Manifold/header/muffler/tail Pipe Problems of Kia Motor Sorento

Kia Motor Sorento owners have reported 27 problems related to manifold/header/muffler/tail pipe (under the engine and engine cooling category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Kia Motor Sorento based on all problems reported for the Sorento.

1 Manifold/header/muffler/tail Pipe problem of the 2013 Kia Motor Sorento

Failure Date: 02/03/2021

I have 112782 miles on this car. I got a check engine light come on and found that had a code p200a. An intake manifold bank #1 problem. After doing research on this it looks like a long ongoing problem with Hyundai and kia's. 4 cylinder and 6 cylinders engines.

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2 Manifold/header/muffler/tail Pipe problem of the 2016 Kia Motor Sorento

Failure Date: 02/01/2020

2016 kia sorrento lx with the 2. 4 engine with 54,000 miles is using 1 quart of oil per 400 miles. The tail pipe is emitting an oily black soot. While driving, an engine ticking noise alerts us that the oil is low. At this rate we will have replaced all the oil with 18. 5 quarts of oil before the scheduled 7,500 mile oil change. The mechanic at the portland oregon area dealership is trying to tell us this is normal. The vehicle is currently involved in their oil consumption test loop, like so many others. I smell a rat.

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3 Manifold/header/muffler/tail Pipe problem of the 2016 Kia Motor Sorento

Failure Date: 12/20/2019

While passing, sudden loss of all power. The check engine light came on. From that point on, very low power. When I got home, there was a fairly loud engine knock and oil coming from tail pipe. Took car to independent shop who diagnosed the issue as rod knock. Had the car towed to kia dealer who then said it needed a new engine. Only 82,000 miles on vehicle. Kia covered the parts and labor to replace. When the shop dropped the engine, they noticed the drive splines on both the awd transfer case and transmission were both rusted and all teeth sheared off on the fwd side of the spines. Rwd still intact. Kia would not cover neither would the extended warranty company because of the rust. That is a sealed unit with multiple rubber gaskets. How could it possibly have rusted? this is a major design flaw as there should been adequate heavy lubricant as well as sealing to prevent these parts from rusting. New transmission required $1800, and new transfer case would have been another $2500. Chose slightly used unit for $1000. It took almost 8 weeks to resolve. Now car is leaking oil on to exhaust. Back to dealer it goes. . .

4 Manifold/header/muffler/tail Pipe problem of the 2017 Kia Motor Sorento

Failure Date: 10/11/2019

We returned to kia dealership 3/9/2020. We were low on oil again. This was after they told us this on our previous visit 2/7/2020 it was our last oil consumption testing. Kia did a full oil and filter change at 60,689 miles. They started another 1000 mile 'oil consumption test' and sealed the dipstick, secured it with a plastic strap attached to the manifold, which the manifold gets extremely hot and could cause the strap to melt and or cause a fire.

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5 Manifold/header/muffler/tail Pipe problem of the 2012 Kia Motor Sorento

Failure Date: 06/15/2019

Tl the contact owns a 2012 kia Sorento. The contact stated that there was excessive smoke coming from the rear tail pipe. There was also reduced engine power when needing to drive more than 40 mph. Century 3 kia (2483 lebanon church rd, west mifflin, PA 15122, (412) 466-1466) was notified of the failures and stated that the vehicle was not included in NHTSA campaign number: 17v224000 (engine and engine cooling). The contact stated that the failures were related to the recall campaign. In addition, the vehicle was not included in NHTSA action number: pe19004 (exterior lighting, electrical system, engine and engine cooling, unknown or other, engine, service brakes, hydraulic). The vehicle was not repaired. The manufacturer was notified of the failures. The approximate failure mileage was 110,000.

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6 Manifold/header/muffler/tail Pipe problem of the 2013 Kia Motor Sorento

Failure Date: 12/12/2018

While driving engine oil lamp lights and since I was less than 2000 yards from home, I costed into driveway. Engine off, I lifted hood and checked oil and it showed nothing. Looking behind car, I notice oil all over back of car rear and some on road and driveway. Filled oil and restarted only to see oil being pumped seemingly out of rear main and front of trans. Took to nearest dealer who fixed problem under 50k warretee. It was oil sending switch located under intake manifold. Seal between metal body of switch and electric connection of same blow out. Seems like epoxy did not hold. Less than 17 k miles later, same thing happens on highway exit ramp had towed 85 miles back to local area since kia couldn't find mechanic to work on it during hunting season. 1500 dollars later after showing mechanic links to the oil leak fix. . . They fix again the same oil sending switch. Some people have had it replaced 3 to 4 times. Canada has this part as a recall. Why not the USA yes I paid for it as warrantee expired due to 5 years.

