2017 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

I am writing to escalate an unresolved issue regarding a Voluntary Emissions Service Campaign performed on my vehicle at Bulldog Kia on July 14, 2026. Shortly after leaving the dealership, my Check Engine Light illuminated. An independent mechanic scanned the vehicle and confirmed that the active fault code directly relates to the components/logic altered during the corporate emissions campaign. I have called the dealership multiple times over the last few weeks and left voicemails for two different service representatives, but my calls are being ignored. I also contacted Kia corporate customer service who responded saying that they could not do anything and that I needed to continue contacting the local dealership (Bulldog Kia). From what I understand this could be a safety issue because it prevents me from being alerted to other safety issues that would trigger the check engine light, and there are also ways in which this could potentially cause the vehicle to slow way down or stop running while driving. As noted above the dealer has been unresponsive to my repeated contact attempts and the check engine light remains illuminated.

NHTSA ID

11755257

Incident

Jul 14, 2026

My high beams and low beams are starting to shut off randomly while driving. They are burning out weekly and having to be replaced. 1 of my tail lights is doing the same exact thing. I replace it. It works for a couple weeks and then goes out. When the headlights shut off my dash shows that i am trying to turn my headlights from auto to another setting, which is not the case. It has happened at night multiple times and that poses a danger because i cant see the road and people cant see my car. I have not had it looked at yet. I do see multiple complaints online for multiple different kia models and years. There is no recall and i do not see a TSB. Just curious with so many issues seen online why anything has not be accomplished or a recall available.

NHTSA ID

11754259

Incident

Jul 31, 2026

Fuel injectors become unseated randomly causing gas to be sprayed inside engine compartment. Issue can be seen upon request. This issue could cause a fire/explosion as fuel sprays out. The issue was repaired once by an Independent shop, then the issue reoccurred and has now reoccurred again. The issue fails randomly and fully with the symptom being the vehicle not wanting to start.

NHTSA ID

11754172

Incident

Jul 15, 2026

2017 Kia Sorento 2.4L GDI engine seized due to connecting rod bearing failure confirmed by P1326 diagnostic code multiple times. Vehicle entered limp mode limiting RPMs to 1800-2000 exactly as described in PI1802 campaign. Engine subsequently fully seized. Battery tested 98% healthy ruling out electrical cause. Vehicle towed to [XXX] Kia Avon Indiana. Kia Techline and Consumer Affairs denied PI1802 lifetime warranty claim citing used vehicle reconditioning despite PI1802 explicitly stating coverage applies to both new AND used vehicle owners per official Kia corporate document dated XXX. Consumer Affairs appeal case XXX opened but Kia states no further appeals possible. Kia is wrongfully denying lifetime warranty coverage guaranteed under PI1802 Product Improvement Campaign. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11754083

Incident

Jun 12, 2026

The contact owns a 2017 Kia Sorento. The contact stated that while seated inside the vehicle with three other occupants and the engine turned off, there was black smoke quickly coming from underneath the hood. The contact and the passengers exited the vehicle. The contact stated that a fire had started in the engine bay on the passenger’s side of the vehicle and another vehicle was damaged in the fire. The fire was extinguished by the Fire Department. The contact stated that a Police report was filed. The contact believed that the vehicle was destroyed, but the insurance company had not yet deemed the vehicle a total loss. There were no injuries sustained. The dealer was not notified of the failure. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 138,000.

NHTSA ID

11753979

Incident

Jul 26, 2026

Mileage

138,000 mi

My 2017 Sorento has sticky/notchy steering. When trying to move the steering wheel, it initially sticks and requires extra force to get it to provide a steering input. Once it gets past the initial resistance, it jerks the car in the direction you are trying to go which required compensation in the other direction. Upon correction, it jerks the car in the opposite direction causing a continual need to correct the steering wheel to keep the car straight and causing the car to not be able to maintain perfectly straight travel. On large sweeping corners, this problem is even more pronounced and feels dangerous. The sticking issue can be felt while stationary and in motion.I am constantly correcting, left to right to keep it straight. I cannot hold the wheel in one position for any length of time. Went to a KIA dealership and they said it needed the steering rack replaced. Others have reported this issue since the Sorento released this series in 2016 for higher trims (SX, SXL). KIA closed my case without notice. Reopened today. A person on kia Forms had to have there rack replaced at 65k miles to correct issue. Asking for a class action against KIA if they refuse to fix this ongoing safety issue they constantly deny. Dealership said this is not the first time this has been replaced for others. KIA needs to own this RECALL!!!

