2016 KIA Sorento
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Vehicles › KIA › Sorento › 2016
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
These records cover every 2016 KIA Sorento. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
8 recalls name the 2016 KIA Sorento. Newest first.
Kia America, Inc. (Kia) is recalling certain 2016-2022 Sorento, 2021-2022 Sorento Hybrid (HEV), 2022-2023 Sorento Plug-In Hybrid (PHEV), and 2017-2022 Sportage vehicles equipped with a tow hitch harness installed as original equipment, or purchased as an accessory through a Kia dealership. Debris and moisture accumulation on the tow hitch harness module…
A fire while parked or driving can increase the risk of injury.
Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will inspect the vehicle, and, as necessary, replace the fuse and/or tow hitch harness module, free of charge. Owner notification letters were mailed August 11, 2023. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC249.
Kia America, Inc. (Kia) is recalling certain 2016 Sedona and Sorento vehicles. The vehicles may have been manufactured with faulty automatic transmission shift lever assembly components, preventing the shift lever from locking, which can allow the vehicle to rollaway.
A vehicle rollaway increases the risk of a crash and injury.
Dealers will inspect and replace the automatic transmission shift lever assembly components, as necessary, free of charge. Owner notification letters were mailed October 7, 2022. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC246.
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…
A fuel leak in the presence of an ignition source can increase the risk of a fire.
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 Motors America (Kia) is recalling certain model year 2016-2017 Sorento vehicles manufactured October 27, 2014, to August 25, 2016, and 2017 Sportage vehicles manufactured December 10, 2015, to August 26, 2016. The affected vehicles are equipped with an accessory trailer hitch wiring harness that, due to a malfunction of the tow hitch module, may result…
If the trailer brake lights stay illuminated while being used, other drivers may be confused, increasing the risk of a crash.
Kia will notify owners, and dealers will replace the trailer tow hitch harness, free of charge. The recall began January 18, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC142.
Kia Motors America (Kia) is recalling certain model year 2016 Kia Sorento vehicles manufactured March 3, 2016 to March 21, 2016. The driver's seatback frame may have been produced with inadequate weld joints and, as a result, the seatback may not function as designed in the event of a rear-end collision.
In the event of a crash, the driver seatback frame could break and fail to restrain a seat occupant, increasing the risk of injury.
Kia will notify owners, and dealers will inspect the welds and replace the driver seatback frame, as necessary, free of charge. The recall began on December 9, 2016. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC140.
Kia Motors America (Kia) is recalling certain model year 2016 Sorento vehicles. A component of the rear suspension may not be properly welded.
The improper weld may break, affecting the rear suspension alignment, thereby increasing the risk of a crash.
Kia will notify owners, and dealers will inspect the welds at the rear suspension cross-member, replacing the rear cross-member assembly, as necessary, free of charge. The recall began July 27, 2016. Owners may contact Kia Customer Service Department at 1-800-333-4542. Kia's number for this recall is SC137.
Kia Motors America (Kia) is recalling certain model year 2016 Kia Sorento vehicles manufactured October 23, 2014, to December 10, 2014. The affected vehicles have a front passenger seat belt whose buckle latch assembly may prevent the front passenger from fastening the seat belt.
If the front passenger seat belt cannot be latched, an occupant sitting in the front passenger seat has an increased risk of injury in the event of a crash.
Kia will notify owners, and dealers will replace the front passenger seat belt buckle cover, free of charge. The recall began on August 18, 2015. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC123.
Kia Motors America (Kia) is recalling certain model year 2016 Sorento vehicles manufactured October 27, 2014, to January 29, 2015. Due to an improperly soldered component in the accelerator pedal assembly, the driver may not be able to accelerate the vehicle.
If the vehicle is unable to be accelerated, there is an increased risk of a crash.
Kia will notify owners, and dealers will replace the accelerator assembly, free of charge. The recall began on February 19, 2015. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC115.
