What 1,237 owners told NHTSA about the 2016 Kia Sorento Plug-in Hybrid

The contact owns a 2016 Kia Sorento. The contact stated that while driving at 50 MPH and depressing the accelerator pedal, the vehicle speed decreased. The contact was able to pull into a parking lot safely. The contact attempted to restart the vehicle, but the vehicle failed to restart as intended. An independent mechanic and a dealer were contacted. The vehicle was towed to the dealer, where it was diagnosed that the engine starter needed to be replaced. The vehicle was then towed to an independent mechanic, where it was diagnosed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 83,000.

NHTSA ODI 11708052

The vehicle is a 2016 Kia Sorento equipped with a 2.0L Turbo Theta II engine subject to the KSDS (Knock Sensor Detection System) safety recall. The original engine was replaced at approximately 70,000 miles under Kia’s engine service program. The replacement engine currently has approximately 32,000 miles. The vehicle developed internal engine damage diagnosed by a Kia dealership as a burnt exhaust valve. A burnt exhaust valve indicates abnormal combustion conditions such as lean operation, pre-ignition, detonation, timing deviation, injector malfunction, or lubrication failure. These are conditions the KSDS recall was intended to detect and mitigate. Kia Consumer Affairs denied warranty coverage, stating that the extended warranty applies only to rod bearing failure and that no further escalation would be pursued. Kia Consumer Affairs declined to escalate the matter for District Parts & Service Manager review and directed the owner back to the dealership. During the prior engine replacement, the dipstick was observed to be glued in place, raising concerns regarding oil level accuracy and lubrication integrity on the replacement engine. This complaint is submitted due to concern that a KSDS safety recall-related engine failure involving abnormal combustion was not properly reviewed or escalated, and that recall procedures were not administered in accordance with their intent.

NHTSA ODI 11706961

Paint is bubbling and peeling off. Been to the dealership and they don’t seem to want to help. I have an extended warranty on the paint until 12/29/2025. They’re giving me the runaround.

NHTSA ODI 11706642

Engine suddenly started making a lot of clattering noise. Oil consumption has been extremely high! Mechanic stated engine needs replaced.

NHTSA ODI 11705186

Vehicle: 2016 Kia Sorento, VIN [XXX] Incident Date: November 13, 2025 Incident Location: Durham, NC (3828 Guess Rd) Cause of Loss: Engine Fire, confirmed by Durham Fire Department Report (Incident #253663) as "originated from under the hood." TECHNICAL NARRATIVE & SYMPTOMS (CRITICAL FOR LIABILITY): I am filing this complaint to report a catastrophic vehicle fire that I believe is directly linked to multiple acknowledged manufacturing defects that create a fire risk in Kia vehicles. ABS/Traction Control Light Warning (Direct Fire Risk Symptom): Immediately prior to the loss, the ABS and Traction Control warning lights were constantly illuminated. This is a known precursor symptom for the defective Hydraulic Electronic Control Unit (HECU) or ABS Module short-circuit, which has been cited in numerous Kia fire recalls (e.g., NHTSA 20V019, 20V519). The fire's origin under the hood is consistent with this component failure. Prior Engine Failures (Systemic Defect History): This vehicle has a history of catastrophic manufacturing defects: The engine assembly was replaced in 2023 due to the known Theta II Rod Bearing Failure. The knock sensor was replaced in September 2025 as part of the KSDS Product Improvement Campaign, demonstrating the vehicle was still under active service for critical engine monitoring defects just weeks before the fire. Potential Tow Hitch Wiring Fire Risk: The vehicle was fully engulfed, but the fire may also be linked to the defect cited in NHTSA Recall 22V703 (tow hitch wiring harness short circuit, which also poses a fire risk). I require a full investigation into this defect leading to compensation for the total loss of the vehicle and consequential damages. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11703758

The safety hazard began with a pattern of ignored warnings by the authorized dealer network. On Aug 15, 2025, I brought the vehicle to Luther Kia of Bloomington for a Check Engine Light. The dealer simply cleared the code without diagnosis, failing to catch early signs of engine trouble. On Sept 22, 2025, the engine failed again. I drove the vehicle in unsafe "limp mode" to Luther Nissan Kia [XXX] ). They found the engine was "4 quarts low on oil" (severe starvation just 37 days after a dealer oil change). Despite this catastrophic finding, they failed to diagnose the root cause and released the unsafe vehicle to me after selling only a spark plug replacement. On Sept 26, when I attempted to pick up the vehicle, the Check Engine Light was flashing immediately at handover. I refused to take the unsafe vehicle. The dealer then replaced an Oil Control Valve (OCV) and released the vehicle to me again later that day. After this second "repair," I drove the vehicle for only a few miles before the engine failed again with a Check Engine Light. The dealer has since admitted in writing (BBB complaint #XXX) that the engine was "deprived of lubrication" due to the initial low oil condition. By ignoring early warnings and releasing a vehicle with a dying engine twice, the dealer put me and other motorists at risk of a sudden loss of power at highway speeds. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11703833

For about 23,000 miles our mechanic has mentioned that the engine is burning oil. The exhaust pipe is covered in black soot. I monitor the oil level and it is always low even after oil changes with no oil leak. This has been provided to Kia with no remedy. Recently our Sorento was in a busy highway and the check engine, oil and battery lights came on and the car went into limp mode. We had the vehicle towed to Kia Chula Vista and the engine will be replaced by them. My concern is that the catalytic converter will soon fail and the engine issues need to be addressed for all of these makes/models before someone gets seriously hurt or killed.

