What 745 owners told NHTSA about the 2015 Kia Sorento Phev

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 ODI 11748406

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 ODI 11746475

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 ODI 11744083

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 ODI 11743877

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 ODI 11741434

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 ODI 11738617

I own a 2015 Kia Sorento with Snow White Pearl paint. The paint is prematurely peeling/delaminating from multiple areas of the vehicle despite normal maintenance and no accident damage. The vehicle was inspected by a Kia dealership, and I was informed that the condition appears to be a paint defect rather than normal wear and tear. The paint failure is occurring in a manner consistent with numerous complaints from other Kia owners involving Snow White Pearl paint adhesion failure. The peeling paint affects the appearance and value of the vehicle and continues to spread. In areas around the roofline/windshield pillars, exposed surfaces may also create long-term corrosion concerns and potential visibility/safety issues. Kia has acknowledged my complaint under Case #26008837 but has not agreed to repair the defect. I am submitting this complaint because this appears to be a widespread manufacturer paint defect affecting Kia vehicles with Snow White Pearl paint.

NHTSA ODI 11737792

The contact owns a 2015 Kia Sorento. The contact stated that while driving at undisclosed speeds, the vehicle hesitated to maintain automotive power. No warning lights were illuminated. The vehicle was taken to a local dealer, where it was diagnosed; however, the diagnostic result was not available. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 94,000.

NHTSA ODI 11734100

Shift arm gear stuck- unable to shift from park to drive to neutral, reverse, etc.

NHTSA ODI 11729177

I was driving with my son when my 2015 Kia Sorento stopped in traffic. I remember warning lights coming on my dash including the engine light, oil light and battery light. However, I was more concerned about getting my hazards on so we would not be hit by another car. Traffic was heavy, it was raining and getting dark. I needed to push my car off the road with the help of another driver. A Hyannis ambulance was a few cars behind me and the EMT's also assisted with the traffic and moving my vehicle out of the road. I called AAA and had my car towed. I was told in writing by the Kia dealership that the engine needed to be replaced. I was told verbally by Kia that it was a rod knock issue. When I asked how it was diagnosed with rod knock she said the mechanic put something down in the engine and said its rod knock. I requested through Kia corporate that the car be inspected for the WTY039 extended warranty and corporate said they would reach out to the dealer and ask that it be checked. I have not received any further communication from the dealership or Kia corporate. Yes the vehicle is available for inspection. Safety was an issue because the car stopped so suddenly in heavy traffic. I was not able to slowly decelerate or steer to the side of the road. I felt like a sitting duck. We were extremely lucky that we were not hit from behind at 35 mph resulting in injury to us and to the drivers behind us. Prior to this event there were no warning lights that had come on and no strange noises from the car. They first appeared when it stopped in traffic.

NHTSA ODI 11726057

Was driving vehicle and it began to run hot, check engine light came on then started to make a knocking sound when getting to 30-35 mph. Was inspected by a service center. There it was confirmed an issue with the motor/head gasket

NHTSA ODI 11725332

Eccessive oil consumpion. I related it to the dealir who did not want yo do anything about it. I present this problem yo the dealr beginning of 2024 and sid not wanted to do anything but instructed me yo gather my receipt and come back. By yhe time i pulle all my record 10 yaer of car maintenanxe iy took me yime and i was necer told yhat after 10 yers yhw warrant will expire and thw miles qhere noy valid anymore. I went by the miles knowing that i could do somwnthing about unyil 100,000 miles. When i went back to my dealer, the dealwr had cl9sed down so i yook yhe cae yo anoyher dealer and was yold couldnt do noti g and i should i called costumere caee. I have been calling molyiple yime but no cooperarion on their hand. Knowing yhat i went thwr early yo rwport thw issue thwy are srill noy taking reapo sability. I am reaxhing out for hwl as the car consume an eccessive amount it keep smelling brurning smell and oild needs to be added ever 1000 mile. Please guide me o. How to proceed 8184724019 if u need to reach me. Thanks for ur help in this matter.

NHTSA ODI 11725094

Dealer driving car 35mph. Check engine light started flashing. Burning plastic smell from under hood. Car cut off. Did not restart. Towed to mechanic, was told engine locked up.

