2020 Kia Sorento

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.

The contact called on behalf of his daughter who owns 2020 Kia Sorento. The contact stated that the vehicle was taken to a dealer for a routine oil change when the contact was informed that there was an unknown issue with the vehicle however, the vehicle was not diagnosed or repaired. The vehicle was taken to a different dealer where it was diagnosed that the transmission fluid was leaking and the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was unknown.

NHTSA ID

11753507

Incident

Jul 27, 2026

Driving on highway at 65, traction control light, airbag light, parking light, bcw warning, all came in at the same time. I was able to pull off to the side and re start engine to clear the lights. As soon as I got up to 40 lights one by one flickered on until up to highway speed and then all flickered and dash dings. Two independent shops ran diagnostics and noted that only battery was dead. Replaced battery and the lights came back immediately.

NHTSA ID

11749809

Incident

Jul 12, 2026

The contact owns a 2020 Kia Sorento. The contact stated that while driving 30 MPH with her daughter and parents in the vehicle, an abnormal squeaking sound was heard emanating from the steering wheel. No warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed that the steering column needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, but the repair was delayed because the manufacturer required information from the dealer, while the dealer claimed to be waiting for a response from the manufacturer. The failure mileage was 19,000.

NHTSA ID

11749302

Incident

Jun 15, 2026

Mileage

19,000 mi

The vehicle suffered a sudden, severe engine malfunction/misfire while in operation, presenting a serious safety hazard on the road. Following the incident, the vehicle was taken to an authorized dealership service center (Repair Order #XXX), where technicians verbally confirmed that the engine requires a complete replacement due to internal mechanical failure. The catastrophic mechanical failure of the engine directly caused consequential damage to the emissions system, entirely clogging the catalytic converter with unburned fuel/debris. Despite the clear link to the known, systemic defects inherent to the Theta II engine line—which is subject to active federal consent orders, safety recalls, and lifetime warranty extensions—both the dealership and Kia Corporate are refusing to honor the 8-year/80,000-mile Federal Emissions Defect Warranty. The manufacturer is attempting to use the catastrophic failure of their own defective, recalled engine line to evade their legal environmental and safety warranty obligations, leaving the consumer stranded without alternative transportation. This represents a systemic effort by the manufacturer to deflect liability for documented powertrain safety failures onto individual consumers. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11741669

Incident

May 27, 2026

Engine is burning oil at a significant rate, when I get my oil changed at the dealers recommendation it is extremely low. I have to replace the oil regularly between oil changes, and there is an exhaust smell. Also lagging when I hit the gas.

NHTSA ID

11738870

Incident

May 19, 2026

Car is 6 years old less then 100k miles and losing oil and motor problems Went through entire oil change in 1 month Kia unable or willing to assist with any coats I was told by a private garage that the motor in my car should be part of a recall that was already listed for 2021 through 2026 but they’re saying it’s not covered

NHTSA ID

11738032

Incident

Mar 1, 2026

2020 Kia Sorento consuming 1.5 or more quarts of oil every 1,000 miles. Completing oil consumption testing with Kia dealer, which requires I take the car back to the dealer every 1k miles, times, so they can verify the oil levels. Last check, when issue was discovered, vehicle was down to only 1qt of oil after driving only 2k miles from previous oil change. Note: the lambda engine was initially included in the latest Kia class action settlement but was dismissed per the plaintiff’s attorney in that case. However there are numerous reports from a large number of 2020 Kia Sorento owners now with the same issue and running into complete roadblocks in terms of recourse as for most the issue does not begin until they exceed the powertrain warranty. Especially if they’re secondary owners and not the original owner.

NHTSA ID

11733852

Incident

Apr 1, 2026

Driver seatbelts randomly unlatches itself while operating vehicle.

NHTSA ID

11733472

Incident

Feb 1, 2026

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: 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.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER NOTIFICATION (SC340 FLIGHT 103 / UM) - This document is the owner notification advising that Kia is conducting a Voluntary Emissions Service Campaign to improve the emissions software logic in the Electronic Control Module (ECM) for certain 2016-2020 MY Sorento vehicles equipped with 2.4L Gas Direct Injection (GDI) engines to ensure compliance with emissions regulations.

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.