2020 Kia Sorento Engine Problems

Office of Defects Investigation National Highway Traffic Safety Administration (NHTSA) 1200 New Jersey Avenue SE Washington, DC 20590 Subject: Safety Complaint – Premature Engine Failure Risk Due to Excessive Oil Consumption and Confirmed Cylinder Scoring – 2020 Kia Sorento Dear Sir or Madam, I am submitting a formal safety complaint regarding a 2020 Kia Sorento that is experiencing severe and abnormal engine oil consumption along with confirmed cylinder wall scoring. These conditions indicate progressive internal engine damage and present a significant risk of premature engine failure. The vehicle has been regularly maintained in accordance with manufacturer service recommendations. Despite proper maintenance, the engine began consuming excessive amounts of oil between normal service intervals. During inspection by the servicing dealership, visible cylinder wall scoring was identified within the engine. Cylinder scoring is a clear indication of internal engine wear and deterioration and can lead to rapid progression toward engine failure. Despite the confirmed presence of internal engine damage, the manufacturer has refused to authorize an engine replacement under the extended warranty program unless the engine experiences complete mechanical failure. The dealership has indicated that the vehicle must continue to be operated and monitored until catastrophic breakdown occurs before replacement will be approved. Requiring the continued operation of a vehicle with confirmed cylinder wall damage and abnormal oil consumption raises serious safety concerns. Progressive internal engine damage can lead to sudden engine seizure, stalling, or loss of power while driving, which creates a potential hazard for the driver, passengers, and surrounding traffic. Given the confirmed cylinder scoring and ongoing excessive oil consumption, I respectfully request that the National Highway Traffic Safety Administration investigate.

The engine check light is on and the car is using more oil than it should. I had the oil changed and had to add quarts before 2000 miles. I called Kia and was told my VIN is not part of the recall. I got an inspection and Cylinder 2 is misfiring and has low pressure so the entire engine needs a replacement.

Oil is leaking from my car. The dealership said I would need to replace the engine. The car is only 6 years old.

The engine is burning oil despite all maintenance being up to date and having fewer than 80k miles. Kia of Duluth Service Center checked the oil and said levels were good on 12/31/25. Fewer than 30 miles were driven and it was brought back to the dealership service center on 1/2/26 and diagnosed with total engine loss due to oil starvation. The extended warranty company (JM&A) are denying coverage because the engine failure is due to lack of oil. They have inspected the vehicle. No warning lights ever came on and this is the second time that this issue has been addressed by Kia of Duluth. The engine could have easily overheated and caught on fire or lost power on the road.

The contact owns a 2020 Kia Sorento. The contact stated that while the vehicle was parked, the contact noticed a small oil leak on the ground underneath the vehicle. The contact checked the oil level and added a quart of oil to the engine. The vehicle was driven approximately 50 miles. The contact parked the vehicle and checked the oil level again. They noticed that the oil level was low and added another quart of oil. No warning lights were illuminated. The vehicle was driven another 15 miles, and the contact stopped at the grocery store. The contact stated that while attempting to restart the vehicle, the contact noticed a clicking sound, as if the engine was attempting to start. The contact continued, stating that the vehicle failed to start. The vehicle was towed to an independent mechanic, where it was diagnosed with complete engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure but provided no assistance. The contact was informed that there was no warranty on the vehicle. The failure mileage was approximately 151,025.

Around 100,000 miles I noticed that my engine was going through a lot of oil. Every time I would get an oil change, I would ask why and they stated that these Kia engines after hitting 100,000 start to burn oil fast and about every 1,000 miles you have to add a quart of oil and go from your normal every 5,000 mile oil change to every 3,000 mile oil change. Some times the oil light would blink but some times it wouldn't. I had a mechanic double check this and he confirmed and said nothing you can do they are just like and he sees it all the time. I kept up with my oil changes every 3,000 miles and every week and a half checking the oil. Around 134,000 miles or so on 11/28/25 at 4:30am I was driving and all of a sudden my car was driving weird and shaking. Soon the engine light came on. The oil light this entire time never came on. I pulled into a Target parking lot an noticed there was no oil in the car and it went through 5qts in a week and a half. I added 4 qts oil to the car and waited for the mechanic shop 1/2 a mile to open up at 7am. The inspected the car and said a cylinder was blown and to drive slow and get it home and just park it and a new engine is needed. I called my mechanic and he came by the house and he looked and it to see if he could fix it and no luck but said that Kia did have recalls on their engines and to fight it. I called Kia and they didn't deny recalls on some cars but not mine. They advised me to do a claim to get help to get the engine on a recall. The car has not been driven since then and remains in the garage and is in perfect well kept condition otherwise.