NHTSA ODI 11724500

I’m tired of replacing my headlight bulbs every month!!! Both high and low beam go out all the time! It’s expensive. Also it is a safety concern. The low beams are dim to begin with and having one go out I have to drive with high beams on due to inability to see. I even upgraded bulbs in hopes of brightening but they also go out all the time.

NHTSA ODI 11724298

Subject: Broken Driver Seat Metal Rod – Safety Hazard in 2015 Kia Sorento To Whom It May Concern, I am writing to report a serious issue involving the driver’s seat in my 2015 Kia Sorento, specifically a broken metal rod inside the seat frame. This part appears to be part of the seat's internal adjustment mechanism and should not fail under normal use. Its failure presents a potential safety hazard. Vehicle Details: Make/Model: 2015 Kia Sorento VIN [XXX] 5 Registered Owner [XXX] m Address [XXX] 4 Email [XXX] m Part Label Information: Label reads: “4 Way Manual” Manufacturer: Johnson Controls, Inc. [XXX] MI The part appears to be a seat adjustment rod or structural component Attached is a photo showing the damaged part and label ️ Description of the Problem: While I was driving I hear a snap my seat then slid forward and I was telted to my left side I was going 65 on the freeway almost crashed into wall I discovered a broken metal rod inside the seat frame. This rod is clearly not meant to break under typical use and poses a risk of: Sudden seat movement while driving Decreased driver safety in the event of a crash Reduced structural integrity of the seat I believe this could be a design or manufacturing defect, and it warrants inspection. I am requesting that this issue be investigated and that I be informed if there are any recalls, extended warranties, or safety programs covering this defect. Attached: Photo of the damaged part and manufacturer label Please let me know how I should proceed. I am concerned about my safety and would like to ensure that others are not at risk from this same issue. Sincere [XXX] [XXX] com INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11722038

The contact owns a 2015 Kia Sorento. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated and remained illuminated. There was a knocking sound coming from the engine. The vehicle was towed the local dealer and was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. No further information was available. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 128,405.

NHTSA ODI 11721770

I was driving on the highway when I proceeded to the turn lane to turn left crossing two lanes of traffic and the vehicle just shut down no warning whatsoever no check engine lights no oil lights nothing and it wouldn’t turn back on when trying it but after about 5 times it turned on and I was able to get it off the highway but couldn’t go any further as the vehicle was making a loud noise and the car was shaking

NHTSA ODI 11720469

The contact owns a 2015 Kia Sorento. The contact stated that while driving approximately 40-45 MPH, the vehicle stalled. There was no warning light illuminated. The vehicle was pulled over to the side of the road. The contact attempted to restart the vehicle, but the engine made abnormal knocking sounds. The vehicle was towed to the residence and failed to restart. A mobile technician diagnosed the vehicle with engine failure. The vehicle was not repaired. The dealer and the manufacturer were not contacted. The failure mileage was 98,954.

NHTSA ODI 11717647

I am filing this complaint regarding a suspected safety defect involving the Theta II engine in my 2015 Kia Sorento. The vehicle developed progressive engine failure symptoms including: Engine knocking and abnormal mechanical noise Loss of power while driving Misfire conditions Excessive oil consumption Progressive deterioration of engine performance These symptoms began at approximately 150,000 miles and worsened over time. Given the documented history of Theta II engine failures involving rod bearing defects, sudden engine seizure, loss of power, and fire risk, I believe my vehicle is experiencing a progression of the same known defect. 2) Safety Risk to Driver and Public The engine condition created serious safety risks, including: Potential sudden engine failure while driving Loss of power in traffic or at highway speeds Increased risk of collision Potential fire hazard associated with Theta II engine failures Despite these risks, Kia and its authorized dealership advised me to continue operating the vehicle. I was explicitly told to “drive it until it fails.” This guidance was given despite Kia’s documented knowledge of Theta II engine defects and associated safety hazards. 3) Manufacturer Response and Denial I reported the engine failure to Kia and its authorized dealership. Kia denied coverage, stating: The vehicle had “too many miles,” and The failure was allegedly “not rod bearing related.” However, Kia and the dealership refused to provide: Complete diagnostic trouble codes (DTCs) Technician notes or inspection reports Compression or leak-down test results Oil analysis or evidence proving bearing failure was ruled out Without this information, Kia’s conclusion that the failure is not related to the Theta II defect is unsupported and unverifiable. 4) Concern of Misdiagnosis and Defect Misclassification Based on the symptoms and known Theta II failure patterns, I believe Kia may be misclassifying a progressive bearing-related engine failure as a non-covered