7 Manifold/header/muffler/tail Pipe problem of the 2015 Kia Motor Sorento

Failure Date: 09/01/2018

Takata recall. I have a 2015 kia Sorento. At about 76,000 miles, the engine began to burn oil. I had it checked for a leak, but the mechanics couldn't find anything. When I start the engine, blue smoke emits from the tail pipe. I am loosing about a quart of oil every 200 miles.

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8 Manifold/header/muffler/tail Pipe problem of the 2013 Kia Motor Sorento

Failure Date: 06/20/2018

While driving car home from a short trip, we started noticing a noise that seemed to sound like a small muffler leak. No loss of power or any warning lights were apparent at all. Continued driving thinking I could have the hole in muffler fixed the next day. After traveling some 30 miles to our exit, getting off the enter state, the car stalled, still no warning lights indicating anything was wrong, . The car restarted and I continued to drive home until it stopped again. I called for road assistance and had it towed to my mechanic.

9 Manifold/header/muffler/tail Pipe problem of the 2012 Kia Motor Sorento

Failure Date: 03/09/2018

This is the second time I have had this problem with this SUV. While driving down the road oil pressure light comes on. I pull off the road right away and shut off. Then I noticed trail of oil on road behind me. I get out and look under front of car and see oil running out on to the ground. Cost $700. 00 last time when repaired. Replaced main seal on motor and replaced oil sending unit. Watched you tube video they said looks like main seal leak but is actually oil pressure sensor. Located under intake manifold and oil runs out end of motor. By transmission and looks like main seal leak. But it's just a $18. 00 oil sending unit. That's leaking.

10 Manifold/header/muffler/tail Pipe problem of the 2013 Kia Motor Sorento

Failure Date: 09/22/2017

Kia replaced my engine twice, due to oil consumption. A month after the first engine replacement, I had the same problems. . Smoke coming out of exhaust, loss of power, stalling and oil consumption. I was in and out of kia's service department. They told me nothing was wrong! I moved from CO to ne, my husband and I had to add oil every 100 miles, with smoke coming out of exhaust and stalling. Lincoln ne kia found an oil leak at the exhaust manifold right away! kia instructs then to replace my engine again! once they replaced engine, they still saw the leak at the exhaust manifold with resulted in more guessing and parts. The day after I picked it up, my husband and I went out to dinner and my Sorento died in the middle of the road. Right away called and got it back in. At first they could not duplicate, however after taking it 50 miles, it died 3 times. They still can't find anything, but feel it may be the throttle body. They put a used one on and have me drive it a few weeks, it didn't die during that time, so they ordered a new one and installed. A month later I drive to CO, I break down, it's towed back and kia can't find anything. I drive it and it dies 1/2 dozen more times, each time I take it right in, but the code has cleared and they can't find anything! finally, it does and the light stays on, it shows it's the map sensor. Kia has a specialist come out to install that and inspect my car. They say it's fixed and safe. I drive to CO on 9/22/17, 2 months later and my engine catches on fire. I loss my brakes, can't put it in park and emergency brake won't work. Flames are everywhere, smoke filling my car. I jump out of my burning, moving car and seconds later the whole thing engulfs in flames! most horrific, awful thing ever! I was lucky enough to have minor injuries. My mental and emotional state are a mess! kia won't do anything!.

11 Manifold/header/muffler/tail Pipe problem of the 2012 Kia Motor Sorento

Failure Date: 07/06/2017

Intake manifold runner code p200a.

12 Manifold/header/muffler/tail Pipe problem of the 2013 Kia Motor Sorento

Failure Date: 06/01/2017

My 2013 kia Sorento is using an excessive amount of oil in between oil changes. I haven't found any oil leaks. Upon starting the kia there is a lot of white smoke coming from the tail pipe. Also has a rough idle. Currently in an independent mechanic shop and they aren't finding an oil leak either. Has been doing this for the 3 years I've owned it. Purchased from a car dealer. Have had regular oil changes.