The contact owns a 2016 Kia Sorento. The contact stated that while driving 30 MPH, the vehicle made an abnormal cranking and popping sound. Upon researching the failure online, the contact learned that the vehicle was unsafe to drive. The contact associated the failure with NHTSA Campaign Number: 16V480000 (Suspension); however, the VIN was not included in the recall. The manufacturer was notified of the failure by phone. The failure mileage was approximately 93,000.
Vehicle caught on fire when driving, putting my mother's life and her passenger at risk. My mother is an elderly Deaf woman, but was able to pull over in time for Fire Department to help contain fire. There were no warning lamps or messages of any problems with car, the car started smoking (smoke also entered cabin) and they pulled over where there was a fire under hood and bystander call emergency services. The car is currently at a tow lot and should be available for inspection upon request. We are waiting for car to be inspected by insurance.
The Steering binds/ sticks at the 12 o’clock position on the highway, requiring sudden extra physical force to break free, which causes the vehicle to oversteer left to right. For record, Auffenberg Kia verified a steering torque measurement of 7.3 Nm (failure limit: 4.5 Nm) per TSB CHA060, but denied warranty repair under WTY023 solely because the instrument cluster lamp was not illuminated. I paid $163.69 and the dealer released an unsafe car back to me.
The dash is split all over the soft padded dash from the heat started with 1 small split grew larger and all over the dash even with a windshield shade and dash mat heat cracks could affect the passenger side dash airbag brought the vehicle new has just over 40000 mi photo enclosed show just a few cracks the whole dash is affected
I am the original owner of a 2016 Kia Sorento and have lived at my original registration address since purchasing the vehicle. The engine suddenly and catastrophically failed/seized due to internal rod bearing failure. The local Kia dealership is denying the recall engine replacement because the KSDS (Knock Sensor Detection System) software update was not performed. However, Kia America failed to mail me a statutory recall notice to my verified address. The dealership is weaponizing Kia's own notification failure to deny coverage for an acknowledged safety defect."
The contact owns a 2016 Kia Sorento. The contact stated that there was coolant intrusion into the engine. The failure was associated with Technical Service Bulletin: 253 (Rev 1, WTY035 - Warranty Extension Program). The contact stated that the issue was caused by a failure of the iron screws on the engine. The dealer was contacted and stated that the oil change records were needed before replacing the engine. The manufacturer was contacted by phone and was made aware of the failure. The failure mileage was approximately 148,764.
The contact owns a 2016 Kia Sorento. The contact stated that while driving at 65 MPH, there was an abnormally strong fuel odor inside the vehicle. The contact stated that while the vehicle was at the dealer for a scheduled service, the contact requested that the dealer inspect the issue. The vehicle was diagnosed with a low-pressure fuel pump failure. The contact was informed that the low-pressure fuel pump needed to be replaced. The vehicle was repaired. The failure mileage was approximately 79,000.
Zubie plug-in obd device for gps tracking and health monitoring of cars. It was triggering an airbag light on the dash which meant in the event of a crash the airbags would not be deployed. My local Kia dealer investigated and found the plug in zubie device was triggering the airbag light in the dash. I contacted zubie and they said they knew about this. This is a huge safety concern for a simple gps obd plugin to be affecting safety systems of cars.