NHTSA ODI 11716580

Formal Complaint on Seized Headlight Sockets and Kia’s Obstruction of Essential Safety Maintenance 1. Incident & Discovery of Defect: I am the owner of a 2015 Kia Sorento. Recently, one of my headlights failed. Upon attempting a routine bulb replacement, I discovered a critical hardware defect: the bulb socket is physically seized. It cannot be rotated or removed by any standard manual force. This is not a simple wear-and-tear issue; it is a mechanical seizure of a component that must remain accessible for safety maintenance. 2. Kia’s Refusal of Technical Guidance: To resolve this without damaging the entire assembly, I contacted Kia America (Case #[XXX]) specifically requesting technical instructions or any written explanations to safely disengage the seized unit. Despite multiple attempts via phone and email, Kia explicitly refused to provide any technical guidance, flatly stating they are "not technically trained" or authorized to share such information. 3. Obstruction of "Right to Repair" & Safety Risk: I firmly believe that a vehicle owner has a fundamental "Right to Repair," especially for essential safety components like headlights. By withholding basic maintenance instructions, Kia is intentionally obstructing my ability to maintain a street-legal, safe vehicle. Driving with a non-functional headlight is a Critical Safety Hazard that severely impairs visibility and creates an immediate risk of fatal accidents—yet Kia has chosen to leave me in this dangerous situation. 4. Exploitative Business Practice & Systemic Failure: This appears to be a deliberate and Exploitative Business Practice. By failing to provide a manual and refusing technical support for a defective, seized part, Kia is effectively forcing consumers into a "forced monopoly" where we must pay for expensive replacements at authorized dealerships for what should be a low-cost, simple bulb change. 5. Request for Investigation: I request that the NHTSA initiate a formal investigation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11715653

- I was driving down 55 mph. on dark, busy highway in Sarasota, Florida (Fruitville Rd.) at approximately 6:15 a.m. on Friday, January 23, 2025. - Suddenly, without warning, the sidewall of the rear passenger side tire completely blew out in a perfect circle around the entire outside of edge. - The tire is currently available for inspection. - The Goodyear dealer claims that the blowout was caused due to underinflation. However, the tread pattern of the tire shows no signs of underinflation. - Since this is my wife's car, I check the tire pressure every other Sunday evening knowing that she'll be driving it to work the next day. - Had there been heavier traffic, the blow out could have caused a major accident if someone was following closely behind me. - The car's TPMS sensors weren't illuminated to indicate there was any low tire pressure.

NHTSA ODI 11714505

Yes there was a recall in a module control panel which still is messed up. It’s been replaced a couple x. Also the dim lights since I bought the car have a very low light were you can hardly see at night. And this SUV drinks gas on long/short trips. I’ve taken it in several times but they keep saying nothing’s wrong and I know there is I have driven my boyfriend vehicle which is a V6 and went the same exact distance and didn’t have to get any fuel until I was about half way back. Something has to give. I love my Kia as I have owned 2. But something is really wrong. Please help. Thanks

NHTSA ODI 11713407

The low beam headlights do not illuminate the highway sufficiently to drive safely. I lowered the aim of my high beam to be able to drive at night and not blind approaching drivers. This is unacceptable for a modern vehicle to be permitted to be sold in this condition.

NHTSA ODI 11712657

I was driving down a very busy road and with no warning my car lost power. It would turn over but not start back up. I was stuck in the middle of a busy road way causing traffic’s to back up. I had to call the police to sit behind me so I wouldn’t get hit from behind.

NHTSA ODI 11710713

My vehicle has a slow speed pick up and I’m getting code p0018 and has very rough idling !

NHTSA ODI 11698466