13 Manifold/header/muffler/tail Pipe problem of the 2013 Kia Motor Sorento

Failure Date: 01/10/2017

The contact owns a 2013 kia Sorento. When the vehicle was started, black smoke appeared under the hood and the muffler that emitted through the vents inside the vehicle. The contact turned the engine off and called an unknown local kia dealer located in salem, or where it was diagnosed that the engine failed and needed to be replaced. The vehicle was not repaired due to the repair fees. The manufacturer was notified of the failure and informed the contact that she did not change the oil when needed; therefore, they would not make any repairs. The approximate failure mileage was 70,000. The VIN was not available.

14 Manifold/header/muffler/tail Pipe problem of the 2011 Kia Motor Sorento

Failure Date: 01/03/2017

We have taken our 2011 kia Sorento to mulitple dealerships to get fixed. All say the engine is shot. There is a seal inside the engine that is making the vehicle not work. There is multiple recalls for other years of the kia Sorento but not ours. The mechanics say that this year and make has had multiple issues with the engine. I am wondering when this year will be recalled for engine issues? when I start the 2011 kia is spudders and blows smoke out the muffler. I have been told that the whole engine needs to be replaced. The spuddering and smoke happens right when I start the vehicle. It is a 2011 and I only have 96k miles on it.

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15 Manifold/header/muffler/tail Pipe problem of the 2011 Kia Motor Sorento

Failure Date: 12/07/2016

The car was not always responding to me when I wanted to accelerate, I would hear the rpms going up but the car would not go faster, then a puff of white smoke would come out the tail pipe. Then one day, I was driving the car and it started making a clanking noise when I would push the gas pedal. It sounded like the noise a roller coaster makes when you are clanking up the hill at the beginning. Took the car to the dealership and they took the engine apart to find the problem. The car has an engine defect that was diagnosed by a kia dealer as a manufacturers defect. Now the car is not drivable and kia is refusing to pay for a new engine. Kia needs to recall all vehicles with these engines. They are built by Hyundai and they recalled their vehicles with the same engines.

16 Manifold/header/muffler/tail Pipe problem of the 2011 Kia Motor Sorento

Failure Date: 08/04/2016

The contact owns a 2011 kia Sorento. The contact stated that an unknown warning indicator illuminated on the instrument panel. The vehicle was taken to a dealer where it was diagnosed that the intake manifold failed and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 30,000. The VIN was not available.

17 Manifold/header/muffler/tail Pipe problem of the 2012 Kia Motor Sorento

Failure Date: 08/02/2016

The car would lose power while driving then accelerate to speed. This was followed by smoke from the tail pipe. I have returned to the yonkers kia dealership on central park avenue in yonkers NY on August 5th, 2016 to look into a problem. A diagnostic was done and it was determined the engine was ruined do to slug build up. I was told that a replacement would coast about $10,000. Odd for me because my wife and I took the car in for regular oil changes and no indication of engine issues displayed on the dashboard. After speaking to a service representative he stated that I would have to support proof of maintenance on my car which would allow my repairs done under our warranty. I became extremely disillusioned after bringing the car into kia due to an issue that can be tied to the manufacturer. We were denied service under the warranty which we are still under. Our car is fairly new with less than 25k miles. We carried out all of the steps thus far including taking care of our investment, proving our car has been taken care off including keeping meticulous annotations (kept in the log provided by kia) and receipts to date. This is another example of big companies looking for loopholes and using tactics to swindle people of their hard earned paychecks. However, kia does not want to honor us. Our paperwork/log/receipts are being taken apart with prejudice in order to not provide services and rectify this issue that is proven to be a defect. We are concluding that based on the poor handling of our case and many others like ours, kia and its affiliates /dealers and corporate, are not about safety and customer satisfaction. All we ask is that kia honors its warranty rather than finagle use on the fabricated notion that we are at fault rather than poor engineering.

18 Manifold/header/muffler/tail Pipe problem of the 2012 Kia Motor Sorento

Failure Date: 02/21/2016

I was driving about 60 mph down 269 highway when all at once I heard a loud pop like sound and then smoke started going out the tail pipe and then under the hood the car lost all power and stopped. I got out and rasised the hood and it was on fire . Luckely someone one was behind me and had a fire exstinquer and put it out. Called police they would not come out called insurance and they sent a tow truck. We bought this car brand new in 2011 and always kelpt it serviced, they took it to the kia lot we bought it from and said it was a fire in the bottom of the engine and it would cost $10,000 to fix it we were still paying on it. So the insurance called it a loss. Now we are out car and no money to boot. I had just took my grandbaby home it could of been really bad. I got on the enternet and found several other 2012 kia Sorentos that had the same problems.

