What 746 owners told NHTSA about the 2015 Kia Sorento Plug-in Hybrid

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

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

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

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

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

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

The contact owns a 2015 Kia Sorento. The contact received notification of NHTSA Campaign Number: 21V331000 (SERVICE BRAKES, HYDRAULIC). The contact stated that while driving at 50 MPH, the vehicle failed to accelerate as intended while depressing the accelerator pedal, and the engine seized. The contact was able to coast to the side of the road, and the vehicle failed to restart. Several unknown warning lights were illuminated. The contact stated that prior to the failure, the vehicle was consuming an excessive amount of engine oil. The vehicle was towed to the residence. A mobile mechanic arrived at the residence to inspect the vehicle and removed the serpentine belt, but was unable to crank the engine. However, no cause for the failure was found. The dealer was contacted, and the contact was informed that, as per the manufacturer, proof of all oil changes performed on the vehicle was needed since the vehicle was purchased, and if the proof was not provided, the vehicle would not be repaired under the recall. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 134,000.

NHTSA ODI 11695233

Faulty motor I have changed oil early every time and every mechanic I’ve been to said the Kia motor is always doing this ! I still owe 9k on this car! It’s burning oil so fast and not going into the engine this is a on going issue with these motors ! I just now hit 100 k miles no reason for my motor to be blowing please put the recall back on for the 2015 Kia’s!!!

NHTSA ODI 11692891

Driving on highway and suddenly heard loud tapping/rattling sound from engine and then engine died resulting in total loss of power steering and acceleration. Was able to coast through an exit and into a parking lot. My entire family was in the vehicle and if we had not been able to coast to a safe spot we could have been involved in a high speed accident. Vehicle was towed to Kia dealership and they diagnosed it as connecting rod failure. No other inspections have been done. No warning lamps displayed before the incident occurred.

NHTSA ODI 11683599

I had catastrophic engine failure while driving with no warning lights indicating my engine was losing oil, the engine and power shut off at 55 miles and hour causing me to lose power steering and power assisted breaking.

NHTSA ODI 11681208

Car had a blown head gasket. Took it to my mechanic and upon inspection determined that the head bolts had stretched. My mechanic said that it was a common problem and service advisor at dealership also agreed it was a common problem. After a little research found a lot of complaints about this problem. Talked to KIA and was told no warranty or recall for this problem

NHTSA ODI 11679300

Cut off in middle of the interstate start smoking

NHTSA ODI 11678103

Engine started making rattling sounds during startup and when accelerating. Kia dealer said the engine failed and needed replaced. Repair cost were around $9000.00.

NHTSA ODI 11677266

Driving the 2015 Kia Sorento coming back from work The car overheated and complete engine failure check engine light with flashing

NHTSA ODI 11667814

What's driving home from work doing 65 mph postal speed limit car begin to overheat and then went in the complete engine failure engine light flashing

NHTSA ODI 11667815