2016 Kia Sorento

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

Hard shifting and kia said I need a new transmission, 99,500 miles

NHTSA ID

11766727

Incident

Sep 2, 2026

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.

NHTSA ID

11765637

Incident

Sep 16, 2026

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.

NHTSA ID

11762893

Incident

Apr 14, 2026

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)

NHTSA ID

11762746

Incident

Aug 30, 2026

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)

NHTSA ID

11761133

Incident

Jul 10, 2026

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.

NHTSA ID

11759097

Incident

Apr 8, 2026

See attached document for complaint.

NHTSA ID

11758158

Incident

May 27, 2026

Mileage

215,640 mi

THE PAINT ISCOMING OFF AND DON'T STICK TO THE VEHICLE. I NEED KIA TO PAINT THIS CAR ASAP

NHTSA ID

11758147

Incident

Aug 20, 2026

TECHNICAL SERVICE BULLETIN: WARRANTY EXTENSION CAMPAIGN: MULTIFUNCTION SWITCH REPAIR (WTY031) - 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 ‘Multifunction Switch Warranty Extension Program’ (WTY031) to repair the multifunction switch knob on 2016-2018MY Sorento (UMa) vehicles, produced at Kia Georgia from October 27, 2014 through March 7, 2018, which may exhibit an intermittent headlamp flickering. The vehicle’s warranty for this issue will be extended from 5 years/60,000 miles to 15 years/150,000 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 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.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: THETA II 2.4L GDI EMISSIONS: ECM LOGIC IMPROVEMENT (SC340 REVISION 5) - 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 upgrade the Electronic Control Module ‘ECM’ system software for certain 2016-2020MY Optima, 2016-2020MY Sorento, 2017-2022MY Sportage vehicles equipped with 2.4L Theta II engines listed in the table below. Kia has become aware that certain 2016-2022MY vehicles equipped with 2.4L Theta II engines may have engine calibrations that were not optimized for emissions standards under certain specific conditions. These calibrations may cause the vehicle to release air pollutants which exceed Federal and California standards. These standards were established to protect your health and welfare from the dangers of air pollution.

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: VOLUNTARY EMISSIONS SERVICE CAMPAIGN: THETA II 2.4L GDI EMISSION SECM LOGIC IMPROVEMENT (SC340 REV 4) - 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 upgrade the Electronic Control Module ‘ECM’ system software for certain 2016-2022MY vehicles equipped with 2.4L Theta II engines listed in the table below. Kia has become aware that certain 2016-2022MY vehicles equipped with 2.4L Theta II engines may have engine calibrations that were not optimized for emissions standards under certain specific conditions. These calibrations may cause the vehicle to release air pollutants which exceed Federal and California standards. These standards were established to protect your health and welfare from the dangers of air pollution.

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.