NHTSA ODI 11703858

The top padded dash of the instrument panel and the lower crash panel of the instrument panel, which the mechanic identified, have been developing cracks since the car was three years old. I made 3 calls to corporate customer service after the dealership said that the warranty had expired. I was told by the manufacturer that as long as I did not get hurt or cause an accident that they could not do anything about replacing the parts. Since then, numerous additional cracks have developed in the padding, showing deep cracks through the padding to the surface below. The airbags are in the area of the damage. I tried many times to submit photos and a statement from the mechanic who was assigned to my car at the dealership, but each time it failed to load the 8 pictures on this form. If you would like, I could mail them to you if you give me the mailing information. I feel that in time, the pieces will become loose while driving the car and cause a distraction, or the airbags could fail. Thank You, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11703497

The car was running as normal and then randomly it started kind of rough and seemed like maybe just cold. But I had my mechanic take a look, and he said that when he started it, which was the next day that it made a loud knocking sound upon start. On the 30th I had it towed out to West Hills Kia in Bremerton. And they reported back that the engine needed full repair. I only owned this car one year and before me it was reportedly well maintained. I maintained it well also! Kia is denying all recall, but it’s a 2016 Kia sorento. It’s within the one or two years that the recall doesn’t cover??? The brake lights also work and always one of them is not working. It is not exclusively one or the other but the bulbs keep burning out. I need to know what to do to get this engine fixed, and it should fall under the bad engines that Kia’s have!

NHTSA ODI 11703351

Engine failed. Took car to Johnson City Kia dealership as advised by Kia of north America. The dealership said the engine failed due to carbon build up which is a problem with the engines, that it was not covered under warranty. I paid over $6,400 to have the engine replaced. When I was driving the car home the engine light came on and I lost power on the interstate causing me to almost get hit by a semi-truck. I took the car back to Kia of Johnson City Tn. the next day. Kia stated that the high-pressure fuel pump had went bad from the time I left the dealership and got home. I paid over $1,350 to replace a High-Pressure Fuel Pump. On the way home engine light and loss of power. I returned to Kia. They stated that gas had gotten into my oil. They changed the oil and I headed home, same issue engine light and loss of power. I told Kia of Johnson City I wanted a refund, and they could put the old part back on. Kia of Johnson City told me to take the car to another dealership that I was not getting a refund, and they would not fix my car. The engine codes and problems were the same as when I picked the car up from Kia. I have tried twice to have Kia of North America buy the car back due to it not being fixed and I do not feel safe in the car. I have taken the car to a Hyundai dealership in Johnson City Tn. and asked them to check the engine code and loss of power. Another $223.05. They stated the high-pressure fuel pump was defective. Fixing same issue multiple times.

NHTSA ODI 11702388

Lost motor power while driving. No warning light before engine failure.

NHTSA ODI 11701987

Mixing coolant with oil engine failure

NHTSA ODI 11699518

My 2016 KIA SORRENTO consumed all oil resulting in engine (3.3L Lambda II) failure within 72 days (3,442 miles driven) of Kia dealer service department complete inspection and service (including oil).

NHTSA ODI 11699308

Around 140k miles the engine started to randomly overheat. We changed the serpentine belt as well as all hoses. The engine then started to burn large quantities of oil. At 142k miles it failed all together and we are now looking at having to purchase a new engine or a new vehicle. After doing some research I read that this was a common issue with the 3.3L V6 Motors and felt the need to provide my case as well.

NHTSA ODI 11697525

Over heating , loss of heat in the vehicle , oil in the radiator fluid so possibly a bad head gasket car has 121000 on it

NHTSA ODI 11696496

The contact owns a 2016 Kia Sorento. The contact stated that the dashboard was cracked in the shape of an air bag on both the left and right sides, causing concerns about a potential inadvertent air bag deployment. There were no warning lights illuminated. The vehicle was taken to a local dealer, who confirmed that the crack was cosmetic and advised the contact to reach out again if the air bag started to protrude through the crack. The vehicle was not repaired. The contact reached out to the manufacturer and provided photos, but received no assistance. The approximate failure mileage was 86,711.