Check engine light came on indicating a problem with cylinder 4(P0304). Replaced all spark plugs and coil pack to no avail. Car still struggles to accelerate even though light has went out. Especially noticeable at higher speeds.

The oil pan got a large crack in it right by the plug

My engine light is on. Codes show cylinder 4 misfire. Code P0304. My vehicle slows down while driving. It takes time to excelerate to a reasonable speed. My vehicle is becoming harder to start each time. I purchased a new battery and replaced spark plugs to no avail. I’ve been told from several mechanics that my engine is bad and needs to be replaced. Kia has refused to replace my engine or help in any way and I feel this is something caused by the manufacture. Others have had the same issue. The vehicle is burning oil and I have practically had to stop driving the vehicle. It is my only means of transportation. I have 113,000+ miles.

Burning oil at dangerous rates. No leak yet having to refill oil weekly. Burning at a rate of 2q per 1k miles. Car currently has 95k miles and has had regular oil maintenance until this issue began a few months ago. This is a frequent issue with the 2020 Sorrento.

Vehicle Information: Make: Kia Model: Sorento Year: 2020 VIN: [XXX] Mileage: ~80,000 miles Complaint Summary: I am filing a complaint regarding excessive engine oil consumption in my 2020 Kia Sorento. The vehicle burns oil between regular oil changes, requiring frequent top-ups. There are no visible leaks, and this consumption poses a serious safety risk, including potential engine failure or fire hazard. Detailed Description: I purchased the vehicle used from a Kia dealership. I requested an oil consumption test from the dealership, but they refused, stating the vehicle is out of warranty. I contacted Kia Consumer Affairs, and they also refused to authorize the test or provide assistance. This engine issue is widely reported by other owners of the 2020 Sorento and similar Kia vehicles, particularly those with Theta II / GDI engines, which are known for oil consumption problems. The vehicle has approximately 80,000 miles, and the oil consumption is significant enough that I must frequently add oil between changes, creating a safety concern. Actions Taken: Requested an oil consumption test from local Kia dealership — refused. Contacted Kia Consumer Affairs for assistance — refused. Maintained detailed records of oil use and maintenance. Request: I request that the NHTSA investigate this oil consumption issue for my vehicle and the 2020 Kia Sorento model line. I also seek guidance on any recalls, service campaigns, or safety actions related to this defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The engine is consuming oil at a rapid rate that could be potentially dangerous. This is happening to other people with the same make and model as well.

My engine has started to burn excessive amounts of oil causing the oil light to flash. I took the car to the dealership and was told that it is a known defect in the engine and that if the car has over 100,000 miles they would recommend getting rid of the car because it could not be fixed and did not qualify for a new engine like they were putting in older models. The dealership said that they had told 9 other families the same thing as me in the last 2 weeks. Apparently the oil flows back into the combustion chamber and ruins the engine and there is no way for the dealership to know until a warning light comes on. Hard to believe since they know there is a major defect in the engine.

My car is burning excessive amounts of oil with no leak

My 2020 Sorento has ALWAYS had regular maintenance , very well taken care of. Started using oil around 80,000 miles, around 98,500 it misfired while driving to work and we were told it was the coil pack and spark plugs needing changed. Ran good for 3 1/2 weeks and we had to change another spark plug. Was told this was “ normal” 1 month later and I’m stuck on the side of the road broken down with no power cause the engine quit. By that time we were over 100,000 so Kia said they wouldn’t cover it. Paid to have a new engine put in. Seems like this is a going thing for this make and model. It needs a recall ASAP. It put us in a terrible financial crisis as it was our only vehicle.

