Engine. Review the 256 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Steering. Review the 100 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Exterior Lighting. Review the 88 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

23 crash reports33 fire reports14 injury reports

What owners actually said

593 reports

76,250 miles · Mar 30, 2016

Steering

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WHILE TAKING THE CAR IN TO THE SERVICE DEPARTMENT FOR A TRANSMISSION PROBLEM, THEY DID A 360 CHECK AND NOTICED THE STEERING COLUMN HAD PLAY IN IT AND MADE A CLICKING NOISE ABOUT A QUARTER TURN EACH DIRECTION. IT IS A PLASTIC GEAR PIECE THAT IS SMALLER THAN A QUARTER, PICTURE WILL BE ATTACHED. THEY SAID IF I DIDN'T GET IT FIXED IT WOULD GET EVENTUALLY WORSE BY WEARING OUT THE TIRES OR ALIGNMENT SO I HAD IT REPLACED. THEY HAD TO TAKE APART THE STEERING WHEEL TO REPLACE IT. IT WAS 20 FOR THE PIECE BUT WITH LABOR MY BILL WAS 181.

NHTSA ODI #10852577

40,000 miles · Mar 30, 2016

Service Brakes

TL* THE CONTACT OWNS A 2011 KIA OPTIMA. WHILE DRIVING AT VARIOUS SPEEDS, THE BRAKE PEDAL WAS DEPRESSED BUT THE VEHICLE FAILED TO SLOW DOWN. THE CONTACT STATED THAT THE BRAKE PEDAL HAD TO BE DEPRESSED WITH EXTREME PRESSURE FOR THE VEHICLE TO STOP. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS…

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NHTSA ODI #10852466

1,445,400 miles · Mar 15, 2016

Electrical System

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2011 KIA OPTIMA BATTERY DIED THE MAIN FUSE INDICATOR WASN'T WORKING. ON WEDNESDAY FEBRUARY 17, 2016 AT ABOUT APPROXIMATELY 5AM ON RT97, I WAS APPROXIMATELY 20 MILES FROM HOME ON MY WAY TO WORK WHEN THE CAR STALLED OUT. I WAS ABLE TO PULL TO THE SIDE OF THE ROAD; I WAITED FOR 2 MINUTES I THEN PUSHED THE START BUTTON ON THE DASH BOARD THE CAR THEN STARTED. I THEN PUT IT IN GEAR AND STARTED DOWN THE ROAD AGAIN I WENT A QUARTER OF A MILE THE OPTIMA STALLED OUT AGAIN. AFTER WAITING 2 MINUTES AGAIN I WAS ABLE TO GET MY CAR STARTED AGAIN I DECIDED TO TURN THE OPTIMA AROUND TO HEAD BACK TO MY HOME. I WAS ABLE TO GET THE CAR HOME WITHOUT IT STALLING. I THEN CHANGED THE BATTERY OF THE KIA OPTIMA WITH A NEW FEDERATED BATTERY THE MILEAGE ON THE ODOMETER WAS 144,540.0

