TECHNICAL SERVICE BULLETIN: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA/KAPPA ENGINES - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information on diagnosing and/or repairing some 2011-2024MY vehicles (refer to the table on pages 9 and 10 for applicable models and engine), which may exhibit a symptom of excessive oil consumption.
full bulletin at NHTSA ↗2012 Kia Sorento engine problems
severe Owners of the 2012 Kia Sorento have filed 344 NHTSA complaints about the engine, typically surfacing around 101,541 miles at roughly $3,100 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See engine across all vehicles →
Failure mileage
Complaints
344
Recalls
0
Avg fix
$3,100
| Model year | engine complaints |
|---|---|
| 2008 Sorento | 17 |
| 2011 Sorento | 190 |
| 2012 Sorento (this page) | 344 |
| 2013 Sorento | 385 |
| 2014 Sorento | 278 |
| 2015 Sorento | 284 |
| 2016 Sorento | 548 |
1crash
35fires
When does it fail?
Of the 344 engine complaints filed for the 2012 Kia Sorento, here's the actual mileage breakdown — failures cluster heaviest at 150,000+ mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Engine accounts for 39% of every owner complaint on file for this vehicle — the dominant problem area across 12 categories tracked.
Owners have filed 344 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
TECHNICAL SERVICE BULLETIN: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA/KAPPA ENGINES - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information on diagnosing and/or repairing some 2011-2024MY vehicles (refer to the tables on pages 8-9 for applicable models and engine), which may exhibit a symptom of excessive oil consumption.
full bulletin at NHTSA ↗TECHNICAL SERVICE BULLETIN: PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published in (PI2002A, PI2002B and SC200**1) titled “Knock Sensor Detection System - ECU Logic Improvement”. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below return to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Ra
full bulletin at NHTSA ↗TECHNICAL SERVICE BULLETIN: PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published PI1803 titled "Knock Sensor Detection System - ECU Logic Improvement" equipped w/THETA II engine. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below returns to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Ra
full bulletin at NHTSA ↗TECHNICAL SERVICE BULLETIN: BEARING CLEARANCE TESTER (BCT) PROCEDURES - This bulletin provides information regarding test procedure of the Bearing Clearance Tester (BCT) Special Service Tool (SST). The SST comes pre-calibrated from the supplier however, in some cases, due to variable shop compressor air pressure, the SST may need to be re-calibrated to ensure that the tool provides accurate readings when testing the engine rod bearing wear. The calibration and BCT measuring point maintenance is included in this bulletin.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Engine failures dominate this dataset of 343 complaints. The most common failure is catastrophic bearing wear causing seized engines or thrown rods—metal contamination in the block, sudden knocking that escalates into complete power loss, often at highway speeds with no warning lights. Owners report large holes rupturing the engine block, costs of $5,000 to $14,000 for replacement engines, and forced use of used engines with higher mileage and the same defect risk. Owners consistently cite proof of regular oil changes, factory maintenance records, and receipts—yet Kia denies warranty claims, citing missing knock sensor codes or claiming the vehicle VIN is not part of recalled engines (particularly 6-cylinder models, which Kia says are not included despite identical failure modes).
A secondary but alarming pattern is engine fires: flames shoot from the hood, thick black smoke fills the cabin, and fires spread too fast to contain. One family barely escaped with two young children. Fires occur both pre-recall and post-recall engine replacement, suggesting the recalls did not address root cause.
Excessive oil consumption (1–3 quarts per 1,000 miles), sudden complete shutdown on highways at 55–75 mph with no dash warning, and check engine lights paired with misfires round out the catalog. Many failures happen immediately post-oil-change or post-service. Dealers routinely cannot reproduce problems during diagnostics, yet failures reoccur within days of pickup. In multiple cases, dealership technicians acknowledged the engine defect was manufacturing-related, not owner neglect—but still refused warranty coverage. The common thread: no warning lights, no engine knock detection, and Kia's refusal to cover engines unless they've already seized or thrown a rod.
Same Kia Sorento engine reports on nearby years: 2011 · 2013 · 2014 · 2015
Failure modes owners describe
Engine seizure from bearing wear / machining defect
Catastrophic engine failure caused by premature bearing wear, metal contamination in the engine, or machining errors during manufacturing. Bearings wear prematurely, leading to thrown or broken rods that rupture the engine block, creating large holes and complete engine seizure.
