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'17 Sportage SX Engine issues (3rd time)

46K views 232 replies 32 participants last post by  Cramerica 
#1 · (Edited)
Note: In the videos below the pedal is full depressed (I.e. "flooring it") while the car shakes and struggles to accelerate. My cylinder #2 has a code stating either a misfire/lack of compression/other issue. This is my second engine, the first one blew a piston at 11119 miles. After that I had an oil leak from my turbo causing 2.5qts of oil to leak from system within 3000miles. I noticed smoke coming from my engine and brought the car into a dealer (per KIAs request they wouldn't tow it if the car was running). I think I lost another piston yesterday. I was driving in the highway when I heard a loud boom and my car shuttered. Then, it regained some power but continued to voilently shake on and off. Now, the car is lacking any power as you can see from these 3 videos. My car idles abnormally low while shaking a lot. The shaking subsides a little at high revs, but is still felt in the cabin and audible.

Does anyone know what this might be? I'm waiting I'm waiting on KIA to approve it to be taken into a dealer. I only have one dealer close by, others are at least 2 hrs away. The local dealer refuses to see my car after I tried to bring it in when I noticed this same issue before my first piston failure. They were really rude and refused to help, so I'm not welcome at their dealership. This is why I can't simply bring the car in, and I don't want to drive it 2hrs away and risk getting stuck in the middle of nowhere.

My second time having the car in the shop as to fix the turbo leak. KIA replaced my tubro and exhaust manifold since they stripped it while 'fixing' my car the second time. Total time in the shop is close to 8 weeks now this year alone. The car is less than a year old too!

I think it's a blown piston again or some other bigger issue. Any thoughts or advice would be great. I'm tired of KIA refusing to help and only wants to repair the car without accepting responsibility. I told them it's dangerous to drive with these issues, of course they told me to deal with it (in more words or less). I have recordings of most calls between myself and them, and full documentation from the dealer and KIA support system they use. Hopefully they will tow it in on Monday.

Videos removed

Pictures are of my first engine replacement and the broken spark plug from cylinder #3. The other pictures are form my oil leak.
 

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#2 ·
I am afraid there is more to this part of the story that you haven't disclosed here.

"Does anyone know what this might be? I'm waiting I'm waiting on KIA to approve it to be taken into a dealer. I only have one dealer close by, others are at least 2 hrs away. The local dealer refuses to see my car after I tried to bring it in when I noticed this same issue before my first piston failure. They were really rude and refused to help, so I'm not welcome at their dealership. "

That just doesn't happen because someone is having a bad day, more took place, what was it?
 
#4 ·
There really isn't. The service manage was extremely rude, and when I asked to speak with his supervisor he told me to leave. I reported the incident to KIA because it was bizarre. They can't do anything since dealerships aren't owned by them of course. Believe it or not in West Texas people can be a**holes.
 
#8 ·
Regardless of the fuel used, a piston should not fail on a car within 12K miles. I fear this has happened to others and will continue to happen until a case is known. KIA took the engine to their research center in Dallas (what I was told) and would not say anything further once the new one came in earlier this year. It's definitely been a frustrating experience overall. Hopefully they do something to fix the issue this time without having to reoccur.
 
#12 ·
I know about the Lemon Law, the bad part is how it works in Texas. There were other legal avenues I can use without using the lemon law directly. In almost every other state you pay no attorneys costs regardless if you win or lose. If you win the opposing side pays the attorney. In Texas you osy everything up front. I'm not going to spend more than my cars total msrp on legal fees when I can use other consumer protection laws. For example, if they can't properly fix it under warranty or refuse there's a specific type of suit that way. This is how it was explained to me by a law office.
 
#15 ·
Rule Section 215.209 of the Texas Administrative Code, if a consumer is successful in obtaining a refund or replacement of the vehicle under the Texas Lemon Law, then the consumer is also entitled to incidental costs.
 
#16 ·
You would want an attorney in Texas who specializes in lemon law cases, and they will go over the case facts, and likely represent you on the basis of contingency. Which means you pay nothing regardless. There is a bit but here. If the Attorney checks all the facts in your case and decides you will not likely win, they may not take the case based on that information.

This is where your personal actions and words can change your results dramatically. Present clear, true facts and you will likely not have any issues.
 
