Kia Sorento Engine Recall: What Owners Need to Know

Is your Kia Sorento making strange noises? Worried about those engine recall notices in your mailbox? You’re in the right place. Today, we’re diving into everything you need to know about Kia Sorento engine recalls – from which models are affected to what steps you should take if your vehicle is on the list.

Understanding Kia Sorento Engine Recall History

Kia Sorentos have been hit with several significant engine recalls over the years, particularly models equipped with the problematic Theta II and Lambda II engines. These issues haven’t been minor inconveniences – they’ve included everything from complete engine failures to fire risks.

The most extensive problems have centered around the Theta II 2.4L engine found in 2011-2014 Sorento models. These engines suffered from manufacturing defects where metal debris in oil passages led to premature bearing wear and, in some cases, catastrophic engine failure. The NHTSA investigated these issues extensively, leading to widespread recalls.

But the problems didn’t stop there. The Lambda II 3.3L V6 engines in 2016-2017 models also faced scrutiny for head gasket and head bolt failures. The NHTSA opened a Preliminary Evaluation (PE23-019) after receiving multiple complaints about power loss while driving.

Most Recent Kia Sorento Engine Recalls

The most recent engine-related recall affecting Kia Sorento models was announced in September 2023 for 2025 models. This recall (SC349) involved only 30 vehicles but highlighted a serious issue: improperly torqued connecting rod bolts that could cause complete engine shutdown while driving.

For 2011 Sorento models, recall SC291 impacted nearly 80,000 vehicles manufactured between October 24, 2009, and June 24, 2011. This recall addressed engine compartment fires during operation, caused by manufacturing debris in crankshaft oil passages.

A smaller but significant recall affected 62 vehicles from the 2017 model year with 3.3L Lambda engines. These vehicles had improperly heat-treated crankshafts that could completely fail, leading to engine stall and fire risks. The affected vehicles were manufactured between March 27-30, 2017.

Warning Signs of Kia Sorento Engine Problems

Before complete failure, your Sorento might give you several warning signs that something’s wrong with the engine. Don’t ignore these red flags:

1. Unusual engine noises – Knocking, ticking, or rattling sounds, especially during acceleration
2. Check engine light – Particularly if accompanied by engine codes P0301-P0304 (cylinder misfires)
3. Smoke from the engine compartment
4. Burning smell while driving
5. Sudden loss of power or stalling
6. Excessive oil consumption between changes
7. Engine overheating warnings on the dashboard
8. Coolant leaks beneath the vehicle

If you notice any of these symptoms, don’t wait for complete failure. The sooner you address potential issues, the better your chances of avoiding catastrophic damage.

Which Kia Sorento Models Are Most Affected?

Not all Kia Sorento models face the same engine recall risks. Here’s a breakdown of the most problematic years and engines:

The 2011-2014 models with the Theta II engines have been the most problematic, with the highest rates of catastrophic failure. The 2016-2017 Lambda engine issues were less widespread but still serious for affected owners.

Newer models (2018 and beyond) show significantly improved reliability after Kia implemented manufacturing changes to address these issues. However, some 2025 Sorento owners have still reported hybrid system problems and engine control system faults.

Extended Warranty Coverage for Kia Sorento Engines

In response to these engine issues, Kia has launched extended warranty programs that provide significant additional coverage beyond the standard warranty:

Theta II Engine Extended Warranty

• Coverage: 15 years or 150,000 miles from original purchase date
• What’s covered: Engine-related repairs related to manufacturing debris issues
• Models affected: 2011-2014 Sorento with 2.4L engines

Lambda II Engine Extended Warranty

• Campaign WTY035 (December 2023): Covers 2016-2017 Sorento with 3.3L engines
• Campaign WTY039 (May 2024): Covers 2014-2015 Sorento, 2015-2016 Sedona, and 2014-2017 Cadenza with 3.3L engines
• Coverage: 15 years or 180,000 miles from original purchase date
• What’s covered: Head gasket and head bolt failures

These extended warranty programs provide substantial peace of mind for owners of affected vehicles, covering major engine repairs that would otherwise cost thousands of dollars.

How to Check if Your Kia Sorento is Under Recall

Determining if your Sorento is affected by an engine recall is straightforward:

1. Locate your VIN (Vehicle Identification Number) – Found on your dashboard near the windshield, driver’s side door jamb, or vehicle registration documents
2. Visit the NHTSA recall lookup tool at NHTSA.gov/recalls
3. Enter your VIN in the search box and click “Search”
4. Review any open recalls listed for your vehicle

Alternatively, you can:

• Check the Kia owner portal after creating an account
• Call Kia customer service at 1-800-333-4542 with your VIN ready
• Contact your local Kia dealership’s service department

Don’t rely solely on recall notices in the mail, as these can sometimes be missed if you’ve moved or if the previous owner received them instead.

The Knock Sensor Detection System (KSDS)

For Theta II engines, Kia implemented an important safety feature called the Knock Sensor Detection System (KSDS) as part of the recall remedy. This software update is designed to detect early signs of engine failure before catastrophic damage occurs.

Here’s how it works:

1. The system continuously monitors engine vibrations
2. When abnormal vibration patterns are detected (indicating potential bearing wear)
3. The system enters a protective “Limp Home Mode” reducing engine power
4. Dashboard warning lights alert the driver to seek immediate service
5. This early warning can prevent complete engine failure or fire

If your Sorento has a Theta II engine and hasn’t received this software update, it’s crucial to have it installed at your dealership as soon as possible. The KSDS system has been effective at preventing more serious failures by catching problems early.

Class Action Settlements for Kia Sorento Owners

The Theta II engine problems resulted in a major class action settlement covering multiple Hyundai and Kia models, including 2012-2019 Kia Sorento vehicles. This settlement provides substantial benefits to affected owners:

• Lifetime warranty extension for engine issues related to the manufacturing defect
• Reimbursement for past repairs you paid for out-of-pocket
• Compensation for vehicle fires resulting from the engine defect
• Rental car cost coverage during extended repairs
• Potential cash compensation if dealers denied warranty coverage

To determine if you’re eligible for benefits under the Kia engine settlement, visit the official settlement website or contact the settlement administrator. Claims deadlines may still be open for certain types of compensation.

Steps to Take if Your Kia Sorento is Recalled

If you discover your Sorento is subject to an engine recall, follow these steps:

1. Contact your local Kia dealership immediately to schedule the recall repair
2. Keep all service records and documentation related to the recall work
3. If you’ve already paid for repairs related to the recall issue, gather receipts for potential reimbursement
4. Document any symptoms or issues you’ve experienced before the repair
5. Follow up with Kia if the recall repair isn’t performed promptly

Remember that recall repairs are performed free of charge by authorized Kia dealers. You should never have to pay for a safety recall repair.

If you experience resistance from a dealer or difficulties getting a recall repair scheduled, contact Kia customer service or file a complaint with the NHTSA.

Manufacturing Improvements for Newer Kia Sorentos

Kia has implemented several corrective actions to address historical engine problems in newer Sorento models:

1. Theta II Engine Improvements:
   • Enhanced cleaning processes to eliminate metal debris during manufacturing
   • Improved quality control inspections
   • Installation of KSDS software to detect impending failures
2. Lambda II Engine Improvements:
   • Increased engagement depth of head bolt threads starting May 2017
   • Improved head gasket design and materials
3. Overall Quality Control:
   • Enhanced manufacturing processes to prevent contamination
   • Improved testing procedures before engines leave the factory

These changes have resulted in significantly improved reliability for 2018 and newer Sorento models, with dramatically lower rates of catastrophic engine failures reported to the NHTSA.