NHTSA ODI #10849832

1,451,900 miles · Mar 15, 2016

Engine

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ON FEBRUARY 26, 2016 I WAS DRIVING TO WORK IN MY 2011 KIA OPTIMA AT APPROXIMATELY 5:45AM ON MD RT. 695 SOUTH I WAS IN THE LEFT LANE GOING 55 MPH DRIVING WITH THE FLOW OF TRAFFIC. THE OPTIMA WAS DRIVING NORMALLY THERE WERE NO SOUNDS COMING FROM THE ENGINE, WHEN SUDDENLY WITHOUT WARNING THE CAR SHOOK VIOLENTLY I LOST ALL POWER AT THE SAME TIME ALL THE LIGHTS ON THE DASH CAME ON. I PRESSED ON GAS PEDAL THERE WAS NO RESPONSE FROM THE OPTIMA I HAD NO POWER. I QUICKLY PUT ON MY RIGHT TURN SIGNAL TO GET OVER THE FOUR LANES; I WAS TRYING TO GET TO THE SAFETY OF THE SHOULDER OF THE ROAD. IT WAS AMAZING THAT WITH ALL THE TRAFFIC I WAS NOT HIT BY ANOTHER CAR BECAUSE I DIDN'T HAVE ANY POWER TO THE WHEELS I WAS JUST COASTING THE OPTIMA WAS STARTING TO SLOW DOWN WITHOUT THE ENGINE TO POWER IT. I ENDED UP ON EXIT 17 WHICH IS SECURITY BLVD. RAMP. I OPENED THE HOOD OF THE OPTIMA I SAW OIL ALL OVER THE ENGINE AND OIL DOWN AROUND THE ENGINE COMPARTMENT. I CALLED AAA TO GET MY OPTIMA TOWED TO THE AUTO SHOP I GO TO IN NEW OXFORD PA. THAT WAS ABOUT 45 MILES WAY FROM WHERE THE OPTIMA'S ENGINE DIED. THE MECHANIC LOOKED AT THE ENGINE; HE STATED THAT A ROD FROM THE ENGINE HAD GONE THROUGH THE ENGINE BLOCK. THE MECHANIC ALSO STATED THAT THERE METAL PIECES AND OIL ON THE OUTSIDE OF THE ENGINE AND AROUND THE ENGINE COMPARTMENT. AFTER THE MECHANIC STATED HE COULDN'T FIND AN ENGINE FOR MY 2011 KIA OPTIMA I HAD IT TOWED TO THE KIA DEALERSHIP IN GETTYSBURG, PA. THE KIA DEALERSHIP STATED THAT THEY WOULD INSPECT THE ENGINE. THEY CHARGED ME $89.00 FOR AN HOUR LABOR TO LOOK AT MY 2011 KIA OPTIMA. I WAS TOLD THAT EITHER THE MAIN BARRING TO THE CONNECTING ROD MALFUNCTIONED OR THE PIN THAT CONNECTS TO THE PISTON COULD HAVE JUST BROKEN. AT THIS PRESENT TIME I STILL DON'T KNOW WHY THIS ENGINE'S MAJOR PARTS CAME APART AND CAUSED ME TO LOSE ALL POWER AND PUT MY LIFE AND THE LIVES OF OTHERS AT RISK.

NHTSA ODI #10849822

78,000 miles · Mar 15, 2016

Steering

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HEARING A KNOCKING NOISE IN THE STEERING WHEEL WHILE SITTING STILL OR MOVING WHEN THE STEERING WHEEL IS MOVED FROM SIDE TO SIDE, ALOT OF FREEPLAY IN THE STEERING WHEEL. WHEN YOU HIT A BUMP THERE IS A LOUD CLANKING NOISE FROM THE STEERING COLUMN. I WAS TOLD BY MY FRIEND WHO HAS A 2012 OPTIMA THAT HE HAS THE SAME PROBLEM AND HE WAS TOLD BY THE DEALERSHIP THAT IT WAS A PLASTIC GEAR IN THE STEERING COLUMN AND WOULD COST ROUGHLY $300 TO FIX. UPON RESEARCH WITH THIS ISSUE I HAVE COME ACROSS SEVERAL OWNERS THAT SEEM TO HAVE THE SAME PROBLEM WHICH KIA KNOWS ABOUT. I FEEL THAT KIA SHOULD CORRECT THIS PROBLEM AT THEIR EXPENSE BEFORE THIS ISSUE KILLS SOMEONE.

NHTSA ODI #10849816

92,000 miles · Feb 29, 2016

Engine

TL* THE CONTACT OWNS A 2011 KIA OPTIMA. WHILE DRIVING APPROXIMATELY 60 MPH, AN ABNORMAL SOUND EMITTED FROM UNDER THE HOOD OF THE VEHICLE AND THE CHECK ENGINE OIL WARNING LIGHT FLICKERED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE CONNECTING ROD FAILED AND THE ENGINE NEEDED TO BE REPLACED. TH…

