Body Control Unit (IBU) or Body Control Module (BCM), or Intelligent Integrated Platform Module (IPM) system on certain 2011-2015MY Sorento (XMa), 2016-2020MY Sorento (UMa), and 2021-2022MY Sorento (MQ4a) vehicles produced within the dates outlined on page 13, which may not be equipped with an immobilizer. This logic upgrade will add anti-theft ignition start logic to the vehicle's system operation which activates when the vehicle is locked with the use of the key fob.
- 11000787This bulletin provides information relating to the correct transmission fluid type and fill quantity requirement for each Kia model. A flush is required ONLY when a transmission is replaced.
- 10252086TECHNICAL SERVICE BULLETIN: PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published PI1803 titled "Knock Sensor Detection System - ECU Logic Improvement" equipped w/THETA II engine. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below returns to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).
- 10243924TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: ANTI-THEFT S/W LOGIC UPGRADE & DECAL INSTALLATION (CS2304) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides the procedure to upgrade the software logic of the Integrated Body Control Unit (IBU) or Body Control Module (BCM), or Intelligent Integrated Platform Module (IPM) system on certain 2011-2015MY Sorento (XMa), 2016-2020MY Sorento (UMa), and 2021-2022MY Sorento (MQ4a) vehicles produced within the dates outlined on page 10, which may not be equipped with an immobilizer. This logic upgrade will add anti-theft ignition start logic to the vehicle's system operation which activates when the vehicle is locked.
- 10242913PITSTOP: AWD SYSTEM CONCERN DUE TO TIRE CIRCUMFERENCE - This Pitstop provides information regarding potential concerns with the All-Wheel-Drive (AWD) system due to tire sizes of differing circumference. Some customers may complain of a chatter sensation felt in the drivetrain of the vehicle and/or the failure of drivetrain component(s). A difference in tire size (width, aspect ratio, construction, rim diameter etc.) may be the cause.
- 10240558TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: ANTI-THEFT S/W LOGIC UPGRADE & DECAL INSTALLATION (CS2304) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides the procedure to upgrade the software logic of the Integrated Body Control Unit (IBU) or Body Control Module (BCM), or Intelligent Integrated Platform Module (IPM) system on certain 2011-2015MY Sorento (XMa), 2016-2020MY Sorento (UMa), and 2021-2022MY Sorento (MQ4a) vehicles produced within the dates outlined on page 10, which may not be equipped with an immobilizer. This logic upgrade will add anti-theft ignition start logic to the vehicle's system operation which activates when the vehicle is locked.
- 10239724CUSTOMER SATISFACTION CAMPAIGN: OWNER RE-NOTIFICATION - This document is the owner re-notification advising that Kia has developed a software upgrade that can be installed on the vehicle to restrict the operation of the vehicle's ignition system should a locked vehicle be the subject of a break-in and theft attempt without the key. This software upgrade will be available to the customer free of charge for eighteen (18) months from the date of the original letter. When the software upgrade is complete, Kia will also provide the customer with window stickers that can be applied to the vehicle to discourage a break-in.
- 10239714TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: ANTI-THEFT S/W LOGIC UPGRADE & DECAL INSTALLATION (CS2304) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides the procedure to upgrade the software logic of the Integrated Body Control Unit (IBU) or Body Control Module (BCM), or Intelligent Integrated Platform Module (IPM) system on certain 2011-2015MY Sorento (XMa), 2016-2020MY Sorento (UMa), and 2021-2022MY Sorento (MQ4a) vehicles produced within the dates outlined on page 10, which may not be equipped with an immobilizer. This logic upgrade will add anti-theft ignition start logic to the vehicle's system operation which activates when the vehicle is locked.
