2016 Kia Sorento: engine knocking or ticking

Filed Nov 4, 2026 · Engine, Fuel system · RI

Severe high-pressure fuel system failure and engine oil fuel dilution creating a fire hazard and engine seizure risk following a corporate engine replacement. On July 15, 2026, my 2016 Kia Sorento (2.4L GDI) received a corporate-covered engine block replacement due to rod bearing failure. On September 30, 2026 (2,332 miles later), the vehicle jerked violently while driving. Inspection revealed the engine oil was heavily diluted with gasoline due to an internal failure of the High-Pressure Fuel Pump (HPFP), creating a fire hazard. The HPFP was replaced out-of-pocket. Kia Corporate Case #26456059 is open regarding this safety issue. A severe safety hazard currently persists. Within 20 days and 176 miles of this fuel pump repair (totaling 2,512 miles on the new block), the vehicle exhibits severe drivability issues and the oil dipstick again smells heavily of gasoline. This fuel dilution compromises oil viscosity, threatening catastrophic engine seizure and creating an active fire hazard. Due to the severity of this fire risk, the Kia Executive Director of Customer Care intervened, ordering an emergency flatbed tow to a different authorized facility. An invoice audit revealed the dealer violated Kia repair protocols, factory TSBs, and federal safety guidelines. Kia’s factory TSB mandates that the high-pressure fuel pipe is a strict, single-use component that must be replaced upon pump removal; however, this part was completely omitted from my invoice, confirming it was dangerously reused. Reusing it introduces a volatile engine-bay fuel leak risk, mirroring the hazardous pattern in the federal safety agency Recall 18V‑907 (Kia Campaign SC172) regarding fuel lines mishandled during engine swaps. Furthermore, the dealer illegally charged retail fees for Service Campaign SC340 materials and withheld all diagnostic trouble codes (DTCs). I request a formal the federal safety agency investigation into unsafe recall compliance and systemic powertrain installation failures originating from the engine replacement.

Filed Oct 20, 2026 · Engine · MA

I am the original owner of a 2016 Kia Sorento and have lived at my original registration address since purchasing the vehicle. The engine suddenly and catastrophically failed/seized due to internal rod bearing failure. The local Kia dealership is denying the recall engine replacement because the KSDS (Knock Sensor Detection System) software update was not performed. However, Kia America failed to mail me a statutory recall notice to my verified address. The dealership is weaponizing Kia's own notification failure to deny coverage for an acknowledged safety defect."

Filed Sep 20, 2026 · Engine, Transmission · NY

Upon a catastrophic engine failure Tasca Kia replaced engine under Theta II settlement. I picked up my kia on 9/12. Engine is not running properly. It’s jerking and there is loud mechanical knocking. I don’t feel safe driving. I’ve contacted Kia corporate beginning 9/16 who contacted Tasca to arrange for tow and loaner. They said Tasca service mgr would contact soon to set up. They never did. I called corporate again later that day and after they called Tasca they were told service mgr went home for the day. As of this date Tasca Kia has not contacted me. I again called Kia corporate 9/17 asking to please escalate and allow me to use another service dept. The only other service location with loaner is a half hour away and I cannot afford another tow or another rental. I am stranded with a car that is not safe due to installation failure or another defective engine. No one from Kia will help in a reasonable time frame. I’m now told it can take up to 48 BUSINESS HOURS for any assistance. In the meantime I’m being forced to decide on whether to risk driving an unsafe vehicle to the service dept or to continue waiting for Kia to contact me.

Filed Jul 7, 2026 · Electrical, Engine · RI

(Transmission and motor) I had taken my car to the dealership on XXX for recalls and all the signal were fine before going there. They took my car back to do the recalls and my son and I waited . Once they were done we left closer to closing time is noticed there was a burn mark on my dash board that wasn’t there before the recalls. Going forward on the way home. We were waved down by a man stating that my signal and brake light weren’t working . So that next day we took my car back to the dealership to see what happen, why all the sudden different alerts were coming up. They had the same mechanic relook at the car and a when finish 31/2 hour latter was told I needed a new transmission, costing $7384.94 which I don’t have . They charge me $179.00 just to confirm what they said about needing a new transmission. I was devastated and confused why I wasn’t told that the day before. So a few days later I took it to another machanic to see if the could see why the lights weren’t working and he ended up putting new bulbs in and got them working but also he put it in a diagnosis machine 2 of them and couldn’t get a reading at all and said I should take it back to find out why he couldn’t get a reading. I was so frustrated at that point I just was upset! I then had a friend of the family mechanic look at it and he said it wasn’t the transmission it was a knock sensor that I needed so I ordered it. When I called him to install the knock sensor he was too busy to do it and it had already been a whole month of waiting so I reached out to a place in Cumberland RI to see if he could install the knock sensor had it towed there and he kept it for three days and said it was a transmission computer and he tried two of them and neither of them worked and charged me $150 for that I was humiliated and crying , I went there to have my car towed home seen him while waiting for the tow truck to come he said I needed a new transmission and now a motor, crying again. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA)