Dear Kia America Customer Care Team, Thank you for your response regarding Case Number While I understand that my vehicle is technically outside the standard factory warranty period, I am formally requesting a managerial review of this decision. This is not a request for a cosmetic repair, but a critical safety concern regarding a life-saving component. The dashboard material directly above the passenger airbag is cracking. As you are aware, the structural integrity of the airbag cover is essential for its correct deployment. My primary concern is that during a collision, these cracks could cause the airbag to deploy incorrectly, or worse, turn fragments of the brittle dashboard into dangerous projectiles aimed directly at the front passenger. A vehicle’s airbag system should not degrade into a safety hazard under normal operating conditions, regardless of warranty mileage. This structural degradation points to a potential material defect rather than standard wear and tear. Before I take further action, I request that Kia America reviews this case under a goodwill consideration (Goodwill Policy), as it directly impacts the crashworthiness and occupant safety of the vehicle. For your records, I am also documenting this issue with the National Highway Traffic Safety Administration (NHTSA) to ensure it is registered as a potential safety risk for this model line. I look forward to your reconsidered response and hope we can resolve this matter safely and professionally. Sincerely Dear Thank you for contacting Kia America, Inc. We appreciate your feedback and the opportunity to address your concerns. We have concluded the research regarding your request for assistance. Your vehicle is out of warranty as outlined in your Warranty and Consumer Information Manual and the
Transmission failure at 99,000 miles Replaced by dealer under warranty
I am the original, single owner of a 2016 Kia Sorento in Snow White Pearl. My vehicle currently has approximately 96,000 miles on it. Roughly one year ago, the factory paint began catastrophically peeling, flaking, and deteriorating in large sheets on the roof and near the passenger-side door. This damage is not the result of environmental wear, stone chips, or poor maintenance. It is a documented, widespread manufacturing defect—specifically, a factory primer-adhesion failure (delamination)—that uniquely impacts Kia and Hyundai vehicles painted in this specific Snow White Pearl finish. I contacted Kia Consumer Care to resolve this issue and was assigned Case Number 26409995. Despite my status as a loyal, original owner of a vehicle under 100,000 miles, Kia issued a blanket denial of assistance. Kia is well aware of this systemic manufacturing defect, as their sister company Hyundai has previously extended paint warranties to 10+ years for identical white paint delamination issues. Kia’s refusal to remedy this known defect constitutes unfair and deceptive consumer business practices under California law. My vehicle specifically features Kia’s "Snow White Pearl", which is widely documented to have a latent factory defect. The core issue stems from an original chemical failure where the white base paint layer did not properly bond or fuse to the factory primer layer. Over time, exposure to atmospheric heat, rain, or vibration causes the top layers to completely delaminate and flake off in massive chunks, often exposing the bare gray primer underneath. When multiple panels peel, it presents a safety hazard if paint flakes off into the vision of drivers behind me.
Vehicle equipped with 3.3L V6 Lambda II engine, covered under active Kia Warranty Extension Campaigns WTY035/WTY039 for engine block head bolt/gasket failure.In July, the vehicle experienced a cooling system issue and was brought to authorized dealer Westgate Kia. Despite explicit campaign guidelines mandating a coolant pressure test and chemical combustion block test for cooling complaints on this engine, the dealership failed to follow the TSB protocol. They attributed the issue solely to an external hose, recommended unrelated peripheral repairs, and released the vehicle without performing the required campaign diagnostics.A few months later, the unchecked progressive manufacturing defect resulted in catastrophic engine failure. The vehicle exhibited intermittent overheating, blew heavy white smoke from the tailpipe (indicating a massive head gasket breach/coolant entering combustion chambers), and ultimately suffered a total loss of cylinder compression, requiring it to be towed back to Westgate Kia.The dealership is currently trying to evade the 15-year/180,000-mile WTY035/WTY039 campaign coverage. The service department is refusing to follow the mandated diagnostic flowchart to check for stripped engine block head bolts, instead claiming the failure is due to a "melted radiator." They are attempting to blame the consequences of the extreme engine overheating on peripheral parts to avoid performing the required engine sub-assembly replacement under the federal campaign.
Hard shifting and kia said I need a new transmission, 99,500 miles
Upon a catastrophic engine failure Tasca Kia replaced engine under Theta II settlement. I picked up my kia on 9/12. Engine is not running properly. It’s jerking and there is loud mechanical knocking. I don’t feel safe driving. I’ve contacted Kia corporate beginning 9/16 who contacted Tasca to arrange for tow and loaner. They said Tasca service mgr would contact soon to set up. They never did. I called corporate again later that day and after they called Tasca they were told service mgr went home for the day. As of this date Tasca Kia has not contacted me. I again called Kia corporate 9/17 asking to please escalate and allow me to use another service dept. The only other service location with loaner is a half hour away and I cannot afford another tow or another rental. I am stranded with a car that is not safe due to installation failure or another defective engine. No one from Kia will help in a reasonable time frame. I’m now told it can take up to 48 BUSINESS HOURS for any assistance. In the meantime I’m being forced to decide on whether to risk driving an unsafe vehicle to the service dept or to continue waiting for Kia to contact me.