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NHTSA ODI #10838965

92,000 miles · Feb 29, 2016

Power Train

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MY KIA OPTIMA (2011) HAD STARTED A TICKING ENGINE NOISE AT AROUND 90K MARK AND NOW IT'S ESCALATED TO A LOWER END WAS TOLD BY SERVICE DEPARTMENTA T ABOUT 92K IT WAS NORMAL NOISE OF CAMSHAFT AND I ONLY NOTICED IT UNDER LOADS AND HIGHER ELEVATION ON OVERPASSES. I HAVE BEEN USING MOBIL1,FULLY SYNTHETIC MOTOR OILS AND A K&N OIL FILTERS. THIS LAST WEEK I HAVE NOTICED THAT IT WAS GETTING LOUDER.AND FROM THE ENGINE COMPARTMENT. I ASKED THE HYUNDAI DEALERSHIP THAT MY WIFE'S 2015 HYUNDAI SANTA FE SPORT WAS GETTINGI TS OIL CHANGED@ AND YES WITH MOBIL1, AND THEY TOLD ME ABOUT A RECALL ON THE MOTOR PLANT IN ALABAMA THAT SUPPLIES THE ENGINES OF BOTH FOR THOSE YEARS MODELS HAD AN METALLIC FRAGMENTS LEFT UN ENGINE AT MANUFACTURER OF ENGINE AND HAS ISSUED A RECALL. SO I CALLED KIA CONSUMER PRODUCTS DEPARTMENT AND THEY APPARENTLY HAVE HIDDEN BEHIND THE RELOCATION TO THE GEORGIA PLANT AND SAID THAT MY CAR IS KOREAN DUH SO THAT MEANS THAT THE ENGINE IS KOREAN. WHEN I CALLED DEALERSHIP AND MACHINE SHOPS BOTH HAVE SAME PARTS JUST A DIFFERENT PART # SO IT WILL AVOID A RECALL BUT THAT IS SPLITTING UP THE DIVISION OF BRANDS NOT THE PLACE WHERE MY KIA ENGINE WAS MADE IN ALABAMA AND SO WAS THE SONATAS. JUST DIFFERENT NUMBERS. CORPORATE GOVERNANCE NEEDS TO STEP IN AND TAKE OUT THE BLATANT DISREGARD FOR THE LAW AND ORDER OF FAITHFUL OWNER'S OF THE KIA AND HYUNDAI VEHICLES. I HAVE NOT HEARD FROM KIA AND IM IN NEED OF THE NHSTA TO GET INVOLVED. AND DO AN INVESTIGATION INTO THE HYUNDAI AND KIA MOTOR PLANTS RECALL FOR YOU AND ME THE CONSUMER PRODUCTS SAFETY COMMISSION NEXT STEP I GUESS.

NHTSA ODI #10838955

71,000 miles · Feb 19, 2016

Engine

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TL* THE CONTACT OWNS A 2011 KIA OPTIMA. WHILE DRIVING APPROXIMATELY 25 MPH, THE CONTACT HEARD A KNOCKING SOUND EMERGING FROM THE ENGINE COMPARTMENT. THE VEHICLE WAS DRIVEN HOME AND THE CONTACT IMMEDIATELY CHECKED THE OIL. SHE NOTICED THAT THE OIL WAS VERY DARK AND HAD A BURNT SMELL. THE VEHICLE WAS DRIVEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE ENGINE HAD TO BE REBUILT OR REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 71,000.

NHTSA ODI #10837205

85,675 miles · Feb 11, 2016

Exterior Lighting

THE LOW BEAM HEADLIGHTS LOOK LIKE FLASHLIGHTS WITH WEAK BATTERIES, YOU CAN ONLY SEE ABOUT 6 FEET IN FRONT OF CAR. THE LENS ON THE HEADLIGHTS ARE CLEAR LIKE NEW ONES, BUT THE HEAT FROM THE BULBS DESTROY THE REFLECTIVE MATERIAL INSIDE THE HEADLIGHT. THE ONLY WAY TO DRIVE AT NIGHT IS WITH THE BRIGHT LIGHTS ON. THE ONLY FIX IS TO…

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NHTSA ODI #10825548

106,421 miles · Feb 10, 2016

Engine

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MY 2011 OPTIMA HAD 106,214 MILES AND WAS ALMOST DUE FOR ANOTHER 3000 MILE OIL CHANGE (WHICH WAS DONE REGULARLY) AND WITHOUT ANY WARNING LIGHTS, SOUNDS, SMELLS ETC. IT STALLED OUT WHILE DRIVING I WAS ABLE TO PULL IN A PARKING LOT. I TRIED TO START IT AND IT WOULD NOT START. I CALLED THE KIA DEALER THAT WAS NOT EVEN A MILE AWAY AND THEY SAID THEY WERE CLOSED AND COULD NOT LOOK AT IT. SO I HAD IT TOWED TO ANOTHER GARAGE, THEY LOOKED AT IT AND SAID THE ENGINE WAS "SHOT" IT DID NOT HAVE OIL IN THE TOP (?) THEY ALSO SAID THAT THE ONLY REPLACEMENT ENGINE THEY COULD FIND WOULD BE CLOSE TO $3000.00 AND WAS OUT OF STATE, SO I WOULD HAVE TO PAY SHIPPING AS WELL AS LABOR. I SINCE HAVE HAD IT TOWED TO MY HOME AND HAVE LOOKED ONLINE FOR ENGINES AND HAVE FOUND HUNDREDS OF COMPLAINTS ABOUT THIS HAPPENING TO OTHERS WITH THE SAME YEAR AND MODEL OF CAR. I ALSO FOUND THAT THE SAME EXACT ENGINE WAS PUT IN THE 2011 HYUNDAI SONATA, AND THAT IT WAS RECALLED BY HYUNDAI. KIA KNOWS OF THIS PROBLEM AND HAS HAD MANY COMPLAINTS THAT ARE ALMOST EXACT WITH VEHICLES WITH EVEN LOWER MILEAGE AND STILL REFUSES TO RECALL THE ENGINE.

