The engine in our 2016 3.3L GDI Sedona seized while we were driving on the freeway going approx 65MPH on 12/29/24. The vehicle was towed to the KIA dealership in our town and examined by the service dept the following morning. We were told that the engine had no oil and it had leaked into the crankshaft where it burned up. Also, the engine compartment was filled with metal shavings. The service tech told us we would need to replace the engine.

- Bellingham, WA, USA

The engine in our 2016 3.3L GDI Sedona seized while we were driving on the freeway going approx 65MPH on 12/29/24. The vehicle was towed to the KIA dealership in our town and examined by the service dept the following morning. We were told that the engine had no oil and it had leaked into the crankshaft where it burned up. Also, the engine compartment was filled with metal shavings. The service tech told us we would need to replace the engine.

- Bellingham, WA, USA

Engine died in the middle of driving. After having it towed and diagnosed, there was no engine oil at all. I still had 1500 miles before the recommended mileage for my next oil change. No warning lights. Engine is totally seized and will need to be replaced. Kia dealership stated that an indicator should have told me that my oil was low and the engine should have shut off prior to running dry. We were driving with my 4 children in the car. Thankfully we were on a side road where we could push the car to safety.

- Fort Worth, TX, USA

My 2016 Kia Sedona developed a loud engine knocking / idling noise around 90000 miles. Had at least one oil change at a non-Kia shop around that time and was given vague warning about Kia engines as to why I was hearing the louder idling. At the time of another oil change at 99631 miles I was told there were a large number of metal shavings found in the oil, and my Check Engine light was illuminated with a message about faulty camshaft timing. After bringing to Kia dealership at that time. They first assessed that the camshafts needed to be replaced. After working for some time they eventually determined that the entire engine needed to be replaced (3.3 Liter GDI_DOHC). The engine was replaced and the car was given back to me. After 2 days of driving the car would not start up again and I had it towed back to the dealership. They needed to replace one of the already-repaired parts (CVVT ASSY / CAMSHAFT ASSY-INTAKE). These engine issues could have occurred at a more problematic time in the middle of a busy highway and could have resulted in damage / harm to human life.

- Sun Prairie, WI, USA

I brought my 2016 Kia Sedona into a mechanic to get checked over and get some new front tires put on on 8/19/24. I was informed that the oil needed changing. So, I changed it as I have always done for years. We took off on a ~2600 mile round trip out east. Once there, I noticed that when I would travel close to a cement divider, a noise was coming from the vehicle that got louder as I accelerated. Thought is was the muffler (sounded like I was hot rodding). There were no engine lights on the dash, so I didn't think there were any major issues. A muffler could wait till I got back. This trip was end of August. There were no other issues, so I put it off. I figured a small hole in muffler or loose. We were called to go back out to New York for 11 days the end of November, and after another 2600 miles, the noise was significantly louder, but mostly noticeable when accelerating. Still idled fairly well. Still no engine lights. On 11/27/24 we took a 600+ mile trip. As of 12/2/2024, I brought the vehicle in to get the spark pugs changed and check the noise. The mechanic said that I was 4.5 quarts low and the noise was knocking in the motor itself. I had replaced the engine oil (synthetic) end of August and now find this Dec. 3rd after bringing it in. It has never burned oil, and there is no evidence of leakage on the floor or anywhere in the engine compartment or oil pan (mine and mechanics observations). Loss of 4.5 quarts in just over 2 months, when never an issue before" And no low oil engine light coming on" This was just taken on 5800 miles of primarily highways. From what I have been reading, knocking prior to engine failure has been popping up, and my family and I could have had a major problem had I gone any longer without checking it out. It is a major issue not having the low oil sensor go off, and suddenly being without 4.5 quarts in such a short time without prior issues, or warning.

