NHTSA Complaint #11700897 — 2022 KIA TELLURIDE

Borescope inspection of the engine shows multiple signs of internal mechanical failure involving oil control, piston ring integrity, coolant intrusion, and cylinder wall damage. Excessive oil buildup is visible above the oil control ring, far beyond what is expected at 59k miles. Cylinder walls show heavy polishing where cross-hatching should be visible, indicating loss of lubrication and abnormal wear. Carbon deposits are extremely thick; in several areas carbon has flaked off and been pulled downward into the cylinder, creating scoring. Straight vertical scoring marks cut through the normal diagonal honing pattern, confirming blow-by and damage to the cylinder sleeves. Evidence of coolant intrusion is present, including orange discoloration consistent with rust/coolant contamination, excessive moisture, and steam-cleaned areas of the combustion chamber. The intake valve and combustion surfaces appear abnormally clean, consistent with coolant steam-washing. This suggests head-gasket failure, a block or head casting defect, or ring damage (possible cracked scraper ring). Coolant in the cylinders can wash away oil from the bore, leading to rusted pistons and accelerated scoring. Multiple pictures show severe scoring and loss of lubrication. This compromises the ability of new pistons or rings to seal, meaning the cylinder walls would continue to allow blow-by, oil burning, coolant intrusion, and friction. Even attempting to polish or recondition these bores would enlarge them, causing piston flutter, noise, and long-term failure. Based on the level of damage, the engine is no longer safe or reliable. A seized piston could cause sudden loss of power at highway speeds, creating a safety risk. The observed defects indicate a potential manufacturing or casting issue that may affect other engines. The dealership and KIA Consumer Affairs have been notified but there has been no replacement or resolution after 3 months of ongoing issues, and 8 weeks of holding my vehicle.