NHTSA ODI #10825370

Official recalls

23V652000 · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Sep 25, 2023

Kia America, Inc. (Kia) is recalling certain 2010-2019 Borrego, 2014-2016 Cadenza, 2010-2013 Forte, Forte Koup, Sportage, 2015-2018 K900, 2011-2015 Optima, 2011-2013 Optima Hybrid, Soul, 2012-2017 Rio, 2011-2014 Sorento, and 2010-2011 Rondo vehicles. The Hydraulic Electronic Control Unit (HECU) may experience an electrical short, which can result in an engine compartment fire while parked or driving.

Consequence & remedy

Consequence: An engine compartment fire while parked or driving can increase the risk of injury.

Remedy: Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will replace the HECU fuse, free of charge. Interim notification letters, notifying owners of the safety risk, were mailed November 14, 2023. Owner notification letters were mailed March 29, 2024 through June 18, 2024. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC284.

18V907000 · Engine; Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

Dec 19, 2018

Kia Motors America (Kia) is recalling certain 2011-2017 Optima, 2012-2017 Sorento and 2011-2018 Sportage vehicles that previously received an engine replacement under recall number 17V-224, warranty, or the Knock Sensor Detection System (KSDS) Product Improvement Campaign. The high pressure fuel pipe that connects to the fuel pump outlet may have been damaged, misaligned or improperly torqued during the engine replacement procedure, possibly causing a fuel leak.

Consequence & remedy

Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.

Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.

Additional source detail variants (2)

Engine

Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.

Remedy: Kia has notified owners, and dealers will inspect and replace the fuel pipe, as necessary, free of charge. The recall began January 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC172.

Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

Consequence: A fuel leak in the presence of an ignition source can increase the risk of a fire.

18V363000 · Air Bags: Air Bag/restraint Control Module

Jun 1, 2018

Kia Motors America (Kia) is recalling certain 2010-2013 Kia Forte, Forte Koup, 2011-2013 Kia Optima and 2011-2012 Kia Optima Hybrid and Sedona vehicles. In the event of a crash, the air bag control unit (ACU) may short circuit, preventing the frontal air bags and seat belt pretensioners from deploying.

Consequence & remedy

Consequence: If the frontal air bags and seat belt pretensioners are disabled, there is an increased risk of injury to the vehicle occupants in the event of a vehicle crash that necessitates deployment of these safety systems.

Remedy: Kia will notify owners. For model year 2011 Sedona vehicles, Kia will instruct dealers to verify the ACU part number and, if necessary, install an extension wire harness kit between the ACU Connector and the Vehicle Harness Connector. For all other affected vehicles, Kia will instruct dealers to install the extension wire harness kit. The recall began September 28, 2018. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC165.

17V224000 · Engine And Engine Cooling:engine

Mar 31, 2017

Kia Motor Company (Kia) is recalling certain 2011-2014 Optima, 2012-2014 Sorento and 2011-2013 Sportage vehicles. Machining errors during the engine manufacturing process may cause premature bearing wear within the engine.

Consequence & remedy

Consequence: Bearing wear may result in the engine seizing, increasing the risk of a crash.

Remedy: Kia will notify owners, and dealers will inspect the engine assembly, and replace the engine if necessary, free of charge. The recall began June 20, 2017. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC147.

