2020 Kia Sorento

Closed defect petition · opened September 12, 2022 · closed December 12, 2023

the engine

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The contact called on behalf of his daughter who owns 2020 Kia Sorento. The contact stated that the vehicle was taken to a dealer for a routine oil change when the contact was informed that there was an unknown issue with the vehicle however, the vehicle was not diagnosed or repaired. The vehicle was taken to a different dealer where it was diagnosed that the transmission fluid was leaking and the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was unknown.

NHTSA complaint 11753507. Filed by an owner and not verified by NHTSA or by us.

Driving on highway at 65, traction control light, airbag light, parking light, bcw warning, all came in at the same time. I was able to pull off to the side and re start engine to clear the lights. As soon as I got up to 40 lights one by one flickered on until up to highway speed and then all flickered and dash dings. Two independent shops ran diagnostics and noted that only battery was dead. Replaced battery and the lights came back immediately.

NHTSA complaint 11749809. Filed by an owner and not verified by NHTSA or by us.

19,000 miles

The contact owns a 2020 Kia Sorento. The contact stated that while driving 30 MPH with her daughter and parents in the vehicle, an abnormal squeaking sound was heard emanating from the steering wheel. No warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed that the steering column needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, but the repair was delayed because the manufacturer required information from the dealer, while the dealer claimed to be waiting for a response from the manufacturer. The failure mileage was 19,000.

NHTSA complaint 11749302. Filed by an owner and not verified by NHTSA or by us.

The vehicle suffered a sudden, severe engine malfunction/misfire while in operation, presenting a serious safety hazard on the road. Following the incident, the vehicle was taken to an authorized dealership service center (Repair Order #XXX), where technicians verbally confirmed that the engine requires a complete replacement due to internal mechanical failure. The catastrophic mechanical failure of the engine directly caused consequential damage to the emissions system, entirely clogging the catalytic converter with unburned fuel/debris. Despite the clear link to the known, systemic defects inherent to the Theta II engine line—which is subject to active federal consent orders, safety …

NHTSA complaint 11741669, quoted in part. Filed by an owner and not verified by NHTSA or by us.

Engine is burning oil at a significant rate, when I get my oil changed at the dealers recommendation it is extremely low. I have to replace the oil regularly between oil changes, and there is an exhaust smell. Also lagging when I hit the gas.

NHTSA complaint 11738870. Filed by an owner and not verified by NHTSA or by us.

Car is 6 years old less then 100k miles and losing oil and motor problems Went through entire oil change in 1 month Kia unable or willing to assist with any coats I was told by a private garage that the motor in my car should be part of a recall that was already listed for 2021 through 2026 but they’re saying it’s not covered

NHTSA complaint 11738032. Filed by an owner and not verified by NHTSA or by us.