I am filing a safety complaint regarding a severe, sudden electronic and mechanical failure of the shift interlock system and the Body Control Module (BCM) that compromises vehicle control and leaves the vehicle stranded in active traffic conditions. While attempting to operate the vehicle, the shifter lever suddenly became physically jammed and highly resistant, refusing to shift out of the "Park" position or smoothly engage into "Drive." Simultaneously, the gear selector indicator (P-R-N-D) on the digital dashboard display went completely blank, indicating a total loss of network communication between the transmission range system and the vehicle's central computer network. Because the vehicle's electronic safety "handshake" failed, the vehicle suffered a no-start condition. To operate the vehicle or move it out of harm's way, I am forced to use the mechanical manual shift-lock override tool. Diagnostic scanning at a professional repair facility confirmed a hard Code P0955 (Auto Shift Manual Mode Circuit Malfunction) due to an internal electronic failure inside the Body Control Module (BCM), which handles the safety grounding circuit for the shift interlock solenoid. Safety Risk Statement: This component failure introduces a severe safety hazard. If a driver is required to quickly shift gears or move the vehicle out of an active roadway, intersection, or railway crossing during an emergency, the physical locking of the shifter and sudden communication dropout prevents immediate vehicle control. Bypassing a safety system via a physical override tool while stranded in traffic is a dangerous distraction. There is an existing safety recall for this model year regarding shifter rollaways (Recall SC246), but it does not address this opposite, widespread BCM circuit failure that permanently traps the shifter and disables dashboard monitoring. I request that the NHTSA investigate this systemic Kia BCM failure pattern for a retroactive safety recall.
I am filing this complaint regarding a 2016 Kia Sorento, VIN [XXX]. The vehicle suddenly broke down while my [XXX] daughter was driving in [XXX] and was taken to Sooner Kia in [XXX]. The dealership diagnosed the engine as seized and stated that it failed because there was no oil, requiring engine replacement. We dispute that conclusion. Within approximately five minutes of the breakdown, my daughter checked the oil at her father’s direction, and the level appeared normal. A mobile mechanic later inspected the vehicle and also reported that the oil level was normal and appeared clean. Sooner Kia now claims the engine was “bone dry” and that lack of oil caused the seizure. We have requested documentation showing how much oil was found, whether any oil was drained, what testing was performed, what internal damage was identified, and what evidence proves that oil starvation caused the failure. We have not received documentation establishing the cause. This is concerning because NHTSA previously investigated loss of motive power involving 2016–2017 Kia Sorento vehicles with 3.3L Lambda II engines under PE23-019. Kia later created extended warranty campaign WTY035 for certain related failures. Please document this complaint and review whether this engine failure may be related to those known issues. We are being asked to authorize an expensive engine replacement without evidence supporting the dealership’s conclusion. Vehicle: 2016 Kia Sorento VIN: [XXX] Dealership: Sooner Kia, [XXX] Manufacturer: Kia America INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
On or about XXX, my KIA Sorento LX FWD Auto 2.4-liter engine with an approximate mileage of 36,000, began having drivability problems, none of which occurred before that date. On XXX the vehicle was serviced at Ourisman Chantilly Kia (VA051) for a Voluntary Emissions Service Campaign (SC340) THETA II 2.4L GDI ECM S/W Upgrade. Records reflect that it was a Theta II Emissions Logic Improvement 250A21R1 0.3 M/H. This was a voluntary campaign from Kia America, Inc., [XXX]. Failure to have this performed, as cited from the Kia Corporate Headquarters, could nullify warranty/warranties. What ensued was a vehicle that stalled, seized, hesitated, and/or jolted at low speeds that had the potential to cause severe injury or accident. Uncontrolled rough accelerating and seizing is a serious complaint, and the causation can be linked to the dealership performing the voluntary recall where the vehicle was purchased