13V114000 · Exterior Lighting:brake Lights:switch

Apr 1, 2013

Kia Motors Corporation (Kia) is recalling certain model year 2007-2010 Rondo, model year 2007-2011 Sedona, Sorento and Sportage, model year 2010-2011 Soul, model year 2008-2011 Optima, model year 2010 Forte, model year 2007-2009 Amanti, and model year 2009 Borrego vehicles. Originally, in April 2013, Kia recalled 623,658 model year 2007-2010 Rondo and Sportage, model year 2007-2011 Sorento, model year 2007 Sedona, model year 2010-2011 Soul, and model year 2011 Optima vehicles. In September 2013, Kia informed the agency that it was adding an additional 356,719 vehicles to this campaign. The total number of vehicles being recalled is now 980,377. In the affected vehicles, the stop lamp switch may malfunction. A malfunctioning stop lamp switch may cause the brake lights to not illuminate when the brake pedal is depressed or may cause an inability to deactivate the cruise control by depressing the brake pedal. Additionally, a malfunctioning stop lamp switch may also result in intermittent operation of the push-button start feature, affect the operation of the brake-transmission shift interlock feature preventing the shifter from being moved out of the PARK position and cause the Electronic Stability Control (ESC) malfunction light to illuminate.

Consequence & remedy

Consequence: Failure to illuminate the stop lamps during braking or inability to disengage the cruise control could increase the risk of a crash. Additionally, when the ignition is in the 'ON' position, the transmission shifter may be able to be moved out of PARK without first applying the brake. This may lead to unintentional movement of the car which may increase the risk of a crash.

Remedy: Kia will send an interim notification to owners in May 2013. When parts are available, owners will receive a second notification and dealers will replace the stop lamp switch, free of charge. Owners may contact Kia at 1-800-333-4542. Kia's recall campaign number is SC098.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

AQ23002 · Hyundai And Kia Abs Module Fires

Opened Nov 17, 2023 · No close date supplied

Status: open (inferred from source dates) · Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.

DP22003 · Loss Of Motive Power

Opened Sep 12, 2022 · Closed Dec 12, 2023

Status: closed (inferred from source dates) · Engine

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing. There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

EA21003 · Engine Fires

Opened Dec 22, 2021 · Closed Feb 5, 2024

Status: closed (inferred from source dates) · Engine

On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles. During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types. The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement. Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia. The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio. The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires. In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines. The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS. It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension. For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied. Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates. To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years. In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires. Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis. Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023). The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

DP21003 · Throttle Control System Vulnerabilities

Opened Nov 12, 2021 · Closed Jun 20, 2023

Status: closed (inferred from source dates) · Vehicle Speed Control:throttle

The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.

PE19004 · Non-crash Vehicle Fires

Opened Mar 29, 2019 · Closed Dec 22, 2021

Status: closed (inferred from source dates) · Electrical System; Electrical SYSTEM:12V/24V/48V Battery; Electrical SYSTEM:12V/24V/48V Battery:cables; Electrical System:alternator/generator/regulator; Electrical System:ignition; Electrical System:ignition:module; Electrical System:ignition:switch; Electrical System:starter Assembly; Electrical System:starter Assembly:relay; Electrical System:starter Assembly:solenoid; Electrical System:wiring; Electrical System:wiring:front Underhood; Electrical System:wiring:interior/under Dash; Engine; Engine And Engine Cooling; Engine And Engine Cooling:cooling System; Engine And Engine Cooling:cooling System:fan; Engine And Engine Cooling:cooling System:hoses/lines/piping/fittings; Engine And Engine Cooling:cooling System:radiator Assembly; Engine And Engine Cooling:engine; Engine And Engine Cooling:engine:gasoline; Engine And Engine Cooling:engine:gasoline:belts And Associated Pulleys; Engine And Engine Cooling:engine:gasoline:turbo/supercharger; Engine And Engine Cooling:engine:other Fuel Types:turbo/supercharger; Engine And Engine Cooling:exhaust System; Engine And Engine Cooling:exhaust System:emission Control ; Engine And Engine Cooling:exhaust System:emission Control:catalytic Convertor; Engine And Engine Cooling:exhaust System:emission Control:crankcase (pcv); Engine And Engine Cooling:exhaust System:emission Control:gas Recirculation Valve (egr Valve); Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe; Exterior Lighting; Exterior Lighting:back Up Lights; Exterior Lighting:back Up Lights:switch; Exterior Lighting:brake Lights; Exterior Lighting:brake Lights:switch; Exterior Lighting:fog Lights; Exterior Lighting:fog Lights:switch; Exterior Lighting:hazard Flashing Warning Lights; Exterior Lighting:hazard Flashing Warning Lights:switch; Exterior Lighting:hazard Flashing Warning Lights:unit; Exterior Lighting:headlights; Exterior Lighting:headlights:concealment Devices; Exterior Lighting:headlights:high/low Beam Dimmer Switch; Exterior Lighting:headlights:switch; Exterior Lighting:tail Lights; Exterior Lighting:tail Lights:switch; Exterior Lighting:turn Signal:flasher Unit; Exterior Lighting:turn Signal:switch; Unknown Or Other

