NHTSA Complaint #11710558 — 2022 KIA SORENTO

I am reporting a serious safety defect regarding my 2022 Kia Sorento Hybrid (Mileage: 91,661). The vehicle was diagnosed with an internal short in the EGR (Exhaust Gas Recirculation) Control Unit (Error codes P0404, P049D). Upon inspection, significant engine oil intrusion was found inside the EGR unit. The EGR system is designed to handle exhaust gases only; the presence of liquid engine oil indicates a critical failure in the powertrain system (likely the PCV system or turbocharger seals) which is forcing oil into the intake/exhaust tract. Safety Risk: This defect causes the EGR system to short-circuit, which can lead to unpredictable engine performance, reduced power, or sudden engine stalling while driving. Any sudden loss of power on a highway poses a severe risk of a rear-end collision. Furthermore, oil intrusion into electrical components increases the risk of thermal incidents or localized fires within the engine bay. Despite the vehicle being within the 10-year/100,000-mile Powertrain Warranty, the dealership (Suntrup Kia South) is refusing coverage, claiming the EGR is not a powertrain component, while ignoring the fact that a powertrain failure (oil bypass) is the root cause of the damage. I request NHTSA to investigate this "oil intrusion into EGR" issue as it appears to be a systemic defect in Kia’s hybrid powertrain that compromises vehicle safety.