19 Manifold/header/muffler/tail Pipe problem of the 2012 Kia Motor Sorento

Failure Date: 01/30/2016

We were told we had a 10 yr, 100000 mile warranty bumper to bumper in Jan 2012 when we bought the vehicle. Last week the airbag light and engine light came on. We took the car to the local kia dealership and was told the warranty didn't cover check engine or airbag problems, even though the dealership service department said they would be covered if the unit was under 5 years old. They want $1000+ to fix the engine light problem on the intake manifold and $1400 to fix the airbag problem. Both units should be under warranty. We had a spare tire problem a month after getting the car. The spare tire was bad and they wanted us to buy a new tire. Nothing we have is covered under warranty it seems. We were told the entire airbag system on the car would not operate unless we paid the $1400 to repair the airbag system.

20 Manifold/header/muffler/tail Pipe problem of the 2012 Kia Motor Sorento

Failure Date: 01/22/2016

@ 66,000 miles, the oil pressure switch, located under the intake manifold, is defective and leaked all the oil out of the engine. You cannot replace the switch/sensor without disassembling the engine. Kia will only cover this repair up to 60,000 miles. An internet search shows this to be a common issue. Additionally, its the same switch that is covered under a recall on the 2011 kia Sorento. Kia customer relations said I shouldn't believe what I read on the internet yet it was the internet I used to make my decision to purchase their product. The oil pressure switch should be on the same recall as the 2011 recall. Same problem same switch. Due to the location of the switch and what is required to access it, the coverage should be the same as an interior engine part 10 years, 100,000 miles. The oil drained while driving/running, and spilled while sitting stationary due to the design of the engine. The oil pools on what was described as a "valley pan" then dumps when parked.

21 Manifold/header/muffler/tail Pipe problem of the 2005 Kia Motor Sorento

Failure Date: 12/08/2015

I was driving down the highway and all the sudden my car gave a big sound and died. The steering was really hard to steer, luckly I was in the slow lane and coasted off the edge of the road. Had it towed to mechanic the started was bad, along with the fuel line and fuel pump. After got it running once again ran fine hour later the crank shaft sensor went out. I have read many many complaints about the same issues, also was told that my fuel tank and bottom was rusting out. And my sway bar is bad. My car shakes, I have had new tires and brakes put on and a new muffler put on. I have had all my oil changes and tune ups. They say there is no recalls, how could there not be recalls here in the USA. They had a class action law suit in canada and kia was made to fix these same issues.

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22 Manifold/header/muffler/tail Pipe problem of the 2016 Kia Motor Sorento

Failure Date: 05/22/2015

2016 kia Sorento. Consumer writes in regards to vehicle will not shift properly and failed to accelerate over 30 mph. The manifold assembly intake was replaced three times.

23 Manifold/header/muffler/tail Pipe problem of the 2006 Kia Motor Sorento

Failure Date: 09/11/2014

My 2006 kia Sorento, manufactured in August 2005 & was a basic vehicle, no luxury model. A rental car business was 1st owner and only had it for a few months, then I bought it from a dealer in sept 2006 w 14,000 miles. It is 8 years old with 108,000 miles. The check engine light turned on, I heard loud banging in the hood, then suddenly it turned off while I was driving on city streets. Traffic was slow moving. I had it towed to an expert mechanic and owner of his own shop. My mechanic has done some preventive maintenance in the past and considered it to be in excellent condition. He took the engine apart and found pieces broken off from the "intake runner butterfly valve assembly & fell into the engine; also there was a bushing failure in the lower induction manifold. My 3. 5 engine was totaled within minutes along with all surrounding parts. The same engine as in the recall. My kia has a 3. 5 engine, same as in the recall bulletin #tt2008020601. The recall bulletin was for kia models 2003-2005, yet this exact incident was described in the recall bulletin. I have two photos of some of the damage (1st photo is the intake runner assembly w/two broken missing butterflies for cylinders 5 & 6 & the 2nd photo of a piece of the butterfly stuck in the intake port of the cylinder head -both taken on 9-12-2014. ) I then had it towed to a garden grove kia dealership. They inspected & gave me an estimate of $11,700. All they said it was out of warranty and that 2006 models was not part of the recall. How can kia corporation guarantee that the same inferior parts were not installed in my 2006 Sorento? it was manufactured in 2005. Kia corporation should take responsibility for the damage due to the fact that this problem was not completely resolved with the 2005 models.