During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Kia Optima, MY 2011-2014 Kia Sorento and MY 2010-2015 Kia Soul vehicles equipped with Theta II, Gamma, Nu and Lambda II engines (approximately 1.7 million vehicles). ODI also reviewed field and other data on other Kia vehicles (approximately 3.6 million additional vehicles) equipped with the same engines used in the above-mentioned vehicles.As a result of this PE, Kia has issued NHTSA Recalls 20V-750 and 21V-844 to address potential engine failures and fires in certain Kia vehicles equipped with various engine types.Additional information on these and other related recall actions is available in the downloadable version of this resume available at NHTSA.gov.In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure-related recalls mentioned above and conducted previously.See the EA21-003 Opening Resume available at NHTSA.gov for more information.Also available in the downloadable version of this resume is a list of the reference numbers for the 444 ODI reports, or Vehicle Owner Questionnaires (VOQs), cited above which ODI received through mid-November 2021.Note that the Manufacturer reports cited above are customer complaints received through March 2019.

Additional source detail variants (392)

Electrical SYSTEM:12V/24V/48V Battery:cables

Electrical SYSTEM:12V/24V/48V Battery

Electrical System:alternator/generator/regulator

Electrical System:ignition

Electrical System:ignition:module

Electrical System:ignition:switch

Electrical System

Electrical System:starter Assembly

Electrical System:starter Assembly:relay

Electrical System:starter Assembly:solenoid

Electrical System:wiring:front Underhood

Electrical System:wiring:interior/under Dash

Electrical System:wiring

Engine And Engine Cooling:cooling System:fan

Engine And Engine Cooling:cooling System:hoses/lines/piping/fittings

Engine And Engine Cooling:cooling System

Engine And Engine Cooling:cooling System:radiator Assembly

Engine And Engine Cooling:engine:gasoline:belts And Associated Pulleys

Engine And Engine Cooling:engine:gasoline

Engine And Engine Cooling:engine:gasoline:turbo/supercharger

Engine And Engine Cooling:engine

Engine And Engine Cooling:engine:other Fuel Types:turbo/supercharger

Engine And Engine Cooling:exhaust System:emission Control:catalytic Convertor

Engine And Engine Cooling:exhaust System:emission Control:crankcase (pcv)

Engine And Engine Cooling:exhaust System:emission Control:gas Recirculation Valve (egr Valve)