- 10236650TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: ANTI-THEFT S/W LOGIC UPGRADE & DECAL INSTALLATION (CS2304) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides the procedure to upgrade the software logic of the Integrated Body Control Unit (IBU) or Body Control Module (BCM), or Intelligent Integrated Platform Module (IPM) system on certain 2011-2015MY Sorento (XMa), 2016-2020MY Sorento (UMa), and 2021-2022MY Sorento (MQ4a) vehicles produced within the dates outlined on page 10, which may not be equipped with an immobilizer. This logic upgrade will add anti-theft ignition start logic to the vehicle's system operation which activates when the vehicle is locked.
- 10236078TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: ANTI-THEFT S/W LOGIC UPGRADE & DECAL INSTALLATION (CS2304) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides the procedure to upgrade the software logic of the Integrated Body Control Unit (IBU) or Body Control Module (BCM), or Intelligent Integrated Platform Module (IPM) system on certain 2011-2015MY Sorento (XMa), 2016-2020MY Sorento (UMa), and 2021-2022MY Sorento (MQ4a) vehicles produced within the dates outlined on page 10, which may not be equipped with an immobilizer. This logic upgrade will add anti-theft ignition start logic to the vehicle's system operation which activates when the vehicle is locked.
- 10233638TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: ANTI-THEFT S/W LOGIC UPGRADE & DECAL INSTALLATION (CS2304) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area.This bulletin provides the procedure to upgrade the software logic of the Integrated Body Control Unit (IBU) or Body Control Module (BCM), or Intelligent Integrated Platform Module (IPM) system on certain 2011-2015MY Sorento (XMa), 2016-2020MY Sorento (UMa), and 2021-2022MY Sorento (MQ4a) vehicles produced within the dates outlined on page 10, which may not be equipped with an immobilizer. This logic upgrade will add anti-theft ignition start logic to the vehicle's system operation.
- 10233308CUSTOMER SATISFACTION CAMPAIGN: OWNER NOTIFICATION - This document is the owner notification advising that Kia has developed a software upgrade that can be installed on the vehicle to restrict the operation of the vehicle's ignition system should a locked vehicle be the subject of a break-in and theft attempt without the key. This software upgrade will be available to the customer free of charge for eighteen (18) months from the date of this letter. When the software upgrade is complete, Kia will also provide the customer with window stickers that can be applied to your vehicle to discourage a break-in.
- 10226555TECHNICAL SERVICE BULLETIN: TRANSMISSION FLUID APPLICATION GUIDE - This bulletin provides information relating to the correct transmission fluid type and fill quantity requirement for each Kia model. A flush is required ONLY when a transmission is replaced, refer to applicable vehicles in the chart starting on page 2.
- 10219692TECHNICAL SERVICE BULLETIN: BEARING CLEARANCE TESTER (BCT) PROCEDURES - This bulletin provides information regarding test procedure of the Bearing Clearance Tester (BCT) Special Service Tool (SST). The SST comes pre-calibrated from the supplier however, in some cases, due to variable shop compressor air pressure, the SST may need to be re-calibrated to ensure that the tool provides accurate readings when testing the engine rod bearing wear. The calibration and BCT measuring point maintenance is included in this bulletin.
- 10210431PITSTOP: INJECTOR HARNESS ROUTING FOR PI1802Y/Z AND PI1803Y/Z ENGINE REPLACEMENTS - This bulletin provides information to address a no-start or hard start with poor running condition after engine replacement under PI1802Y/Z or PI1803Y/Z. Some replacement long blocks may come with pre-installed fuel rail, injectors, and injector wiring harness. If the condition is present, it is possible that the injector harness was not installed correctly. The connections may be swapped from cylinder No. 1 and cylinder No. 4, and from cylinder No. 2 and cylinder No. 3.
- 10209438TECHNICAL SERVICE BULLETIN: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA/KAPPA ENGINES - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information on diagnosing and/or repairing some 2011-2021MY vehicles (refer to the tables on pages 8-9 for applicable models and engine), which may exhibit a symptom of excessive oil consumption.
