2015 Kia Sorento

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.

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

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.

Paint De lamination on Snow White Pearl due to manufacturing defect Date listed was the date it started to peel. Started peeling around the window first. Then it continued on the front hood.

NHTSA ID

11755502

Incident

Dec 2, 2024

I parked my car and it was sitting for about an hour I came back to the car and heard a humming noise found that weird but I had to drive home about 10 mins later I parked car, sound was still going even while car was off. So I thought to let it sit for another while. Came back to car sound was still on I started car and the abs, traction, & brake light came on and not even 2 mins later my car starts smoking. So immediately I shut it off and have to leave my car parked in another city because I didn’t want to risk driving it home. Fast forward to next day. I got to my car and notice the speedometer had went out. i called Kia because I read about the HECU ABS recall. the service rep assured me my car would be covered so I pay a tow to get it towed to Kia dealer where they then tell me the recall had been repaired in a year that I didn’t even own the car and they refuse to look at it or fix without a fee. With this problem being a fire hazard and a manufacturing problem I should not have to come out of pocket for Kia mistake. I will be escalating this to corporate level.

NHTSA ID

11749754

Incident

Jul 8, 2026

My 2015 Kia Sorento is experiencing a catastrophic structural failure of the exhaust system where the front manifold catalytic converter has internally collapsed This is a severe safety hazard because the physical blockage of the exhaust flow creates massive engine backpressure stalling when trying to drive even a small hill on highway, risking sudden engine stalling, unprompted deceleration, and power loss at highway speeds, which increases the risk of a crash. Furthermore, the blocked exhaust gases generate extreme temperatures under the hoods if it's running hot presenting a distinct vehicle fire hazard. I have maintained this vehicle and had all previous safety campaigns addressed, including a complete engine replacement and the required engine control software updates. Despite these recalls being fully completed, the vehicle has still suffered this severe exhaust system failure. The Check Engine light was on, and diagnostic scanning shows fault code P2096.I thought it was my transmission but a professional dealer assessment confirmed a manifold catalytic converter," "contamination of honeycomb on front of rear catalytic converter," and severe "contamination on the O2 sensor."He could not fixed An oxygen sensor replaced had to be fixed by someone else Abrasive ceramic dust from the melting manifold structure is actively being drawn back into the engine cylinders, threatening to destroy the newly replaced engine that Kia replaced but . this failure mirrors the exact physical mechanics and safety risks outlined in Kia's previous safety campaign SC176 (NHTSA Campaign 19V-120). Despite experiencing the identical defect and safety threat on a fully updated vehicle, my VIN was excluded from the recall I am filing this complaint because this known safety defect poses an active threat to my safety.my husband was a 100% disable vet who passed in April 2025,I can'a afford to have this same item repaired that Kia suppose to have repaired,Please help me

NHTSA ID

11748406

Incident

Jun 5, 2026

My 2015 Kia Sorento is experiencing a catastrophic structural failure of the exhaust system where the front manifold catalytic converter has internally collapsed and broken apart. This is a severe safety hazard because the physical blockage of the exhaust flow creates massive engine backpressure, risking sudden engine stalling, unprompted deceleration, and power loss at highway speeds, which increases the risk of a crash. Furthermore, the blocked exhaust gases generate extreme temperatures under the hood, presenting a distinct vehicle fire hazard. I have proactively maintained this vehicle and had all previous safety campaigns addressed, including a complete engine replacement and the required engine control software updates. Despite these recalls being fully completed, the vehicle has still suffered this severe exhaust system failure. The Check Engine light was on, and diagnostic scanning shows fault code P2096. A professional dealer assessment confirmed a "collapsing manifold catalytic converter," "contamination of honeycomb on front of rear catalytic converter," and severe "contamination on the O2 sensor." An oxygen sensor replaced in December 2025 has already been destroyed by the upstream ceramic debris. Abrasive ceramic dust from the melting manifold structure is actively being drawn back into the engine cylinders, threatening to destroy the newly replaced engine. This failure mirrors the exact physical mechanics and safety risks outlined in Kia's previous safety campaign SC176 (NHTSA Campaign 19V-120). Despite experiencing the identical defect and safety threat on a fully updated vehicle, my VIN was excluded from that specific campaign, and Kia corporate has flatly denied goodwill assistance. I am filing this complaint because this known safety defect poses an active threat to vehicle control and occupant safety. I've attached the current repair assessment, and can provide the assessment of the previous replacement of the O2 sensor when warranted.

NHTSA ID

11746475

Incident

Jun 1, 2026

2015 Kia Sorento fire on the 7th I was drive lost brakes and steering and as soon as I stop to get out to check the whole truck went up in flames

NHTSA ID

11744083

Incident

Jun 7, 2026

I am filing a safety complaint regarding a Kia vehicle I purchased from CarMax Waldorf approximately 3 months ago. The vehicle has developed a strong gasoline/fuel odor that is consistent with a possible fuel leak. This creates a serious safety concern, including the risk of fire or explosion while driving or operating the vehicle. The issue began shortly after purchase and has continued. The vehicle is now unsafe to drive due to the strong fuel smell. When I contacted CarMax about the issue, I was instructed to take the vehicle to a Kia dealership instead of CarMax inspecting or addressing the safety concern themselves. I believe this is improper handling of a potentially dangerous defect in a recently sold vehicle. At this time: * Vehicle emits strong fuel/gas smell * Safety risk increases while driving * Vehicle has been in my possession for only 3 months * Issue appears to be early or pre-existing defect * I was redirected away from CarMax responsibility I am requesting that this safety issue be investigated as a potential fuel system defect and documented appropriately.