Engine And Engine Cooling:exhaust System:emission Control

Engine And Engine Cooling:exhaust System

Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe

Engine And Engine Cooling

Engine

Exterior Lighting:back Up Lights

Exterior Lighting:back Up Lights:switch

Exterior Lighting:brake Lights

Exterior Lighting:brake Lights:switch

Exterior Lighting:fog Lights

Exterior Lighting:fog Lights:switch

Exterior Lighting:hazard Flashing Warning Lights

Exterior Lighting:hazard Flashing Warning Lights:switch

Exterior Lighting:hazard Flashing Warning Lights:unit

Exterior Lighting:headlights:concealment Devices

Exterior Lighting:headlights:high/low Beam Dimmer Switch

Exterior Lighting:headlights

Exterior Lighting:headlights:switch

Exterior Lighting

Exterior Lighting:tail Lights

Exterior Lighting:tail Lights:switch

Exterior Lighting:turn Signal:flasher Unit

Exterior Lighting:turn Signal:switch

Unknown Or Other

DP18003 · Non-crash Vehicle Fires

Opened Aug 21, 2018 · Closed May 10, 2019

Status: closed (inferred from source dates) · Electrical System; Electrical System: Instrument Cluster/panel; Electrical SYSTEM:12V/24V/48V Battery; Electrical SYSTEM:12V/24V/48V Battery:cables; Electrical System:alternator/generator/regulator; Electrical System:ignition; Electrical SYSTEM:IGNITION:ANTI-THEFT:CONTROL Module; Electrical System:ignition:module; Electrical System:ignition:switch; Electrical System:propulsion System:traction Battery; Electrical System:starter Assembly; Electrical System:starter Assembly:relay; Electrical System:starter Assembly:solenoid; Electrical System:wiring; Electrical System:wiring: Rear Compartment/trunk; Electrical System:wiring:front Underhood; Electrical System:wiring:fuses And Circuit Breakers; Electrical System:wiring:interior/under Dash; Engine; Engine And Engine Cooling; Engine And Engine Cooling:cooling System; Engine And Engine Cooling:cooling System:fan; Engine And Engine Cooling:cooling System:hoses/lines/piping/fittings; Engine And Engine Cooling:cooling System:radiator Assembly; Engine And Engine Cooling:engine; Engine And Engine Cooling:engine:gasoline; Engine And Engine Cooling:engine:gasoline:belts And Associated Pulleys; Engine And Engine Cooling:engine:gasoline:turbo/supercharger; Engine And Engine Cooling:engine:other Fuel Types:turbo/supercharger; Engine And Engine Cooling:exhaust System; Engine And Engine Cooling:exhaust System:emission Control ; Engine And Engine Cooling:exhaust System:emission Control:catalytic Convertor; Engine And Engine Cooling:exhaust System:emission Control:crankcase (pcv); Engine And Engine Cooling:exhaust System:emission Control:gas Recirculation Valve (egr Valve); Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe; Exterior Lighting:brake Lights; Exterior Lighting:brake Lights:switch; Exterior Lighting:fog Lights; Exterior Lighting:fog Lights:switch; Exterior Lighting:hazard Flashing Warning Lights; Exterior Lighting:hazard Flashing Warning Lights:switch; Exterior Lighting:hazard Flashing Warning Lights:unit; Exterior Lighting:headlights; Exterior Lighting:headlights:concealment Devices; Exterior Lighting:headlights:high/low Beam Dimmer Switch; Exterior Lighting:headlights:switch; Exterior Lighting:tail Lights; Exterior Lighting:tail Lights:switch; Exterior Lighting:turn Signal; Exterior Lighting:turn Signal:flasher Unit; Exterior Lighting:turn Signal:switch; Unknown Or Other

In a letter dated June 11, 2018, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a safety defect investigation into non-collision related fires on model year (MY) 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles. In a letter dated July 24, 2018, CAS requested that MY 2010-2015 Kia Soul vehicles be added to the petition. CAS stated that there is a higher number of complaints to NHTSA regarding non-crash fires on these vehicles compared to other similar vehicles. The Office of Defects Investigation (ODI) had already opened Recall Queries (RQ17-003 and RQ17-004) on all Kia and Hyundai vehicles equipped with Theta II engines for engine failures that may cause stalling and fires.The queries cover most of the petition subject Optima, Sorento, Sonata, and Santa Fe vehicles but not any of the subject Soul vehicles.On August 21, 2018, ODI opened a Defect Petition (DP18-003) to evaluate whether to grant or deny the CAS petition. ODI sent Information Request letters to Kia and Hyundai (September and October 2018) requesting information on all engine and non-engine related fires in the petition vehicles.ODI performed extensive analysis on the information obtained from Kia and Hyundai. During the DP18-003 analysis, Kia and Hyundai each initiated three additional safety recalls related to engine compartment fires on certain petitioned and non-petitioned vehicles (nearly 740,000 total vehicles: Recalls 18V-907, 18V-934, 19V-101, 19V-063, 19V-120, and 19V-204). Based on ODI?s review of the applicable materials, including responses to Information Requests sent to multiple manufacturers, Vehicle Owner Questionnaires (VOQ), and Early Warning Data, NHTSA decided to grant the petition.The CAS petition was granted on March 29, 2019. Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) have been opened to assess the scope, frequency, and potential safety-related consequences of alleged defects relating to non-collision vehicle fires in the 2011-2014 Kia Optima and Sorento, 2011-2014 Hyundai Sonata and Santa Fe, and 2010-2015 Kia Soul.Attached is a list of the reference numbers for the 404 VOQs cited above.