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24 Manifold/header/muffler/tail Pipe problem of the 2003 Kia Motor Sorento

Failure Date: 08/04/2014

I was told by the mechanic that "something happened inside the engine that cannot be repaired". Prior to the engine failure (may, 2014) the rear throttle plate came apart and lodged in the lower intake manifold. The mechanic was unable to retrieve the screws and one was even lodged in a cylinder head. A throttle plate assembly was installed and the car was drivable but with an audible noise. At this time I was told the same problem exists with many kia's and yet a recall has not been issued. My car is not drivable, it's a v6 and the left side of the engine is completely shut down and I feel kia could have avoided this with a recall when they have known for years that the problem exists.

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25 Manifold/header/muffler/tail Pipe problem of the 2003 Kia Motor Sorento

Failure Date: 02/01/2008

Engine light came on back in February and had it to two different mechanic shops which replaced spark plugs and one coil pack. Engine light still on so I took to kia dealer and they replaced spark plugs with platnium ones and replaced other 2 coil packs. Vehicle has been back to dealer several times for the past several months for check engine light replacing intake manifold due to recall but light came back on and they have had my vehicle most recently for the past 4 weeks. I went to pick it up yesterday as they said they had to replace the cylinder heads with reconditioned ones and all gaskets and seals. As I started to leave the dealership light came back on and vehicle is there again. Obviously mechanics at dealers don't know what's causing these problems and cannot fix them. I feel that kia should buy everyone out of their Sorentos plus give them the value of the vehicle (without deducting for problems) plus a 15% compensation for putting the customers through this or maybe put a brand new engine in vehicle. A new engine or remanufactured engine was replaced in this vehicle back in August, 2006. I originally put my date down as March, but looking back, this has been going on since February!! this is the second complaint I am filing.

26 Manifold/header/muffler/tail Pipe problem of the 2004 Kia Motor Sorento

Failure Date: 09/25/2006

I had back firing and the possibility of stalling. Of course I did report this to lawleys, but their response was, well we can't find the problem, so when the check engine light comes on, then bring it back. I had traveled to el paso, TX. And when I was ready to come home, I started this vehicle and it had a very loud clicking noise. I had no oil in the car and there was no warning. As far as the verification of oil changes, I had some, but I didn't have a recent one because it was not time to change the oil until I got back home, but they did not care. Well, the second time that I had a problem I was in willcox, az. It's about 50 miles outside of sierra vista. When I got out there the check engine light came on, and if you read your manual, then you know not to drive the kia with the check engine light on. They said to drive it home. This was on a Saturday. I had to wait until Monday to bring it into the shop. Come to find out, there was a very big problem with the engine. The lack of power, the backfiring of the engine, it all came from a cylinder misfire. There were dents in the piston top, cylinder wall was damaged, and valve damage, to include metal shavings in the cylinder. It is stated in my report that there were concerns about this problem being in the intake manifold with other vehicles. This caused the damaged areas that I recently mentioned. This of course caused problems with the performance of the engine. If you are having the same problems with your kia and your dealership tells you they can?t find the problem, then mention the concerns about the intake manifold. Every dealership knows that these vehicles are badly made and they will find any reason to not have to pay to fix your vehicle. Make sure you have your receipts or they will not be willing to help you at all. After my dealership diagnosed it, they said that because I was missing an oil change, I would have to pay $350 (for the fluids needed) and that they would replace the engine.

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27 Manifold/header/muffler/tail Pipe problem of the 2005 Kia Motor Sorento

Failure Date: 06/05/2005

1) slowed car to put into park & car lunged forwarded, backed off, lunged forward, backed off, etc. Tapping sound came from engine. 2) car engine stopped and would not restart (stalled on roadway) 3) it is currently in the dealership for repairs, after they told me they couldn't get it to duplicate the problem (although the 1st day it was in the dealership, they anknowledged it was "misfiring". ) they have now stated that a clip on the intake manifold comes dislodged and end up in the catalytic converter, and this could have caused the problem. My car has been out of service for 3 days, as of this writing, as they have ordered a new intake manifold.



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