2016 Kia Sorento: fuel pump failure

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 · Fuel system · 79,000 miles · CA

The contact owns a 2016 Kia Sorento. The contact stated that while driving at 65 MPH, there was an abnormally strong fuel odor inside the vehicle. The contact stated that while the vehicle was at the dealer for a scheduled service, the contact requested that the dealer inspect the issue. The vehicle was diagnosed with a low-pressure fuel pump failure. The contact was informed that the low-pressure fuel pump needed to be replaced. The vehicle was repaired. The failure mileage was approximately 79,000.

Filed Dec 1, 2025 · Engine, Fuel system · TN

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.

Filed Oct 13, 2025 · Engine · TN

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.

Filed Sep 13, 2025 · Fuel system · FL

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

Filed Aug 9, 2025 · Electrical, Engine · AZ · fire

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.

Filed Jun 30, 2025 · Fuel system · AZ

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

Filed Sep 26, 2023 · Engine, Fuel system · FL

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

Filed Jul 31, 2023 · Engine, Fuel system · FL · fire · 3 injuries

Fire from fuel pump engine failure catalytic converter issues from engine

Filed Apr 10, 2023 · Engine, Fuel system · CA

The engine was going through over 5 quarts of oil about once a month. There were no visible leaks. For months, there was no check engine light illuminated so the dealership couldn't help determine and fix the problem without charging over $10,000 to open the engine, which I couldn't afford. A Service Advisor, in their words, told me to, "Run it until it dies," so that they can start using the warranty. This to me was very unsafe, especially for my infant who was there when she said this. Months later, the car started shaking intensely and the check engine light finally came on. The car stopped working in the middle of the freeway but I was able to exit and take it to the nearest dealership. They were able to run a diagnosis and said it was an engine misfire and they replaced it (I was able to use my warranty for some of the repairs but still had to pay about $4000). It didn't take long for the car to stop working again. They then said there was a problem with the fuel pump so I had them replace it. I had barely just left the dealership when the car stopped working again. They replaced the catalytic converter, which was a part of a voluntary recall. For months after, they've been trying to figure out the issue with no success. It has been sitting at their service center since November 2022 with no solution.

Filed May 13, 2022 · Engine, Fuel system · IL

The car engine was using excessive amounts of oil at 80,000 miles. The dealer in an attempt to save the engine did a major flush. Several components failed within 10,000 miles of that service. Spark plugs, fuel pump and catalytic converter. The car would lurch forward. It stalled at 65 mph! We were scared it would start on fire or stall again. The first time it happened there were no warning lights. After the spark plugs and fuel pump were replaced there was an engine warning light on. The dealer did check it out and the latest test revealed a hole in the catalytic converter. They could not guarantee that that was the only issue. We chose not to have any additional repairs and sold the car at a loss because we were scared to have our grandkids in the car.

Filed Dec 19, 2021 · Engine · VA

On December 18, 2021, my 2016 Kia Sorento with approximately 20,100 miles, 2.4L Gasoline Direct Injection ("GDI") engine suddenly lost power on an eight lane Washington, DC area highway. The Malfunction Indicator Lamp (MIL) began to blink continuously. The first opportunity for an exit navigating through the construction zone, with the vehicle rapidly failing, was taken and the dealer, Ourisman Chantilly of Virginia, was contacted immediately. This confirms that the Kia Motors America, Inc. Product Improvement Campaign for the Electronic Control Unit (ECU) Knock Sensor Detection System (KSDS) was installed on January 12, 2019, with a mileage reading of 13,726 in the Commonwealth of Virginia at Ourisman Chantilly of Virginia. the federal safety agency Recall ID: 18V907000 for the high-pressure fuel pump leakage, Kia recall number SC172, includes 2012-2017 Sorentos. This could be a major fire hazard and pose a serious threat for injury or death. This vehicle has no safety recalls with the federal safety agency; the list of affected Sorento 2016 VINS excludes my vehicle. This dangerous defect of engine failure in a well-maintained, low mileage vehicle sold to me as a five-star safety rated "Pre-Delivery Inspection" (PDI) certified with no mechanical issues and examined as safe, may have had the apparent defects from the purchase date with the mileage delivery of nine (9).