NHTSA ID

11753754

Incident

Jan 8, 2026

My 2017 Kia Sorento experienced a catastrophic, sudden engine lockup on the roadway due to a known manufacturing defect involving rod bearing failure. This defect caused complete loss of motive power and stalled the vehicle on the road, creating an extreme safety hazard for myself, my passengers, and surrounding motorists.Prior to the failure, the vehicle heavily consumed its own motor oil at a dangerous rate of nearly 5 quarts every 1,000 miles. I repeatedly attempted to address this with Kia, completing three separate official oil consumption and combustion tests. The vehicle failed all three tests. Despite documented failures of these critical safety components, Kia Corporate and the local dealership, court Kia, issued bad-faith warranty denials. As a direct result, I was forced to drive a dangerously unstable vehicle for 8,148 additional miles until the engine permanently and violently seized on the road.After being towed, the engine was confirmed to be completely locked up. My husband subsequently dropped the engine's oil pan and discovered a pieces of physical rod bearing debris and pieces of a snapped timing chain floating inside. The vehicle had full engine oil at the time of failure, as we were constantly topping it off to counteract the severe consumption defect.Manufacturer and Dealer Misconduct / Safety Cover-Up:The servicing dealer, Regal Kia, and Kia Corporate Case Manager Jennifer (who previously denied the vehicle after the consumption test failures) have actively colluded to falsify safety records to escape their lifetime warranty obligations under the federal engine class action settlement.The dealership deliberately withheld the vehicle's diagnostic trouble codes (specifically camshaft codes triggered when the timing chain snapped), falsely telling Kia Corporate that "no codes" existed. They fabricated a false history, claiming I stated the vehicle "stalled and the oil light flickered" prior to arrival, despite the vehicle being towed in with a p

NHTSA ID

11753403

Incident

Apr 30, 2026

On XXX, the oil warning light was illuminated in our 2017 Kia Sorento SXL and that the vehicle was leaking oil. We brought the vehicle to an independent repair facility (Tire Kingdom, Cairo, NY) for diagnosis on XXX. The repair facility provided an oral assessment with photographs indicating a suspected rear main seal leak. The engine was dry on the top but excessively wet between the engine and transmission, consistent with a significant oil leak in that area. We were advised that the vehicle could be driven in short intervals of approximately 25 minutes, provided that oil levels were closely monitored and topped off as needed. On XXX, we began driving the vehicle to transport our daughter to a train station 25 minutes away. Halfway through the trip, the vehicle began producing a metallic noise from the engine compartment. We immediately pulled over safely and turned off the engine. After stopping, we discussed next steps and then attempted to restart the vehicle. The engine started but immediately produced a severe mechanical rattling noise. It was shut off within approximately one second of startup. The vehicle was not driven further. The vehicle was then towed to Romeo Kia in [XXX]. Kia performed a diagnostic assessment and determined that the engine required complete replacement, with an estimated repair cost of approximately $10,000. This vehicle previously had a remanufactured engine installed in 2023 following a prior catastrophic engine failure. Between installations, the vehicle was maintained in normal service and was not overdue for scheduled oil changes at the time of this incident (27 days to go). At no point prior to the failure event was there clear indication of immediate catastrophic engine failure beyond the initial oil warning and leak condition. The failure progressed from a diagnosed external oil leak to immediate mechanical failure upon restart, requiring towing and full engine replacement. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11748442

Incident

Jun 28, 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.