NHTSA ID

11743877

Incident

Jun 5, 2026

While driving on interstate 380 south,with cruise on ,my engine failed with loud knocikng, Ihad two tractor trailors behind me ,i was lucky to get off road onto side of shoulder this was on May 5,2026. this was the second 2.4 liter theta 2 motor in my sorento, first motor failed at 58.000 miles, second motor failed at 138,000miles. auto was taken to kia dealership in Blakely ,Pa. a NEW MOTER HAS BEEN INST.ALLED UNDER WAURENTEE.MY ENGINE HAS THE KNOICK SENSOR AND SOFTWARE INSTALLED

NHTSA ID

11741434

Incident

May 5, 2026

I am filing a safety complaint regarding a 2015 Kia Sorento equipped with the 2.4L Theta II engine. The vehicle developed progressive engine knock, reduced power, and check engine warnings while driving. Diagnostic trouble codes include P0017, P0014, and P0340 relating to crankshaft/camshaft timing correlation and camshaft position faults. A Kia dealership performed diagnostic testing using Kia diagnostic equipment (KDS) and documented abnormal knock activity across all cylinders. The dealer repair order specifically states: * “Found data PIDs for additional knock noise” * “All registering knock on all cylinders” * “Recommend replacement of engine sub assy based on knock detection” The vehicle experiences engine knocking and loss of power that create concern for sudden engine failure or stalling while driving, which could increase crash risk. This complaint is being submitted because the symptoms appear consistent with the known Theta II engine defect involving connecting rod bearing failure, engine knock, seizure, and potential engine failure.

NHTSA ID

11738617

Incident

Aug 4, 2025

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - 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 to install a Theft Deterrent Ignition Cylinder Protector on certain 2010-2022MY Kia vehicles outlined on page 20, which may not have been equipped with an immobilizer and whose Integrated Body Control Unit (IBU) / Body Control Module (BCM) did receive the Anti-Theft Software Logic upgrade under CS2301/02/03/04/05/06/07/08/09 TSBs. In an effort to help prevent thefts of Kia vehicles, a protective cover will be permanently affixed to the ignition cylinder. This Theft Deterrent Ignition Cylinder Protector prevents the removal of the key lock cylinder thereby preventing access to the ignition tumbler.

TECHNICAL SERVICE BULLETIN: WARRANTY EXTENSION CAMPAIGN: OIL PRESSURE SWITCH (OPS) REPLACEMENT (WTY026 REVISION 2) - 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 replacement of the Oil Pressure Switch associated with the ‘Warranty Extension Program’ (WTY026) on some 2014-2018MY vehicles listed in the table below, for repairs that may be necessary to address an Oil Pressure Switch leak in the eligible vehicles listed below from 10 years/100,000 miles to 15 years/150,000 miles, whichever comes first, starting from the date the vehicle was first put into service. This warranty extension is to address the Oil Pressure Switch leaking condition at no cost to the customers during this extended warranty period.

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - 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 to install a Theft Deterrent Ignition Cylinder Protector on certain 2010-2022MY Kia vehicles outlined on page 20, which may not have been equipped with an immobilizer and whole Integrated Body control Unit (IBU) / Body Control Module (BCM) did receive the Ant-Theft Software Logic upgrade under CS2301/02/03/04/05/06/07/08/09 TSBs. In an effort to help prevent thefts of Kia vehicles, a protective cover will be permanently affixed to the ignition cylinder. This Theft Deterrent Ignition Cylinder Protector prevents the removal of the key lock cylinder thereby preventing access to the ignition tumbler.

TECHNICAL SERVICE BULLETIN: ENGINE SUB ASSEMBLY INSPECTION/REPLACEMENT (WTY039 - REVISION 7) - 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 associated with the ‘Warranty Extension Program’ (WTY039) to diagnose a coolant leak from the cylinder head gasket area and, if necessary, replace the engine sub assembly on 2014-2015 MY Sorento, 2014-2017 MY Cadenza, and 2015-2016 MY Sedona vehicles, equipped with 3.3L GDI engines. The warranty coverage for repairs related to the cylinder head gasket will be extended from 5 years / 60,000 miles to 15 years / 180,000 miles, whichever comes first, starting from the date the vehicle was first put into service.

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - This bulletin provides information to install a Theft Deterrent Ignition Cylinder Protector on certain 2010-2022MY Kia vehicles outlined on page 19, which may not have been equipped with an immobilizer and whose Integrated Body Control Unit (IBU) / Body Control Module (BCM) did receive the Anti-Theft Software Logic upgrade under CS2301/02/03/04/05/06/07/08/09 TSBs. In an effort to help prevent thefts of Kia vehicles, a protective cover will be permanently affixed to the ignition cylinder. This Theft Deterrent Ignition Cylinder Protector prevents the removal of the key lock cylinder thereby preventing access to the ignition tumbler.

CUSTOMER SATISFACTION CAMPAIGN: OWNER NOTIFICATION (CS2312) - This document is the owner notification advising that Kia is conducting Customer Satisfaction Campaign. A software upgrade that addresses the social media theft method has been made available to owners of eligible Kia model vehicles free of charge at authorized Kia dealers since 2023. In addition to the anti-theft software, a new zinc-reinforced ignition cylinder protector hardware upgrade has been developed and can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Because the subject Kia vehicles were not factory-equipped with an engine immobilizer and were previously eligible for the software upgrade, these vehicles are eligible until March 31, 2027, to have the ignition cylinder protector installed—if requested—at no cost through an authorized Kia dealership. (Mailing of these notifications to vehicle owners will be completed from December 17, 2025 through February 27, 2026)