- 10206642TECHNICAL SERVICE BULLETIN: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA/KAPPA ENGINES - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information on diagnosing and/or repairing some 2011-2021MY vehicles (refer to the tables on pages 8-9 for applicable models and engine), which may exhibit a symptom of excessive oil consumption.
- 10205866PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published PI1803 titled "Knock Sensor Detection System - ECU Logic Improvement" equipped w/THETA II engine. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below returns to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).
- 10205426TECHNICAL SERVICE BULLETIN: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA/KAPPA ENGINES - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information on diagnosing and/or repairing some 2011-2021MY vehicles (refer to the tables on pages 8-9 for applicable models and engine), which may exhibit a symptom of excessive oil consumption.
- 10203695This bulletin provides information regarding test procedure of the Bearing Clearance Tester (BCT) Special Service Tool (SST). The SST comes pre-calibrated from the supplier however, in some cases, due to variable shop compressor air pressure, the SST may need to be re-calibrated to ensure that the tool provides accurate readings when testing the engine rod bearing wear. The calibration and BCT measuring point maintenance is included in this bulletin.
- 10203659PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published PI1803 titled "Knock Sensor Detection System - ECU Logic Improvement" equipped w/THETA II engine. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below returns to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).
- 10202226TECHNICAL SERVICE BULLETIN: PARTIAL REPAIR OF C-MDPS MOTOR, ECU, WORM GEAR AND/OR STEERING COLUMN HOUSING - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information regarding the partial repair of the Motor Driven Power Steering (MDPS) Motor, Electronic Control Unit (ECU), Steering Column Housing, or Worm Gear Assembly. When the steering wheel is rotated a scraping noise can be heard originating from the lower bearing on the Worm Gear Assembly on some 2010MY~ Kia models listed on page 8, equipped with a Column Motor Driven Power Steering (C-MDPS) unit. On some vehicles when the steering wheel is rotated a scraping noise can be heard originating from the lower bearing on the Worm Gear Assembly and does not affect the steering effort.
- 10201615TECHNICAL SERVICE BULLETIN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published in (PI2002A, PI2002B and SC200**1) titled "Knock Sensor Detection System - ECU Logic Improvement". Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below return to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).
- 10201529TECHNICAL SERVICE BULLETIN: INFORMATION FOR HEADLAMP CONDENSATION AND MOISTURE - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information relating to some Kia models that may exhibit fogging, condensation, and/or moisture inside a headlamp assembly. Generally, a fogging condition is considered normal and can be eliminated by turning on the headlamps with the engine running for up to 30 minutes or during normal driving conditions. Headlamp assembly replacement WILL NOT be necessary in most cases.
- 10201158TECHNICAL SERVICE BULLETIN: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA/KAPPA ENGINES - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information on diagnosing and/or repairing some 2011-2019MY vehicles (refer to table below for applicable model and engine), which may exhibit a symptom of excessive oil consumption.
- 10199451TECHNICAL SERVICE BULLETIN - PRODUCT IMPROVEMENT CAMPAIGN PI1803_TSB_R6: KNOCK SENSOR DETECTION SYSTEM - ECU - LOGIC IMPROVEMENT (PI1803) - This bulletin has been revised to include additional information. This bulletin provides information related to a software update to the Engine Control Unit (ECU) to install the Knock Sensor Detection System (KSDS) in order to protect the engine from excessive connecting rod bearing damage.
- 10189545TECHNICAL SERVICE BULLETIN: PARTIAL REPAIR OF C-MDPS MOTOR, ECU, WORM GEAR AND/OR STEERING COLUMN HOUSING - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information regarding the partial repair of the Motor Driven Power Steering (MDPS) Motor, Electronic Control Unit (ECU), Steering Column Housing, or Worm Gear Assembly. When the steering wheel is rotated a scraping noise can be heard originating from the lower bearing on the Worm Gear Assembly on some 2010MY~ Kia models listed on page 8, equipped with a Column Motor Driven Power Steering (C-MDPS) unit.