#19 ·
They did the first time, and it was a 130mile one way trip. I still had to pick up the car and waste time away from work to do it. Dealerships service depts aren't only open M-F making matters worse. At this point they should replace the car, or account for the value lost from these huge repairs. I'm going to pursue legal avenues if KIA can't resolve it properly.
 
#18 ·
Thank you for all of the responses. The law office I spoke with in Austin (not where I live) was telling me something else but I'll check into my options once I hear back from KIA. I document everything and have no reason to lie. I gave KIA numerous chances to fix the issues in the past and they more or less we're uncooperative until I persistently bothered them. It shouldn't take dozen of phone calls to get my car fixed each time.
 
#20 ·
Sorry to hear about your misfortune. Certainly no one expect this sort of serious issues with a new car. The attitude of your first dealer is unbelievable as they are getting paid by KIA for warranty jobs.

Sound like there is some kind of (serious) manufacturing defects in the engine somehow. Assuming you have contacted KIA USA Head Office and made them aware that you will be taking legal action under consumer protection this time if they can fix your car properly. KIA should also pay to have your car tow to a dealership of their choice for the repair.
 
#21 ·
I haven't notified them yet seeing as I don't have legal counsel at this time. The problem is when I secure counsel, they automatically have a hands off approach and can't do anything (KIA). I'll have to see if KIA will tow it in, then contact an attorney (maybe in the reverse order).

The real problem is I'm on engine #2, turbo #2 and exhaust manifold #2. Those are the major components replaced between my two big repairs to date. I think they either did a poor job installing something or have a QC issue/design defect. I seem to be very unlucky when it comes to this car. Right now I have no choice but to try and drive it because I still work M-F and I'm not paying out of pocket for a rental. I told KIA about this issue coming up before it really got bad and they didn't do anything. Yes, I'm referring to KIA USA where I have a direct case manager. I told this person I'm going to share my story because they aren't getting things done and it shouldn't be swept under the rug. I feel this experience is important to show people how they refuse to take the issues seriously and do everything they can not to address it.
 
#24 ·
This is serious stuff, and it happens often enough to give all of us with SXs cause for concern. However, KIA has a lot of turbo cars out there so I have to feel that chances are with us to not have severe problems. Everything here started with spark plug failure/cracked insulators which basically destroys the affected cylinder except for the turbo oil seal failure and the exhaust manifold failure, both of which could possibly be blamed on ham-fisted mechanics doing the first engine repair/swap. It seems to me that if there exists a spark plug that is better than the factory ones perhaps we all should put them in. In the meanwhile, just be alert to any change and don't delay in following up on it - this engine normally runs smooth and quiet - if you experience rough running and loss of power, something is very wrong. On the subject of dealers' shops proficiency, it is statistically impossible that every shop will have a competent, experienced staff. I know that makes it tough. As for being alert, I learned many years ago to do things like simply look where your car was parked when you are leaving for any fluids. Don't be confused by water which normally drips out of the AC evaporator behind the dash. If you don't know for sure, get down there and smell it/feel it.
 
#25 ·
Given the problems that are coming to light with the Theta II engines and the recalls I am definitely concerned. Sure, they haven't included our years in the recalls, so far, but it's not a stretch to imagine that that could change. Hyundai & KIA are claiming the problems were strictly manufacturing process related and were corrected but there is apparently at least one engineer who has claimed that there is a design flaw with these engines.
 
#26 ·
The fact that there is a relatively small number of failing engines (problematic on their own) vs a large number of engines not experiencing issues, and in fact, many of them still running with well more than 100,000 miles on them would tend to validate their claims of a manufacturing issues vs design. Let's not forget the Theta II series is now on it's seventh year of production, so there are many in the field with large number of miles on them already.

As far as potential issues with recent models made in the past 2 years or so, I would tend to believe the manufacturing process issues have been corrected and they have also implemented other tuning and parts changes since then, as well as using a different, smaller turbocharger would indicate they have toned it down somewhat in pursuit of further reliability.
 
#29 ·
I have an update from KIA. They're being even more irresponsible than the last time too! Since the two closest dealerships to me are awful (see my first post) I was told to wait while they figure out what to do. This process could be a few days from my understanding, but I requested a call back today regardless. The rep said I have to drive my car until then i.e. be in an unsafe vehicle longer subject to losing power randomly now (even while driving) until KIA figures out what to do. They don't even know if they're going to tow it or request I drive 3hrs to another dealer to which I refuse for the obvious reasons.
 