on March 15, 2015, in [XXX]. Further, this vehicle has a full and complete record of all repairs and symptoms, which includes, and is not limited to, maintenance, Service Campaign, Service Action, Recall, and Product Improvement. This vehicle, included in a class of vehicles with a history of potential engine failures, has a Lifetime Engine Warranty extension coverage included in PI1802 Y/Z Engine R&R Warranty Bulletin 2020-26 and PI1802W/X Warranty Bulletin 2018-10. Therefore, when the records were reviewed for the initial Voluntary Emission Service Campaign recall code SC234 completed in 2022, along with my former NHTSA Complaint Number XXX submitted electronically, an apparent history of obfuscation relating to material safety concerns emerges. KIA America, Inc. sold this Kia as a five-star safety rated vehicle. It now makes me feel uneasy with its defective drivability. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
I went in a few months ago for a routine oil change. My car has had zero operating issues since I had the engine replaced around 5 years ago. They told me that I need to have a voluntary emissions update performed, so I gave consent. (The letter I received a few days later referred to it as "Voluntary Emissions Service Campaign.")On the way home, it seemed to drive rougher. I figured it was relearning some of the basic operating values. The following morning, it idled rough and then when I began driving, it would lurch forward irradically for the first one or two minutes of driving. I called the dealership and they insisted that it was coincidence. They said they will look at it, but there would be a charge. I have noticed a pattern since then. During normal driving, it is now smooth. It only happens on cold starts. Allowing it to idle elimiates the issue. However, it continues to idle rough on cold starts. If I drive it after it warms up, however, it does lurch forward. After this, it drives normal. Today I went in to the dealership for another oil change and asked about it. They continued to insist that it was impossible, but that I could leave it overnight and pay to have it looked at with the understanding that the two cannot be related. The safety issue is that it will literally make the car lurch forward when barely touching the gas. If this continues to worsen, it will cause a wreck. It has not been formally inspected, but I can provide dash cam footage.
See attached document for complaint.
The paint iscoming off and don't stick to the vehicle. I need KIA to paint this car asap
Vehicle: 2016 Kia Sorento EX VIN: [XXX] Current Mileage: Approximately 67,000 Component: Paint/Body (Exterior Finish) My 2016 Kia Sorento (Snow White Pearl / Pearl White) has developed premature, multi-panel paint failure. Flaking began appearing on the roof rail area above the front doors in late summer 2025, followed by flaking on the hood, and later bubbling on the rear driver-side door. Flakes recovered from the ground beneath the vehicle have consistently been approximately the size of a 50-cent piece. At the manufacturer's request, three independent, licensed California collision repair facilities inspected the vehicle. All three independently identified a paint adhesion or chemical bonding failure, not ordinary wear. One shop's written estimate states verbatim that "the sealer did not chemically bond when basecoat was applied." Another states it cannot warranty a repair unless affected panels are stripped to bare metal and fully refinished. Repair estimates to properly address the condition range from approximately $9,000 to $17,000. Kia has already acknowledged this as a defect meriting manufacturer assistance, having extended a goodwill offer covering partial repainting costs. I am filing this report to document a paint system manufacturing defect, consistent with a pattern reported by other Kia Sorento owners and referenced in at least one prior Kia service bulletin (SA166) addressing paint peeling on Sorento door panels. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
While I was driving, my 3.3 V6 engine on my 2016 Kia Sorento seized up with no warning. There is no visible oil on the dip stick, although I have changed my oil routinely. There has never been visible oil outside of the engine or on the ground. I never had any warning light come on. I believe the engine burns an extreme amount of oil, which is putting people in a dangerous situation and financial hardship.