When: Varies widely: 69,000 to 144,000+ miles; one case at 25,000 miles with oil sludge; typically occurs mid-highway or during normal driving
Symptoms owners cite: Knocking or rattling noise from engine that escalates quickly; Engine shaking or grinding sounds; Loss of power / vehicle stalls suddenly with no warning lights; Metal in coolant or engine oil; Oil leaking from hole in engine block; Smoke from under hood; Engine refusing to restart or barely cranking
Codes mentioned: No codes in many cases; DTC 1326 (knock sensor) sometimes absent despite bearing wear, No dashboard warning lights in majority of failures
Repairs/costs cited: Complete engine replacement required; costs reported $5,000–$14,000; many owners denied coverage even with proof of regular maintenance; some dealerships install used engines with higher mileage and same defect risk; engine can fail again post-replacement
Recalls/TSBs owners mention: NHTSA Recall 17V224000 (March 2017) for 4-cylinder models only; NHTSA Recall 20V750000 (knock sensor software update); NHTSA Recall 23V652000 (fuel system); many 6-cylinder models explicitly excluded from recalls despite identical failure mode; KIA refuses coverage claiming VIN not part of recall or vehicle not eligible if knock sensor software not updated; warranty denied if no knock sensor codes present; some owners report lifetime warranty on replacement engine, others denied
Engine fire
Engine bursts into flames while driving or immediately after arrival at dealership. Fires spread rapidly with thick black smoke. Causes include bearing failure, oil leaks, fuel leaks, or manufacturing defects.
When: At 92,000 miles (pre-recall); approximately 6 weeks post-engine-replacement recall; while pulling into dealership parking lot; during normal highway driving
Symptoms owners cite: Flames shooting from under hood at all sides; Thick black smoke; Strong smell of gasoline; Smell of gas while driving (noted before fire event); No warning lights before fire ignition
Codes mentioned: No warning lights reported in most fire cases
Repairs/costs cited: Vehicle total loss; entire interior melted; flames spread too quickly to salvage any parts; children and family barely escaped in one case
Recalls/TSBs owners mention: No documented recall specifically addressing engine fires; one owner told fire risk mentioned in letter but no preventive action taken; post-recall engine fires suggest recall did not resolve root cause
Excessive oil consumption / burning oil
Engine loses 1–3 quarts of oil between service intervals (every 300–1000 miles or less) without visible leaks. Related to bearing wear, metal contamination, or internal engine damage. Can occur before full seizure or as sign of failing replacement engine.
When: Between 6 weeks and 2+ months after routine oil change; some cases post-recall engine replacement; mileage 112,700–151,000+
Symptoms owners cite: Check engine light comes on for loss of oil; Oil level drops rapidly without visible external leaks; Rough running or jerking sensations; Burning smell; Engine stalling or attempts to stall; Throttle spikes; Low oil lamp illuminates
Codes mentioned: Check engine light for loss of oil, No diagnostic codes in some cases despite symptoms
Repairs/costs cited: Dealers perform oil consumption test (2,000–1,000 mile intervals); replacement engines recommended but not covered unless engine makes knocking sound or fully seizes; owners forced to top off oil frequently; spark plugs degrading; one replacement engine consumed 2.5 quarts in 950 miles
Recalls/TSBs owners mention: KIA states engine replacement only covered if vehicle makes knocking sound or engine seizes; will not replace proactively; owners told to drive until seizure occurs (deemed unsafe by consumers); some dealerships covered under extended warranty, others denied
Complete engine shutdown / stalling on highway
Engine dies suddenly while driving, often at highway speeds (55–75 mph), with no warning lights or sound. Vehicle loses power steering, brakes, and all electrical function momentarily. Creates extreme safety hazard in traffic or on interstate.
When: Occurs at various mileages (38,000–112,000+); some cases multiple times on same vehicle
Symptoms owners cite: Complete loss of engine power with no warning; Vehicle loses power steering and power brakes; No dashboard warning lights; Engine will not restart immediately (sometimes restarts after 15–30 seconds or longer); All electrical systems die momentarily; No noise or rattling before shutdown
Codes mentioned: No codes found by dealer diagnostic in majority of cases, Dashboard lights go dark
Repairs/costs cited: No repairs completed in many cases; dealers cannot reproduce problem during diagnostic; owners stranded on highway requiring tow truck; one case cost $200 to tow 65 miles
Recalls/TSBs owners mention: NHTSA Recall 20V750000 addresses knock sensor software; no permanent fix identified by dealers; software updates performed in some cases but failures persist; no recall issued in early cases; ECM (engine control module) replacement mentioned but not widely done
Transmission upshift hesitation / poor shift logic
Transmission hangs in lower gears during acceleration, refusing to upshift to proper gear. Vehicle stays in 3500+ RPM range even after acceleration complete. Requires manual (Sportmatic) upshift to correct. Damages fuel economy.