- 10189272TECHNICAL SERVICE BULLETIN: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA ENGINES - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information on diagnosing and/or repairing some 2011-2019MY vehicles (refer to table below for applicable model and engine), which may exhibit a symptom of excessive oil consumption.
- 10186041TECHNICAL SERVICE BULLETIN: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA ENGINES - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information on diagnosing and/or repairing some 2011-2019MY vehicles (refer to table below for applicable model and engine), which may exhibit a symptom of excessive oil consumption.
- 10183431TSB - USE OF AFTERMARKET USB CHARGING CABLES IN USB/12V PORTS - This article provides information regarding the use of USB ports and 12V power outlets to connect/charge mobile phones. Customers may experience issues with their head units that may be related to the use of aftermarket USB charging cables, including; * Electrical interference and limited or no functionality when attempting to play music, or when charging a device through the USB port * Excessive static or noise when listening to the audio source * Malfunctions and screen freeze of the head unit screen * Slow down of the system response while device is plugged in * Music will not play from iPhone 5 or 6 with Kia iPod cable and aftermarket adapter * No or limited functionality when trying to play music from an Apple device
- 10183333TECHNICAL SERVICE BULLETIN: PARTIAL REPAIR OF C-MDPS MOTOR, ECU, WORM GEAR AND/OR STEERING COLUMN HOUSING - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information regarding the partial repair of the Motor Driven Power Steering (MDPS) Motor, Electronic Control Unit (ECU), Worm Gear Assembly or Steering Column Housing on some 2010MY~ Kia models listed on page 8, equipped with a Column Motor Driven Power Steering (C-MDPS) unit.
- 10183332TECHNICAL SERVICE BULLETIN: PARTIAL REPAIR OF C-MDPS MOTOR, ECU, WORM GEAR AND/OR STEERING COLUMN HOUSING - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information regarding the partial repair of the Motor Driven Power Steering (MDPS) Motor, Electronic Control Unit (ECU), Worm Gear Assembly or Steering Column Housing on some 2010MY~ Kia models listed on page 8, equipped with a Column Motor Driven Power Steering (C-MDPS) unit.
- 10183313PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published in July 2018 (PI1803, Rev 10, 03/16/2020) titled "Knock Sensor Detection System - ECU Logic Improvement" equipped w/THETA II engine. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below returns to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).
- 10180663WARRANTY EXTENSION PROGRAM - This document is the notice to the vehicle owners, advising them of the Warranty Extension on the Occupant Detection System Sensor Pad to fifteen (15) years with unlimited mileage, starting from the date the vehicle was first put into service.
- 10180662WARRANTY EXTENSION PROGRAM - This document is the notice to the vehicle owners, advising them of the Warranty Extension on the Occupant Detection System Sensor Pad to fifteen (15) years with unlimited mileage, starting from the date the vehicle was first put into service.
- 10180661WARRANTY EXTENSION PROGRAM - This document is the Question and Answer document regarding the Warranty Extension on the Occupant Detection System Sensor Pad to fifteen (15) years with unlimited mileage, starting from the date the vehicle was first put into service.
- 10180660WARRANTY EXTENSION PROGRAM - This document is the notice to dealer parts and service managers, advising them of the Warranty Extension on the Occupant Detection System Sensor Pad to fifteen (15) years with unlimited mileage, starting from the date the vehicle was first put into service.
- 10180659WARRANTY EXTENSION PROGRAM - This document is the notice to dealer principals, advising them of the Warranty Extension on the Occupant Detection System Sensor Pad to fifteen (15) years with unlimited mileage, starting from the date the vehicle was first put into service.
- 10179255PITSTOP - BRAKE CALIPER LEAK INSPECTION - This PITSTOP provides information related to a brake caliper fluid/oil substance found on some Kia vehicles, due to possible excess assembly oil applied during assembly.
Every KIA Sorento model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.