On Saturday the 18th of July, the car was fine, on Sunday 07/19/2026 got ready to take car to regular scheduled oil change and it was making a blown engine noise, the rod had failed, Safety issues where the people at oil change could have had a rod thrown out the bottom of the engine, or my car could have failed in the middle of the road causing an accident. No warning signs, no limp mode, no engine light, no noted metal in oil on previous oil changes. Inspected at Kia, does not meet any recall warranties, however service manager at West Hills Kia stated this is in an internal engine failure and should not have happened with our service records and care of vehicle.
I recently took my 2016 Kia Sorento L to the Kia dealership for the Emissions update recall. The next day when I started it up and put it in drive, it started jerking hard when I was trying to speed up (going from first to second gear). I had to stop and then slowly push the gas so it wouldn't jerk so hard, then it finally switched gears and was smooth. Ever since it's happening only at the first cold start up of the day, and have sluggish acceleration throughtout the day. No lights on or codes. I took back to dealership twice and they said they couldn't replicate it and so they aren't sure, but it definitely still does it (anyone riding with me notices before I even mention it).
I have a 2016 kia sorento I was having a problem with the shifter it would not go into park and had to use the shift override button I contacted the dealer there was an active recall they refused to repair or replace the shifter because it was inspected by the dealer in 2022 and as far as they where concerned that satisfied the recall The recall is still valid, and does not have close date how can they refuse to repair . It is still a safety issue
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
On November 13, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-019) to investigate allegations of loss of motive power relating to head gasket and/or head bolt failure in Model Year (MY) 2016-2017 Kia Sorento vehicles equipped with the 3.3 L Lambda II engine. When the investigation was opened, ODI had received 13 Vehicle Owner Questionnaires (VOQs) related to reports of loss of motive power. In an information request letter dated November 30, 2023, ODI requested technical information and failure data relating to the alleged defect in the subject MY 2016-2017 Kia Sorento as well as several peer vehicle populations which share the 3.3 L engine. In its February 26, 2024, response to ODI’s information request, Kia provided 2022 customer complaints (including techline and field reports) and 1738 warranty claims representing 2411 unique vehicles within the subject vehicle population. Of the customer complaints provided by Kia, they identified only 53 unique allegations of a loss of motive power resulting from the alleged defect. Kia determined that the remaining reports were minor vehicle drivability or engine performance issues. ODI reviewed the information provided by Kia, along with additional VOQs submitted to NHTSA following the opening of the investigation. When eliminating duplicative reports across the data sources, the total number of allegations of loss of motive power relating to the alleged defect in the subject vehicles is 77, representing an incident report rate of 59 per 100,000 vehicles. The MY 2016 Kia Sorento exhibited both the highest overall complaint rate and loss of motive power report rate across all subject and peer vehicle populations, representing an incident report rate of 102 per 100,000 vehicles. Across all data sources, there are no allegations of crashes or fires relating to the alleged defect. The one injury incident reflected in the failure summary table above is related to a consumer who was reportedly burned (minor burn requiring medical attention) while attempting to remove the coolant reservoir cap following a loss of motive power event. In their response to ODI, Kia described that if the threads of a head bolt hole in the subject engine becomes damaged, the clamping force between the cylinder head and engine block can decrease in the area of the affected head bolt. Kia’s assessment of the alleged defect is that when the failure occurs, drivers are provided with numerous warning signs prior to a potential loss of motive power event. According to Kia, potential warning signs associated with this failure include coolant leak/consumption or noticeable coolant odor, engine oil leak/consumption, engine temperature gauge rising to “H” (hot), check engine light illuminating, engine cooling fan remaining on following the engine being shut off, HVAC system not functioning properly, unusual engine noise, difficulty starting the vehicle, and smoke/condensation emitting from the engine compartment or exhaust. Through both its review of the information provided by Kia and outreach to consumers, ODI confirmed that there is reasonable detectability present in the vast majority of occurrences of the alleged defect. To mitigate the alleged defect, Kia increased the engagement depth of the head bolt threads for all subject engines, beginning in May 2017. ODI’s analysis of the failure data demonstrates that this corrective action correlates with a much lower incident report rate for engines produced following the change (8 per 100,000 vehicles for the MY 2018-2020 Kia Sorento). In December 2023, Kia launched extended warranty campaign WTY035 covering failures associated with the alleged defect in the subject vehicle population through 15 years or 180,000 miles, whichever comes first. Through its investigation, ODI identified the following peer vehicle populations, which were produced prior to the corrective action and exhibit failure rates comparable to the subject vehicles: MY 2014-2015 Kia Sorento, MY 2015-2016 Kia Sedona, and MY 2014-2017 Kia Cadenza equipped with the 3.3 L engine. Through discussions with ODI during the investigation, Kia decided to launch extended warranty campaign WTY039 in May 2024, which covers these peer vehicle populations through 15 years or 180,000 miles, whichever comes first. Based on analysis of the failure data indicating a low incident report rate of loss of motive power for the alleged defect, and in consideration of the warning signs which frequently occur from head gasket and/or head bolt failure in the subject engines, ODI is closing this Preliminary Evaluation. The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
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.