Additional source detail variants (208)

Electrical SYSTEM:12V/24V/48V Battery:cables

Electrical SYSTEM:12V/24V/48V Battery

Electrical System:alternator/generator/regulator

Electrical SYSTEM:IGNITION:ANTI-THEFT:CONTROL Module

Electrical System:ignition

Electrical System:ignition:module

Electrical System:ignition:switch

Electrical System: Instrument Cluster/panel

Electrical System

Electrical System:propulsion System:traction Battery

Electrical System:starter Assembly

Electrical System:starter Assembly:relay

Electrical System:starter Assembly:solenoid

Electrical System:wiring:front Underhood

Electrical System:wiring:fuses And Circuit Breakers

Electrical System:wiring:interior/under Dash

Electrical System:wiring

Electrical System:wiring: Rear Compartment/trunk

Engine And Engine Cooling:cooling System:fan

Engine And Engine Cooling:cooling System:hoses/lines/piping/fittings

Engine And Engine Cooling:cooling System

Engine And Engine Cooling:cooling System:radiator Assembly

Engine And Engine Cooling:engine:gasoline:belts And Associated Pulleys

Engine And Engine Cooling:engine:gasoline

Engine And Engine Cooling:engine:gasoline:turbo/supercharger

Engine And Engine Cooling:engine

Engine And Engine Cooling:engine:other Fuel Types:turbo/supercharger

Engine And Engine Cooling:exhaust System:emission Control:catalytic Convertor

Engine And Engine Cooling:exhaust System:emission Control:crankcase (pcv)

Engine And Engine Cooling:exhaust System:emission Control:gas Recirculation Valve (egr Valve)

Engine And Engine Cooling:exhaust System:emission Control

Engine And Engine Cooling:exhaust System

Engine And Engine Cooling:exhaust System:manifold/header/muffler/tail Pipe

Engine And Engine Cooling

Engine

Exterior Lighting:brake Lights

Exterior Lighting:brake Lights:switch

Exterior Lighting:fog Lights

Exterior Lighting:fog Lights:switch

Exterior Lighting:hazard Flashing Warning Lights

Exterior Lighting:hazard Flashing Warning Lights:switch

Exterior Lighting:hazard Flashing Warning Lights:unit

Exterior Lighting:headlights:concealment Devices

Exterior Lighting:headlights:high/low Beam Dimmer Switch

Exterior Lighting:headlights

Exterior Lighting:headlights:switch

Exterior Lighting:tail Lights

Exterior Lighting:tail Lights:switch

Exterior Lighting:turn Signal:flasher Unit

Exterior Lighting:turn Signal

Exterior Lighting:turn Signal:switch

Unknown Or Other

RQ17003 · Scope And Timeliness

Opened May 18, 2017 · Closed Dec 22, 2021

Status: closed (inferred from source dates) · Engine

NHTSA opened Recall Query (RQ) 17-003 to investigate the timeliness and scope of Kia?s Theta II GDI engine recall (Recall No. 17V-224), and Kia?s compliance with reporting requirements. On November 23, 2020, the Agency entered into a Consent Order with Kia to administratively resolve NHTSA?s assertions of violations of law in connection with RQ17-003. NHTSA?s assertions included that Kia may be liable for civil penalties on multiple grounds, including that Recall No. 17V-224 was untimely and Kia?s recall report contained certain inaccuracies.Under the Consent Order, Kia agreed to a total civil penalty of $70,000,000. The total civil penalty included a payment of $27,000,000 as a Non-Deferred Amount.Kia also agreed to a sum of $27,000,000 as an Abeyance Amount to be deferred and held in abeyance pending its satisfactory completion, as reasonably determined by NHTSA, of the requirements of the Consent Order.Kia also agreed to a $16,000,000 Performance Obligation Amount to be expended by Kia to fulfill specified Safety Data Analytics Infrastructure obligations. The Consent Order also includes other terms designed to enhance Kia?s safety practices, and requires Kia to retain a Third-Party Auditor who directly reports to NHTSA.Other than RQ17-003, the Consent Order is not intended to affect any other current or future investigation of NHTSA which may involve vehicles equipped with Theta II GDI engines. In particular, Engineering Analysis (EA) 21-003 (which is upgraded from Preliminary Evaluation (PE) 19-004) continues NHTSA?s evaluation of certain performance and design issues relating to the Theta II and other engines.Nothing in the Consent Order discharges Kia from any obligation to comply with the Safety Act or regulations thereunder, including the obligation to carry out recalls in accordance with the law, and to initiate a recall upon any future determination by Kia, or upon any finally adjudicated order from NHTSA, that vehicles equipped with Theta II GDI engines contain a defect related to motor vehicle safety or do not comply with an applicable FMVSS.This RQ is closed. Closure of this RQ has no bearing on the terms of the Consent Order, including Kia's ongoing performance obligations, and does not represent a determination by the agency as to Kia's performance under the Consent Order to date.

Additional source detail variants (2)

Engine