- Nevada, IA, USA

Regularly serviced vehicle (2016 Kia Sedona SXL 3.3L) within recommended intervals; most recently on 9/10/2024 at ~117k miles. Invoice indicates dealer put in full capacity of oil (6qt). Vehicle also received multipoint inspection including checking all fluids; non were reported low or in need of flush/replacement. Vehicle had begun to make extra engine noise (rattle/growl) on startup, not sure precisely when; I estimate just in the last few months, maybe September or October. Took 220 (one way, ~440 total) mile trip on 11/5-11/7/2024; vehicle performed well other than aforementioned startup noise. [XXX], vehicle noise had increased significantly and "engine control system" message with CEL was present on the dashboard which was later extinguished after an engine restart. No other warning/error indications were present before or since. Onboard vehicle diagnostics run by the owner (Kia "eServices" app) on 11/12 did not indicate any issues. It was decided we better not drive it and service was scheduled for 11/22. On the same day (11/12) we found the oil to be low by 4.5 qts. Filling the oil to "full" removed a significant amount of the engine noise but (layman's) inspection did not reveal any oil leakage and no other signs of oil burning had been noted previously. One additional trip of ~16 miles made on 11/19 and 6 miles to service on 11/22 (now at 121k miles). Dealer upon inspection stated rod bearings were bad and engine needed replaced. Retrieving the vehicle from service and driving home, it catastrophically failed losing all power in highway traffic and could not be restarted. I'm reporting this because I saw DP24-001 and PE23-019 which seem to be very similar to my issue. I see no reason why a regularly serviced engine could fail so quickly other than a possible manufacturing defect. The engine/components have not been touched since the dealer appointment on 11/22. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Saint Joseph, IL, USA

Description of Incident: What component or system failed or malfunctioned, and is it available for inspection upon request" The engine of my 2016 Kia Sedona seized due to a lack of oil. The oil pressure warning light, which is designed to alert the driver to low oil pressure or oil-related issues, did not illuminate to indicate any problem. The engine is still available for inspection upon request. How was your safety or the safety of others put at risk? While the engine seizure did not occur while driving, it created a potential hazard for future operation of the vehicle. Had the issue occurred during the 20-mile drive home or on future trips, it could have led to a sudden loss of power, putting the driver, passengers, and others on the road at risk. Has the problem been reproduced or confirmed by a dealer or independent service center? The Kia dealership confirmed that the engine seized due to a lack of oil. However, they have not provided a detailed diagnostic report or explanation for why the oil pressure warning light failed to illuminate. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives, or others? The vehicle has been inspected by Kia but has not been examined by third parties such as insurance representatives or law enforcement. Were there any warning lamps, messages, or other symptoms of the problem prior to the failure, and when did they first appear" There were no warning lamps, messages, or other symptoms prior to the failure. The oil pressure warning light, which should have alerted us to the issue, did not illuminate at any point. Best assessment: My assessment is that the oil pressure warning system failed to function as designed, leading to the engine seizing without warning. This malfunction prevented us from addressing the oil issue in time to avoid catastrophic engine damage.

- Topeka, KS, USA

Thursday, October 31, 2024, the engine blew on our Sedona. Approximately 164,000 miles on the engine. We maintained regular maintenance on the engine and oil changes. Left us stranded on a main highway. State Department of Natural Resources Conservation Officer protected us until county sheriff could respond. The engine light warning was on.

- Spiceland, IN, USA

I continued to loose engine oil at a rapid speed. Oil loss was excessive for the amount of driving.

- Romeoville, IL, USA

Air conditioning became less cool over the summer. Early October 2024, slight rattling noise heard in engine on acceleration. Approximately a week later, the battery died and was replaced. In the following days, rattling noise became louder and also heard a tapping sound. No warning lights, check engine light, etc. Taken to a local mechanic who inspected and informed us the timing chain is nearly completely worn and it has rubbed a hole in the side of the engine. A complete engine replacement is needed!

- Bledsoe, KY, USA

Engine is completely shot. I make all oil changes on time and the engine failed. It was burning oil. Only 111k miles.

- Kalamazoo, MI, USA

Car seemed to be running as normal except for a slight rattle sometimes when starting. No warning lights, overheating etc. After listening to radio while parked, Car acted as if battery was dead. AAA couldn't get it started. Had it towed to dealership and was told it was a catastrophic engine failure.

- Huntington Beach , CA, USA

Car would not accelerate while driving, while this did not cause an accident in this incident there was definitely the potential for that outcome. Upon inspecting the vehicle, found the vehicle was low on oil by 4 quarts, and no warning lights were on indicating there was a problem with the vehicle. Monitored the vehicle over the next several days to determine if there were any visible oil leaks and there was not. Further inspection by the dealership confirmed there was no visible oil leak and was followed by an oil consumption test by the dealership. Dealership determine that 2 quarts of oil were consumed by the engine over the course of 1,000 mile which is indicates a failure of the test and problems within the engine.

