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.

- Saint Francis, MN, USA

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)

- Richfield, MN, USA

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)

- Durham, NC, USA

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.

- Elizabethton, TN, USA

Fuel pump leaking gas from a crack around electrical connections on top of it. Fire hazard.

- Coral Springs, FL, USA

This scenerio happened and fire resulted with total loss. Fuel system, gasoline: Delivery: Hoses, lines/piping, and fittings Recall date 2018-12-18 Recall no. 18V907000 Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak. Hide details Recall consequence A fuel leak in the presence of an ignition source can increase the risk of a fire. Recall action Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.

- Surprise, AZ, USA

Fuel pump is leaking, unsafe to drive vehicle, no check engine light just really bad smell of gas

- Marana, AZ, USA

1) I bought this car in October 2021, when it had ~79,000 miles on it. After ~2,000 miles, it showed a low engine oil sign, and it has been showing this issue since then, i.e., I have to change my oil/filter after every ~2000 miles. It has incurred a huge cost. I talked to the dealers, but they did nothing to solve this problem and charged me ~$1200. Funny part. Whenever I go for an oil change, they say that KIA/HYUNDAI cars have this engine problem. It's a joke to this system that the Govt still allows them to roll on the USA roads. 2) Today, this car had a flashing engine light. I will go to a mechanic tomorrow, but afraid of how much they will charge.

- Tucson, AZ, USA

Check engine light came on again after recall for engine bearing failure and engine block was determined to qualify for replacement by home Kia dealer, est July / August 2024 in North Hampton NH. After motor block changes the engine light came on and off while in Florida vacationing. Today-??s date is February 17, 2025 and my vehicle is presently in the hands of a local independent service center here in Florida. Other indicators recently noticeable were rough idle starting in the morning. The service center initially suggested problem might be injectors, and gasoline was noticeably in the oil pan. I-??m presently waiting for a further / complete diagnosis from the service center. Relative to myself and my spouses safety further research on my own fire could be a potential with injectors causing a garage to be ignited and life threatening to us.

- Milton , NH, USA

Unknown

- Maryland Heights, MO, USA

Unknown component or system failed. My car suddenly stalled while on the highway, not allowing me to increase speed (over 40 mpg) and then stopped. I was scared to death when that happened on the highway as we could have been hit by other vehicles. I was able to restart it but it kept doing it, gradually reducing my speed to 20mpg then a lamp warning sign appeared. The car only has 50,000 miles on it and no warning light or prior failure before this happened on 11/29/2024. I took it to Kia for inspection and they told me if the engine will have to be replaced, it will take 3 months. They took my car in for inspection and I am now 10 days without a car and I have not yet heard from Kia.

- Fairfax, VA, USA

While driving on the parkway, the vehicle would not accelerate and would stall. After pulling over, vehicle would restart but repeated the pattern. Made it to Advanced Auto who ran codes and had the camshaft modulator changed. Vehicle made it back onto parkway. 40 miles from home, the vehicle began to shake, loose power, made loud sound and died. Towed home. Mechanic said out of oil but I had oil changed less than 1000 miles ago when vehicle purchased. New codes showed crankshaft position sensor. Changed part. Replaced starter and a new battery. Still nothing. Stating probable engine failure. I've only owned this vehicle for 2 months!

- Lexington, KY, USA

Car when into a low power mode, could not keep it running, took 5 times to go thru a very busy intersection and motor was making a knocking noise, smells like burnt oil-motor, misses out..The car was towed into a KIA dealership,3 weeks later they said it was fixed, drove off and didn-??t even make it a mile until it started knocking and having the same smell like burnt motor, went into a reduce power.now it-??s been 3 more weeks or more and still nothing is getting resolved. Yes the dealership knows about this issue. Yes warning messages came on when it went into low power mode. This is motor number two as the motor was replaced less than 12 months ago.

- Moore, OK, USA

Knock sensor goes bad. Car does not receive fuel to engine. Cuts off while driving and will not accelerate over 20 mph

- Rochester , NY, USA

Car ran fine until we stopped for gas, went to get back on the highway when the car wouldn't accelerate >25mphs, almost got hit from this. The car was then towed to the near by Kia dealership and they found that it was a compression issue with a known issue in the engine and now we need a new engine or scrap the car. Kia is not willing to fix their horrible product and has told us to just suffer.

- Corinth, NY, USA

this vehicle is a match box waiting to kill someone. I've been reporting these problems an nobody has follow up. on 08/20/2023 fuel pump had to be replaced after fumes coming into vents report one on 06/03/2023 issue happened again, 0n 09/04/2023 engine went out. after getting vehicle back catalytic converter and manifold was burnt out do to engine.had it inspected by a muffler shop. kia will not replace anything even if they are told it was caused on behalf of there produce

- Jacksonville , FL, USA

3.3 liter engine - no warning not part of recall or knock sensor per Kia - driving slow ( thank God ) just died. Towed to the dealer - hearing 3 different story-??s " Diagnosis " Manifold or Rod Bearing issue - whole engine needs replaced over 15k cost. Doing research on this issue snd see many complaints on all makes and models / expect a recall on this vehicle in time as well - it-??s only a matter of time till someone is hurt or killed due to Kias repeated negligence in regards to engine failure - the dealer and corporate are ignoring this and that is not acceptable.

- North Fort Myers , FL, USA

Fire from fuel pump engine failure catalytic converter issues from engine

- Jacksonville, FL, USA

was driving at 11mph and car would not Accelerate almost causing and accident issues with engine sparking flames fuel system problems, transmission issues when putting the vehicle into park. Engine problems check engine light keeps blinking on an off system says park vehicle do to diagnosed problems. suspension issues afraid to drive vehicle do to so many safety problems.

- Jacksonville, FL, USA

automatic transmission shift lever assembly components, fuel pipe exhaust causing fumes to come through the vent area causing fire and smoke. accelerator assembly issues when driving

- Jacksonville , FL, USA