Filed Jun 23, 2026 · Engine · 119,000 miles · CT

The contact owns a 2016 Kia Sorento. The contact stated that after the vehicle was parked and turned off for approximately an hour, the vehicle was restarted and there was a knocking sound coming from the engine compartment. The contact continued driving and the knocking sound increasing in volume and frequency. There were no warning lights illuminated. The vehicle was taken to a certified mechanic and was diagnosed with engine failure. The contact was informed that the engine needed to be repaired. The mechanic referred the contact to the dealer for assistance. The vehicle was taken to the dealer and the contact was informed that since the vehicle was not repaired under the federal safety agency Campaign Number: 22V703000 (Trailer Hitches); the dealer was unable to repair the engine ffailure. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 119,000.

Filed Jun 9, 2026 · Engine · 74,000 miles · PA

The contact owns a 2016 Kia Sorento. The contact stated that while driving at various speeds, abnormal engine oil consumption was noticed. No warning light illuminated. The vehicle was taken to a local dealer, where it was diagnosed with engine oil consumption, but repairs could not be made until a knocking sound was heard. The contact stated that the vehicle was no longer experiencing the failure but was repaired under an unknown recall. The contact stated that occasionally, while driving at various speeds, the Check Engine warning light illuminated. The vehicle was taken back to the same local dealer, where it was diagnosed with a catalytic converter failure. The vehicle was not repaired due to the cost. The manufacturer was made aware of the failure. The failure mileage was approximately 74,000.

Filed Mar 18, 2026 · Engine · 98,000 miles · GA

The contact owns a 2016 Kia Sorento. The contact stated that while his wife was driving, the battery, check engine, and oil warning lights were simultaneously illuminated. The driver reported hearing a low rattling sound and observed smoke coming from the engine compartment. The contact stated that the dealer declined to service the vehicle because the knock sensor was not installed by the previous owner. The vehicle was towed to a local dealer, where it was diagnosed with a connecting rod bearing failure. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 98,000.

Filed Feb 20, 2026 · Engine · KY

The engine stalled while driving on the expressway. Myself and my daughter and her friend were in the car. The vehicle started right back up, and I was able to drive the car home (less than 2 miles away). The following day, my wife got an oil change, and went on the expressway, and the engine stalled again causing her to have to navigate the car, with no engine power, to the side of the highway and wait for myself and a tow truck. Both times were very dangerous. We had the vehicle towed to a mechanic, who said the crank shaft & rods and bearings for the engine look like they failed and seized up, causing the engine to complete lock up and stall, requiring a full engine replacement. Kia is refusing replacement saying we are not covered by the previous complaints and concerns, stating our vehicle is not covered specifically, stating that the 3.3L engines were not covered under the previous recall/extended warranty offered on engines in the same yr/make/model as our vehicle. The check engine light came on, and there was a slight knocking sound as the car was idling just before the engine stall, and as the engine stalled, the oil lamp and the battery light came on. This happened both times. The symptoms appeared just before complete engine failure. We get the vehicle serviced at Kia, and had the oil changed by Strickland Brothers the day of. We were concerned that the engine light came on due to potential of the oil needing to be changed. We do not have any electronic files or reports for this issue yet.

Filed Jan 13, 2026 · Engine, Transmission · MN

Our 2016 Kia Sorento had 86k miles on it, loud knocking began and days later catastrophic engine failure. Rods and bearings are busted on my 3.3 Liter, V6 GDI engine. It died while my wife was driving it to the dealership. Estimated repair is 19k, metal shavings in the oil. It is available for inspection. My wife was driving it on the highway when the engine failed. Dealer confirmed the rods and bearings were broken.

Filed Dec 24, 2025 · Engine, Fuel system · MN

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.

Filed Dec 8, 2025 · Electrical, Engine · NC · fire

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., the federal safety agency 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 the federal safety agency 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)

Filed Dec 5, 2025 · Electrical, Engine · WA

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!