#32 ·
They are fobbing you off which is very irresponsible. Perhaps the upper management was not aware of the seriousness of the problem. I would suggest calling KIA USA and ask to be put through the the KIA country manager. Don't hang up until you talk to the country manager. Often the lower rung managers could not care less but senior management may take more of an interest.

This is a potentially serious safety issue as they they are asking you to drive with a CEL light on. Sloppy's suggestion above is good regarding CEL.
 
#30 ·
if you have a CEL that is on and KIA are telling you to continue to drive the vehicle I would definitely document that. Tell the rep you want a letter telling you it is ok to continue driving the car the way it is.

Take a time/date stamped photo or video of the instrument panel showing the CEL on and the mileage. Make a note of the time/date the KIA rep told you it is was ok to continue driving the car. Tell the KIA rep that is what you are doing and why (to protect yourself). Be polite and courteous even tho all you really want to do is give the guy a good slap upside the head and shoulders.

Driving the car with the CEL on is generally not recommended except for short distances, like to the dealer for example. Your owner's manual tells you this. General operation with the CEL on is a no no particularly if it is obvious that the engine is not operating correctly, which in your case is pretty damned obvious. In that situation serious damage can result so you need to make it clear that KIA's rep said it was ok to drive it.

good luck with it. keep us posted
 
#33 ·
Another small update. The rep from KIA USA back stepped and said now I should pay for a rental because they're doing me a favor by trying to find a dealer to service it. I shouldn't pay out of pocket for something with no guarantee of reimbursement when KIA has known about the issue since day one. The rep said otherwise drive the car (all calls are recorded on my end). I've stated numerous times how the car is extremely unsafe so they definitely know (understanding is another story) about my concerns. At this point I don't know what to do overall. I haven't heard back for what they're going to do with my car either. I spoke with a few law firms and I'm awaiting to see if any will take up my case. Right now I'm going to drive the car home so it's not sitting in my work parking lot and hopefully I'll get a rental tomorrow.
 
#35 ·
KIA finally agreed to tow my car 2.5hrs to another dealer, but they acted like it was a huge favor. I clearly stated it's their obligation to tow the car under warranty to the closest dealer. That is the closest one who will actually see the car. The bad part is I'm forced to ride with the tow truck driver and miss most of my work day to the dealer, otherwise I can't get s rental vehicle. I adamantly said no, but they refused to budge. So I get to miss work for this nonsense yet again and I'm not happy about it. I have tons of meetings every day on top of my regular work making this a huge hassle. I'm waiting on a call back from the law firms I spoke with still too. It's looking like it'll be another long repair given my cars track record. I document everything for this reason because I frankly don't trust any car company now.
 
#37 · (Edited)
I figured some more information from my past repairs will really illustrate how bad things got each time. I redacted a lot of information (dealer name, tech name etc) for privacy reasons. Here are my work orders, and KIA tech hotline dealer notes.

Edit: Repair orders removed for now
 
#39 ·
Here are the rest so far. I have many more pages, but these are the most relevant ones. I'm sure I'll get another stack of paperwork when the car gets dropped off/picked up.
To be quite honest, looking at the repair record. This lemon car should be replaced not repaired !

It is worth getting hold of someone senior at KIA and see what they can do with this lemon car. Next step is obviously legal action.

KIA customer service front line people are mucking you around which is unacceptable.
 
#43 ·
Yeah sounds like your situation is a lot different than mine. I got a top of the line rental, they of course swapped out the engine, and when Peak Kia scratched the crap out of my car putting the new engine in they painted that. I wouldn't settle for $1800 either. Hold their feet to the fire and get what you deserve... which is a new Sportage.
 
#44 ·
Like I said KIA doesn't seem to care. I'm in the process of retaining an attorney so if we go to court I'd love to see this all become public record at trial. What I deserve is my money back not a Sportage. You could not pay me enough to drive another KIA after this disaster.
 
#55 ·
I hesitate to say this, but this is why when selecting a vehicle to purchase, you know adequate support is available for it near where you live. With only 1 dealer within an hour drive, that's not very good.

Unfortunately, there is a wide swath of the United States and Canada where this is definitely an issue. It sounds like you have a lousy dealership.
 
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