When: From new (233 miles); ongoing throughout ownership
Symptoms owners cite: Transmission holds lower gear during smooth acceleration; Engine RPMs remain at 3500+ when cruising; No upshift after foot removed from accelerator; Vehicle drastic deceleration when foot backs off gas instead of smooth coast; Manual Sportmatic upshift required to reach 5th or 6th gear; Fuel economy well below EPA rating (20 MPG vs. claimed 23–28 MPG)
Codes mentioned: No codes mentioned
Repairs/costs cited: No repairs documented; owner reports issue has persisted since purchase
Recalls/TSBs owners mention: No documented response; appears to be programming issue in transmission control module
Starter / ignition system malfunction with unintended vehicle movement
Vehicle lunges or jumps backward while parked and start button is pressed. Accompanied by audible grinding or mechanical noise. Transmission may slip during city driving. Problem intermittent and difficult for dealers to reproduce.
When: Intermittent; occurs repeatedly across multiple shop visits
Symptoms owners cite: Vehicle lunges backward while in Park during start; Audible mechanical noise at moment of lunge; Transmission slip during city driving (subtle); Whole car jumps as if trying to shift into Reverse; Noise described as starter hitting flywheel
Codes mentioned: No codes found; dealers rewired electrical and found no electrical problem
Repairs/costs cited: Starter replaced but problem persists; dealership unable to reproduce despite hearing noise; rewiring performed; owner fears vehicle will eventually move out of Park and hit someone
Recalls/TSBs owners mention: Dealer unable to diagnose; repeated visits result in no fix; dealership blames inability to reproduce despite documented noise and multiple visits
Metal contamination in engine and coolant system
Metal particles, flakes, or shavings found in engine oil and coolant during diagnostic. Indicates bearing or internal component wear. Radiator cap melts from sustained overheating. Problem repeats in replacement engine.
When: First engine at 69,000 miles (V6); replacement engine again at 122,000 miles (approximately 50,000 miles on replacement)
Symptoms owners cite: Metal flakes and shavings in oil and coolant; Radiator cap melts from overheating; Engine overheats without temperature gauge warning; Engine knocking noise; Loss of power; vehicle smolders; Engine smoking; fire department called in one case
Codes mentioned: No warning on temperature gauges despite overheating
Repairs/costs cited: New radiator installed (multiple times); replacement engine installed but same metal contamination problem reoccurred; second radiator replacement at 122,000 miles; dealer acknowledged maintenance was impeccable and problem unrelated to owner care
Recalls/TSBs owners mention: Recall 17V224000 applies only to 4-cylinder engines; 6-cylinder models with identical failure denied coverage; dealer refused to contact KIA; owner directed to pay all costs despite acknowledged manufacturing defect
Crankshaft / timing chain failure with loss of power
Engine components fail, causing sudden loss of power, rough running, and bent valves. Related to bearing wear or manufacturing defect. Timing chain failures noted in some post-recall inspections.
When: At 44,516 miles (crankshaft sensor failure); later at same vehicle; some cases post-recall engine inspection
Symptoms owners cite: Engine shuts off without warning on highway at 70 mph; Fluttering noise followed by knocking noise; Loss of power; hard to accelerate; Loss of steering and braking power; No smoke; no warning lights; Rough idle; need to pump gas pedal to start; Timing chain failure; bent valves; compression problem
Codes mentioned: Crankshaft sensor fault in early case, No codes in later case despite major component failure
Repairs/costs cited: Engine replacement required ($2,100–$4,200 for used engine); remanufactured short block assembly replaced twice in one case due to continuing noise; excessive sludge noted in some cases; no clear diagnosis provided in multiple instances
Recalls/TSBs owners mention: Warranty denied by KIA despite documented regular maintenance; owner forced to pursue attorney and demand letter before partial coverage; dealership paid half cost after owner letter to dealership owner
Oil pressure sensor / switch failure with oil loss
Oil pressure switch located under intake manifold becomes defective and leaks all engine oil out. Cannot be replaced without major engine disassembly. Located in a position where oil pools in valley pan and drains when vehicle parked.
