NHTSA Complaint #11519719 — 2015 KIA SOUL

At the inspection & emissions test on 01/10/2023, the vehicle failed with a P0420 cat code & Kia recommended I pay to replace the catalytic converter. The first P0420 was found in Aug '19 at an Auto Zone. The vehicle is available for inspection. My safety & those of others is at risk per the recall number 19V120 dated 04/12/19: "A defect has been identified which relates to motor vehicle safety. The defect may cause damage to the catalytic converter... If this condition occurs, you may hear knocking noise from the engine and/or the Malfunction Indicator Lamp (MIL) may illuminate. Kia will upgrade the Catalytic Overheating Protection (COP) logic in the Engine Control Unit (ECU) and if necessary replace the catalytic converter and/or engine at no cost to you." This Kia's ECU was upgraded on 04/24/19. About 3 months later, the check engine (CE) light illuminated. Auto Zone found a P0420 code but the Kia dealer found a P0455 & suggested the gas cap was not installed properly. They cleared the code and sent me away. The CE was back on Nov '19. An appointment with Kia on 01/14/20 revealed a P050A code which had no resolution. The dealer "reset engine adaptive values as per techline and released vehicle back" to me. I drove in stress, praying the vehicle doesn't catch fire since it was losing significant oil. I added additional quarts about 1500 miles after each oil change. After a while I got used to the CE being on. In August of '21, AutoZone found a P0420 diag code again. I didn't think Kia would resolve the problem. I finally called Kia in May of '22 & was told of another recall #SA485. I took the Kia in on 05/31/22 with the CE light on. After the ECM upgrade the CE light was off until a few miles were driven. Inspection on 01/10/23, Kia dealer found P0420 Cat Code, failed the vehicle, & told me vehicle is no longer covered under warranty. I think the vehicle should have been recalled for catalytic converter like other 2015 Souls. Please recall this Kia.