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Discussion Starter #1
Girlfriend bought a Sportage AWD 2.4 brand new 20,000kms ago, all servicing done at the dealer, just had the recall done for the reprogramming of the knock sensor to detect engine failure... 5,000kms later... engine failure (i think)

Car is currently at the dealer for diagnosis, so far the service has been great. They gave her a 2011 forte5 as a loaner. At the back of my mind I hope it was just an overly sensitive programming in the monitor but the symptoms leading up to the failure point otherwise.

Driving along at highway speed (110kmh) engine revved to redline, came back down, throttle had no response, engine died and coasted to the side of the road with check engine light flashing. Left car for a few minutes, attempted to restart and nothing. (verbatim from girlfriend)

I'll keep you all updated!
 

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2011 Forte SX 2.4L (thankfully MPI) A/T 144K miles
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.... At the back of my mind I hope it was just an overly sensitive programming in the monitor....
Actually that would be the worst of all the possible outcomes. Kia would be able to find nothing wrong and just hand the keys back to her. Then it would be just a question of how long until it goes into LHM again, x number of times.

But no concern about that possibility, because it certainly sounds like the engine in her vehicle is headed to the dumpster. And that's a place where every newly blown Theta will find plenty of company.
 

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Doesn't sound like engine failure to me - more like a bad throttle position sensor or throttle actuator. Its safe for the engine to go to the redline as long as its not for the whole 500 laps. :) It can't go over the redline. Did anybody stop to wonder how come the engine was able to go to the redline with the car in gear and not accelerating? Somehow the trans went to neutral or something went wrong with the ECU/trans control. This is the kind of problem that possibly could be related to the software update.
 

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.... Did anybody stop to wonder how come the engine was able to go to the redline with the car in gear and not accelerating? ....
The KSDS was designed to force limp mode when an early indication of engine knock is detected. But who knows what forcing a supposedly controlled limp mode turns into if there's a sudden catastrophic engine failure. The bottom line for me is that there was a flashing CEL, which doesn't get triggered from much other than the KSDS. That, along with the failure to restart, sure makes it sound like a blown engine to me. But this is speculation on my part, and I certainly could be wrong. If the OP follows up with the outcome, then we'll find out what actually happened to her vehicle.
 

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.... engine died and coasted to the side of the road with check engine light flashing. Left car for a few minutes, attempted to restart and nothing. (verbatim from girlfriend ....
The above account from your GF does not match what Kia wrote under 'Customer Report'. From what they're saying, the vehicle was always able to run in limp mode, and never stalled out. Anyway, it doesn't matter now, and glad to read it's back on the road. Hopefully that was the last time that flashing CEL shows up.
 

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Discussion Starter #10
Well it happened again! Same exact problem, highway cruising, flashing check engine light, stop car, turn off, turn back on, no movement at all. The "man" in me wants to disconnect the battery and then try it but we didn't buy a new fkcn car to have to be worrying about that nonsense. This time my girlfriend is stranded over an hour away. Guess who has to burn two hours of his day and $30 in fuel because of this fckn Kia? Can't wait for Monday.
 

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They already replaced the knock sensor harness, so at this point the only 2 remaining options are knock sensor replacement or a new engine.
 

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Discussion Starter #12
Just a side note about Kia's roadside assistance, they only tow to the nearest dealer which is 1r and 20 mins from home. We're going to have to fight to have it towed to the dealer closer to home I am assuming.
 

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Presumably you would have had much more serious issues down the road, engine fire, etc. They use the sensor to detect problems before they get that bad, but unfortunately the sensing design has not been perfect
 

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I'm curious, had we not done the knock sensor campaign would we have had these issues?
That's a multiple choice answer. The first part is that your vehicle would definitely not have had the first limp mode and knock sensor harness replacement, if the update had not been done. However the other part of the answer is that the (presumed) engine failure was going to happen, irrespective of the update being done. The update was a monitor-only change, and did not cause the engine to fail.

Now if OTOH the engine actually didn't fail, then it would be yet another false positive. But I don't think that's the case, based on your description of the vehicle being dead.
 

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Discussion Starter #16 (Edited)
The thing that worries us is we like to go on random road trips, sometimes as an over night trip. Our most recent one was 6hrs away where there was no cell service for an hour or two in either direction. I've never owned a car that's given me this uneasy feeling before and I owned an F150 with the 5.4 3v. Hopefully the issue can be solved with this service.
 

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Discussion Starter #17
Word from the dealer is her particular year and model required a revision to the programming of the knock sensor after the initial campaign... This is what gets me.. "You wouldn't have known you needed it until the car stopped running" - Service manager. I'll post the work order this evening.

That's comforting, so the last trip we did could have left us stranded in the middle of nowhere, with no cell service or anyone around. Now I'm going to be into this issue for an entire days worth of driving and a tank of gas because Kia couldn't get their programming figured out.
 

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Word from the dealer is her particular year and model required a revision to the programming of the knock sensor after the initial campaign... This is what gets me.. "You wouldn't have known you needed it until the car stopped running" - Service manager. I'll post the work order this evening. ...
That's the first time I've seen anything like what you wrote above (and I spend lots of time looking for this stuff). The whole limp mode thing is very well known, but 'stopped running' without there being a failed engine is brandy new (to me anyway). I'll be very interested to read the work order, and also anything else they might have to say to you about this incident.
 

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Discussion Starter #20
We've got a new? or maybe not new issue? The car spends most of it's life in ECO (unless I'm driving) When cruising or accelerating moderately, the engine will rev briefly all the way to red line and then settle back down. I haven't witnessed it and asked the condition of the roads (maybe losing traction?) and if it really went all the way to redline or was just slipping (as they do a little first thing to warm up the trans) and she said it goes "all the way up". It's very similar to the original issue BEFORE it would shut down and start flashing the check engine light.

Something isn't right with this car, she doesn't drive hard so I don't believe she's actually accelerating all the way to redline and the fact that it happens while cruising is very odd. Almost as if the trans disengages or goes to neutral for a brief time. Also we've noticed the fuel mileage has increased considerably since the last "recall of the recall". Last years winter L/100 was about 9.5-10 and this winter it's 11.5-12. I understand there are a lot of factors at play but there's something f*cky (trailer park boys reference)
 
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