In a letter dated September 30, 2021, Mr. Gerald James (the petitioner) requested that NHTSA conduct an investigation of the Model Year (MY) 2015-2017 Kia Sorento equipped with 3.3L V6 ?Lambda? engines for ?severe oil leaks? from the oil pressure switch (OPS) that could ?lead to engine failure? with little warning to the driver. Mr. James based this request on his own experience and data found in NHTSA?s Vehicle Owner Questionnaire (VOQ) database. NHTSA reviewed the material cited by the petitioner, information submitted by Kia, NHTSA?s testing, and other pertinent information in NHTSA databases.On November 12, 2021, ODI opened Defect Petition DP21-002 to evaluate the petitioner?s request. ODI performed an analysis that included evaluation of the petitioner?s vehicle, searches of ODI complaints from vehicle owners, non-dealer field reports, manufacturers? supplemental information relating to design of the component, and component testing performed by ODI.On December 16, 2021, ODI and Kia North America performed a joint inspection on the petitioner?s vehicle. ODI and Kia agreed the OPS was leaking oil and observed oil in the crevices atop the engine block. The vehicle received a new replacement OPS and was delivered back to the petitioner. The original part that was removed from the subject vehicle was retained by ODI for further analysis.As of December 30, 2022, for the MY 2015-2017 Kia Sorento population of 161,519 vehicles with 3.3L engine, NHTSA reviewed internal data and has identified no consumer complaints or field reports in its database, with unique Vehicle Identification Numbers (VIN), citing engine failure or stalling related to the petition?s allegation of defective OPS. When combined with the supplemental warranty and technical analysis from the manufacturer, field report and customer complaint data in response to the Information Request letter sent, NHTSA identified no unique VINs alleging engine failure or stalls caused by OPS leaking on the subject vehicles named in the petition.On April 4, 2022, the Vehicle Research and Test Center (VRTC) performed testing of the petitioner?s component (OPS) based on testing protocol consistent with Kia?s specifications for the subject vehicle. The testing involved the petitioner?s original OPS in a controlled system to replicate the subject vehicle?s oil pressure, flow, and temperature. VRTC determined that a vehicle would have to miss more than a dozen oil change intervals to reach low engine oil capacity. Testing also revealed the OPS would operate, as manufacturer intended, illuminating the vehicle?s MIL to alert the driver of lower oil pressure.In April of 2022, Kia North America issued a warranty extension that extended the coverage of the Oil Pressure Switch from 5 years/60,000 miles to 15 years/150,000 miles on MY 2014-2018 Sorento, MY 2014-2016 Cadenza, and MY 2015-2018 Sedona vehicles, all equipped with the 3.3L Lambda engine. The extended warranty coverage includes diagnosis, repair, and applies to customers experiencing engine oil leaking from the engine or if the engine oil pressure warning light stays illuminated after the engine is turned on.After a thorough review of the material submitted by the petitioner, information already in NHTSA's possession, testing performed by VRTC, technical information provided by Kia, the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that an engine failure due to the alleged defect is likely and does not warrant a formal investigation. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be publi
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
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