The contact owns a 2020 Kia Sorento. The contact stated while driving at approximately 55 MPH, there was white smoke coming from under the hood. The contact stopped the vehicle on the side of the highway. The contact had recently had an oil change completed at an independent oil replacement shop. The contact called the shop, and a technician was sent to the location. The technician checked the engine oil level and stated that there was no oil on the dipstick and added four quarts of engine oil. The vehicle was repaired; however, the contact stated that the vehicle had started to emit white smoke from the engine compartment and the check engine warning light was illuminated. The contact had taken the vehicle to a local dealer who diagnosed the vehicle and determined that the vehicle needed an engine oil flush. The vehicle was repaired but the contact stated that the failure reoccurred. The vehicle was not taken back to the dealer or an independent mechanic. The vehicle not repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 150,000.

The engine oil level drops from "Full" to "Low" after driving approximately 2,000 miles. I have visited three different auto repair shops, including an official Kia service center, but none of them could explain the reason for the oil loss. They all acknowledged the issue but said they don't know what is causing it.

Complete engine failure while traveling on the highway with no warning. No check engine lights came on. Engine started knocking and would turn off when traffic came to a stop. As I was in a construction zone, I had no safe space to pull over. Car ran this way for about 10 minutes until I could safely pull over. It then would not restart. Confirmed to be complete engine failure. Oil change had just been completed three weeks prior. There are only 73k miles on this vehicle.

Engine was in limp mode after having the KBS software earlier this year installed. Engine is currently at 115,000 miles, oil has been changed consistently. The engine has been consuming the oil and burning it fast, where I need to add oil constantly.

What component or system failed or malfunctioned, and is it available for inspection upon request?- MY CAR IS BURNING OIL AT A RATE OF AT LEAST 1 QT PER 1K MILES How was your safety or the safety of others put at risk?- DRIVING A CAR WITH INSUFFICIENT OIL COULD LEAD TO ENGINE FAILURE OR FIRE. I DRIVE MY [XXX] DAUGHTER AS WELL AS MYSELF AND FAMILY IN THAT CAR ON A DAILY BASIS. THE CAR COULD LEAVE ME STRANDED OR CAUSE A FIRE. I AM AFRAID TO DRIVE IT AND THEREFORE HAVE NOT DRIVEN IT. I AM CURRENTLY WITHOUT TRANSPORTATION DUE TO THIS ISSUE. I WILL NOT RISK MY FAMILYS SAFTEY. Has the problem been reproduced or confirmed by a dealer or independent service center?- YES THIS IS A KNOWN ISSUE BY KIA AND MANY VECHILES WITH THE SAME MAKE AND MODEL HAVE BEEN RECALLED. 2 INDEPENDANT SERVICE CENTERS HAVE CONFIRMED MY CAR IS BURNING OIL AND IT IS UNSAFE. KIA HAS ALSO CONFIRMED IT IS BURNING OIL. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? -YES KIA PERFORMED AN INITAL OIL CONSUMPTUPN TEST WHICH IT FAILED, BUT REFUSE TO DO ADDITIONAL TESTS/REPAIRS DO TO SERVICE RECORD DOCUMENTATION. I AM STILL WITHIN MY 10Y/100K WARRANTY BUT THEY WILL NOT COVER IT. IT IS A DEFECTIVE ENGINE AND IS A MANUFACTURER DEFECT NOT USER ERROR Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear- THE OIL LIGHT WENT OFF THE FIRST TIME IN DEC 2024 AND I IMMEDIATELY TOOK IT TO SHELL STATION. THIS WAS BEFORE I WAS DUE FOR AN OIL CHANGE. THEY TOLD ME I HAD NO OIL. IN FEB 2025 I GOT ANOTHER OIL CHANGE AT VALVOLINE AND WAS TOLD THE SAME THING. KIA CONFIRMED THE OIL CONSUMPTION IN APRIL 2025 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)