NHTSA ODI 11694941

My 2016 Kia Sorento SX AWD shows a noticeable delay in the powertrain when shifting from Park into first gear. The car hesitates before moving, which affects drivability and feels like a transmission lag. I consider this a safety issue because the delay could cause the car to stall unexpectedly. I’m especially worried about driving with my children or merging onto highways, where a stall or hesitation could lead to loss of control and increase the risk of an accident.

NHTSA ODI 11693520

The engine failed. Had a new engine put in the car. Driving the car home the car lost power on the interstate causing me to almost get hit by a semi trailer. Called Kia Dealership and was told to bring car back. They said it had a bad high pressure fuel pump. I had it replaced, same issue. They said they would not fix the engine to take it somewhere else. Called Kia of north America to report the safety issue and I didn't feel safe driving the car. I wanted the car to be bought back. They denied it and would not honor the warranty. They said i could not file a lawsuit against them? Engine is bad. I sent a written statement to Kia of American with all paperwork notarized.

NHTSA ODI 11693009

Loss oil in big quantities headed to engine damage

NHTSA ODI 11693143

We have a 2016 Kia Sorento that has the Snow White Pearl paint. Our vehicle has a tad over 100k miles and the paint is peeling. We take care of our car and always have it clean and do not understand why this is happening. Paint is flaking / peeling off in large amounts exposing the primer underneath. I had a body shop look at it and they say it looks like something went wrong with the painting process when vehicle was made. I have a 1997 ford ranger that has 280k miles on it without this issue so I do not believe that this is a mileage / age issue. I did reach out to kia but had no luck with this problem. Thank you so much for your time and any help is greatly appreciated.

NHTSA ODI 11691002

While driving the vehicle started making loud engine noises. Contacted the extended warranty department and got the car in the shop. The engine had blown and had metal in the oil pan and oil filter. The car had a fresh oil change and showed to have a clean maintenance history. Just purchased the car a month prior. Warranty covered the replacement of the motor.

NHTSA ODI 11689313

The intake valve cam Engine Variable Valve Timing (VVT) Sprocket pin wasn't properly seated in the phaser and worked its way out. Additionally, the corresponding hole in the camshaft was machined too deep, allowing the pin to completely depart the phaser and move into the camshaft. This resulted in no control over valve timing and the Bank 2 camshaft over-advancing the intake valves to 63 degrees from standard. This is under-engineering of critical engine parts and poor quality control by Kia. It caused the engine to go into "limp home mode" with a significant reduction in power and a flashing check engine light. Had this happened towing a trailer, or in poor driving conditions, the vehicle may have been difficult to control and put occupants in danger. The pin was found completely inside the camshaft. There seems to be low quality engineering with this manufacturer, as there are many reports of these known problems.

NHTSA ODI 11689528

I am receiving an engine problem on uvo. I took it to autozone to run a diagnostic test and states cam sensor engine problem. It is using excessive oil. I keep my engine oil changed consistently on time. It is not making it to the next oil change date before I have to add oil. This is my main source of transportation and I am on social security and cannot afford engine failure repair. This should not be happening since I have my oil changed consistently. Please advise.

NHTSA ODI 11689179

My KIA, engine just died. I was at a stop light, the light turned green I pressed on the accelerator to go and at the middle of the intersection the engine died. Not certain what had happened or why the engine would die. After a week I had the vehicle towed to a car shop. The same shop that had just done a maintenance on the vehicle in July 2025. I have attached the copy of receipt from the work that the shop had done. When they looked at it they thought at first it was the key fob, so a new key fob was done, it still did not start. Then it was thought to believe it was the starter, so a new starter was installed, vehicle still did not start. At that time I was advised that it was the engine that had siezed. My complaint is that there was no warning signs or signals in the vehicle of anything mechanical going wrong or needing any kind of attention. No warning light displayed on the dash. I drove the vehicle not knowing why would my engine just die, my miles is between 175,000 - 178,000 so the last thing I would think to happen is my engine siezing up on me. Warning lights give you something needs to be looked at and figured out. But as a safety you get nothing displayed then your engines just dies, anything could happen when you are in the middle of traffic, highway or even if it was in the middle of the train tracks. I had spoken to KIA Dealer Service and he advised my vehicle does not have an engine recall but there were a recall in the past for engines such as mine. The KIA Dealer Service advised that they would have to do an inspection, at a cost of $270.00 dollars, and unfortunately it would have to be towed. Advised me that if I wanted to get a new engine it would cost $12,000.00. The vehicle is available for inspection just need to be towed.

NHTSA ODI 11688542

Just bought the car, was perfectly fine during the test drive, no lights on or engine codes present. On my way home check engine light came on showing code P0420 , catalyst system efficiency below threshold (bank 1), saying the catalytic converter needs to be replaced. Did some research and found there were certain 2016 Kia Sorentos recalled for this issue, but doesn’t show up on affected vehicles list when I look up my VIN # .

NHTSA ODI 11687231