- Oak Forest, IL, USA

Engine Seized

- Romeoville, IL, USA

Car has bad oil leak Defective GDI engine which instantly stalled out while driving Car also has bad coolant leak, warped head gasket seal Smell of gas from top of the engine block

- Midland Park, NJ, USA

On [XXX], my vehicle overheated and started to leek coolant. This happened while driving at about 65 MPH with my family. No check engine lights came up just noted that the HVAC started to blow hot air and then the vehicle shutdown making difficult to break. I remembered that received a letter from Kia on May 26, 2014 that extended the warranty to 15 years / 180,000 miles for this type of issues - warranty number WYT039. I took it to a Kia dealership in Puerto Rico to get service and they diagnose the vehicle with the same issue as stated in the letter. However, Kia claims that they can't do the work because it is in Puerto Rico and I will have to take to USA mainland. I argue that federal law covers Puerto Rico for Safety Recalls and Warranty information and that they can discriminate for this. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Moca, PR, USA

What component or system failed or malfunctioned, and is it available for inspection upon request" The vehicle's engine and electrical system appear to have failed, resulting in a fire originating from the engine compartment. The vehicle is currently at a salvage yard and available for inspection upon request. How was your safety or the safety of others put at risk? The fire occurred while my wife was picking up our children from school. Fortunately, they were able to exit the vehicle safely, but the incident posed a significant risk to their safety and could have resulted in severe injury or death. The vehicle was completely engulfed in flames and is now unusable. Has the problem been reproduced or confirmed by a dealer or independent service center? The specific issue leading to the fire has not yet been reproduced or confirmed by a dealer or service center. However, the vehicle had been previously serviced by Gilman Honda on March 12, 2024, due to a loud grinding noise and issues with the air conditioning, for which I was charged $855. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? The vehicle has not yet been inspected by Kia or any other manufacturer representative. I have opened a case with Kia, and they are aware of the incident and have expressed interest in inspecting the vehicle. My insurance company has been informed, but they have not inspected the vehicle. The vehicle has not been inspected by the police. Were there any warning lamps, messages, or other symptoms of the problem prior to the failure, and when did they first appear" There were no warning lights or messages indicating a potential problem immediately before the fire. However, the vehicle had been experiencing intermittent grinding noises and air conditioning malfunctions, which were brought to the attention of the service department on March 12, 2024.

- Universal City, TX, USA

On May 10, 2024 my van all of sudden started to jerk, stall and then die. My husband was able to make it to the side of the road before it died, but barely. There was no warning, no oil pressure lights, no engine lights nothing. It was running fine and then it wasn't. We took it to a shop because Valley Kia of Modesto was slammed. The mechanic at the shop told us we needed to make sure there was oil in the vehicle as there was none. I told them that I'm always keeping up with my oil. They repaired it and it cost close to $3,000. Then one month later on September 8, 2024. my husband and I are driving and out of the blue this time it starts to make a clinking noise, stall and die on us. It died on the highway and my husband was able to keep it rolling to the side of the road. Again, no warning, no oil pressure light, no signal light, no warning at all. Once we are safe, my husband checks the oil, there is none in the engine. We had only drove 2,446 miles in total from when we picked up the van from the shop on August 6th. From August 6th to September 8th and only 2,446 miles later all of of the oil the mechanic put in the van was gone. I took it to Valley KIA of Modesto and they tried to say it was the other mechanic's fault. I explained that there is an underlying issue with the vehicle causing it to use up so much oil and no warning or anything. There was never any oil leaks under the vehicle, oil leaking out of the engine, or smoke coming out of the tailpipe. Nothing to indicate something was wrong. Now they tell me I need a new engine and is not willing to admit that there is an extended warranty on the oil pressure switch due to it malfunctioning. They did admit that they can tell the check engine light is not registering that the engine is bad or showing any indication it's not running right. Now I have a KIA Sedona that needs a new engine due to faulty sensors and some other underlying issue of extreme oil consumption.

- Ceres, CA, USA

The vehicle suddenly uses all the oil and the engine locks up with no warning. No lights or guages alert the driver/owner.

- Creston, IA, USA

My car started over heating, took it to dealer, they said I had a blown head gasket. Since it isn't covered under warranty, they said I had to pre-approve a $2700 motor teardown in order to see if there were any other problems. Thank goodness there were, the head bolts separated. The engine was covered under dealership extended warranty since I bought it used from a Hyundai dealer.

- Sellersville, PA, USA