When: At 66,000 miles
Symptoms owners cite: Oil pressure warning illuminates; Rapid oil loss while driving and parked; Oil pooling in engine valley pan area; Oil draining completely when vehicle sits
Codes mentioned: Oil pressure warning light
Repairs/costs cited: Switch requires engine disassembly; expensive repair; oil drains both while running and while parked due to design flaw
Recalls/TSBs owners mention: KIA warranty covers only to 60,000 miles despite problem at 66,000; same switch is recalled on 2011 models; owner claims same recall should apply to interior engine parts (10 years/100,000 miles)
Check engine light / rough running / misfire
Check engine light comes on; vehicle runs rough, jerks, or misfires in one or more cylinders. Often accompanied by loss of power, throttle spikes, or stalling attempts. Related to bearing wear, knock sensor malfunction, or spark plug degradation.
When: Varies; some cases after fuel injector cleaning; others at 151,000 miles; some during acceleration or highway driving
Symptoms owners cite: Check engine light illuminates; Rough running; jerking or bucking; Cylinder misfire (codes P0300–P0304 type); Ignition coil and fuel injector faults (some); Spark plugs degraded; Throttle spikes; attempts to stall; Loss of power on acceleration
Codes mentioned: Check engine light with misfire codes (cylinder 4 misfiring noted), Ignition coil faults, Fuel injector codes (in some cases)
Repairs/costs cited: Spark plugs and ignition coils replaced; fuel injector cleaning performed; problems persist in many cases; fuel injection/throttle body service charged $199.95 in one case with no resolution
Recalls/TSBs owners mention: Dealers unable to explain cause; some attribute to recall-related issues; no definitive fix provided; owners continue to experience rough running
Loss of power / limp mode activation
Vehicle suddenly loses power or goes into limp mode (reduced acceleration), often while changing lanes or accelerating. Knock sensor malfunction or engine control module issue causes restriction. Vehicle decelerates to 20–40 mph regardless of pedal input.
When: At 35–40 mph during normal driving; after recall inspection in some cases; post-software update
Symptoms owners cite: Sudden loss of power / reduction to 20–40 mph max speed; Cannot exceed speed limit regardless of accelerator input; Check engine light illuminates; Knock sensor malfunction indicated; Limp mode activated
Codes mentioned: Knock sensor fault codes, Check engine light
Repairs/costs cited: Knock Sensor Detection System (KSDS) software update performed but failures persist; knock sensor replacement may be required
Recalls/TSBs owners mention: NHTSA Recall 20V750000 addresses KSDS software update; update completed but failures continue; manufacturer declines coverage if vehicle is out of warranty; extended warranty promised but not always honored
Synthesized from 344 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 7 most recent
The contact owns a 2012 Kia Sorento. The contact stated that her son had reported that the vehicle was losing motive power and had failed to exceed 15 MPH while driving. The check engine warning illuminated. The contact advised the driver to pull over and to stop the vehicle. The vehicle was towed to a local dealer, who diagnosed the vehicle and advised that the engine had failed the engine…
Driving on the highway, engine began to tick and make strange noise, engine light flashed, oil light cam on and engine ceased.
Tl* the contact owned a 2012 Kia sorento. While driving 60 MPH, the vehicle abruptly decelerated. The contact was able to coast the vehicle onto the road shoulder, attempted to check under the hood, and found that the engine was on fire. The manufacturer was notified. The VIN was not available. A police report was filed. The vehicle was destroyed. The approximate failure mileage was 62,000. *tr
My car is starting to rattle on cold starts only. It now has 142000 and still has the issue. I took my car to summit place Kia and they said my car doesn't fall under technical bulletin 140 even though it falls under the engine type and manufacture date. I do routine maintenance with records and they said I missed the replacement window because I bought the car used. After reading multiple…
Vehicle has started consuming high amounts of oil as it passed 90,000 miles. Received an oil low light and needed to add 3.5 quarts of oil. Took to a ki dealership who noted that there were no visible leaks, but plugs were burning white. Kia corporate forces the dealer to install knock detection sensor update which voids all previous engine recalls. In the past, high oil consumption was enough…
Tl* the contact owns a 2012 Kia sorento. The contact stated that while driving approximately 25 MPH, the vehicle stalled without warning. The failure was recurring. The vehicle was taken to a dealer but was unable to be diagnosed. The vehicle was not repaired. The manufacturer was made aware of the problem. The approximate failure mileage was 13,000. Updated 03/12/14*lj *tr
While driving the engine seized up leaving the vehicle without power. Had to coast car to the shoulder of road and was later removed by a tow truck. Was traveling north on state highway 83 in monroe county ga.
Had engine trouble with your 2012 Kia Sorento?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2012 Kia Sorento?
It's a meaningful issue. 344 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 265 complaints that reported odometer mileage, most engine failures cluster between 77,500 and 127,000 miles, with the median around 101,541. A quarter of owners report trouble before 77,500; a quarter make it past 127,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2012/Kia/Sorento.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.