IllustrationWHILE DRIVING IT FELT LIKE THE VEHICLE WAS OFF BALANCE. THIS OCCURRED BECAUSE THE RIGHT FRONT RIM BUSTED. THIS OCCURRED TWICE TWO YEARS AGO BECAUSE CONSUMER OVERLOADED THE VEHICLE. THE SAME RIM BUSTED AGAIN WITHOUT THE VEHICLE BEING OVERLOADED.*AK
2001 Kia Rio
Owner reports · Recalls · Investigations
More warning signs than most Rio years
Owner complaints for the 2001 Kia Rio are substantially higher than the model-year median of 38.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Rio years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
170–25K
2125–50K
2450–75K
475–100K
9100–150K
0150K+
75 reports with mileage · 148 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Engine And Engine Cooling. Review the 52 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 33 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Wheels. Review the 31 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
21 crash reports14 fire reports8 injury reports
Wheels complaints
31 reportsIN DECEMBER OF 2003 I STARTED HEARING A LOUD CLANKING FROM THE PASSENGER-SIDE, REAR WHEEL. ASSUMING IT WAS THE REAR BRAKES NEEDING REPLACED, I PURCHASED THE PARTS. UPON REMOVING THE HUB CAP I SAW THAT THE RIM WAS SEVERELY CRACKED. WITHIN AN INCH OR SO OF ACTUALLY BREAKING COMPLETELY APART. (THE BRAKES WERE NOT WORN.) W…
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IN DECEMBER OF 2003 I STARTED HEARING A LOUD CLANKING FROM THE PASSENGER-SIDE, REAR WHEEL. ASSUMING IT WAS THE REAR BRAKES NEEDING REPLACED, I PURCHASED THE PARTS. UPON REMOVING THE HUB CAP I SAW THAT THE RIM WAS SEVERELY CRACKED. WITHIN AN INCH OR SO OF ACTUALLY BREAKING COMPLETELY APART. (THE BRAKES WERE NOT WORN.) WHEN I RETURNED THE BRAKE PARTS TO HIGH DESERT KIA, IN VICTORVILLE, CA., I TOLD THE SERVICE DEPARTMENT ABOUT THE CRACKED RIM AND INQUIRED OF THE WARRANTY ON THE RIMS. I WAS TOLD THE WARRANTY PERIOD IS 30,000 MILES.(AT THE TIME, MY VEHICLE HAD APPROX.55,000 MILES.) THEN IN JUNE OF 2004, I HEARD THE SAME CLANKING FROM THE DRIVERSIDE, REAR WHEEL. UPON INSPECTION I FOUND THAT THIS RIM HAD ALSO CRACKED IN THE SAME MANNER AS THE FIRST. REALIZING THE FATAL CONSEQUENCES THAT COULD OCCUR SHOUL A RIM FAIL AND BREAK APART WHILE THE VEHICLE IS IN MOTION, I FIRST NOTIFIED YOU AND THEN THE KIA MOTORS HEADQUARTERS LISTED IN MY OWNERS MANUAL. UPON EXPLAINING THE CRACKING OF THE TWO RIMS AND WHAT HIGH DESERT KIA'S RESPONSE WAS TO ME, I WAS TOLD TO RETURN TO HIGH DESERT KIA AND THEY WOULD BE INSTRUCTED TO REPLACE ALL 4 OF THE RIMS ON MY RIO, AT NO CHARGE.BUT IT WOULD BE A ONCE ONLY REPLACEMENT. AND THE RIMS WOULD ONLY BE WARRANTIED FOR THE 12 MONTHS THAT IS STANDARD FOR REPLACEMENT PARTS. THE RIMS WERE REPLACED ON JULY 17TH, 2004. UPON MY INQUIRY, I WAS ASSURED THE 4 NEW RIMS ARE FROM A DIFFERENT LOT NUMBER AND MADE IN 2003.*AK
CONSUMER NOTICED THAT THE CENTER OF THE WHEELS CRACKED AND FELL APART. CONSUMER BEGAN TO HEAR A CLANKING SOUND COMING FROM THE LEFT REAR WHEEL. AS THE CONSUMER BEGAN TO REMOVE THE WHEEL THE CENTER BROKE UP IN THE PROCESS. THIS PROBLEM AFFECTED THE TWO BACK WHEELS. *AK
VEHICLE BEGAN MAKING A LOUD GRINDING NOISE WHEN COMING TO A STOP. THINKING IT MAY JUST BE THE BRAKES THAT WERE GOING OUT, RETURNED VEHICLE TO THE SHOP. UPON INSPECTION THE SHOP FOUND THAT ALL 4 OF THE 13 INCH WHEELS HAD STRESS FRACTURES. THE FRONT 2 WERE THE WORST AS THEY HAD BEGUN TO SPLIT. WAS TOLD THAT THERE WAS A POSSIBLITY …
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VEHICLE BEGAN MAKING A LOUD GRINDING NOISE WHEN COMING TO A STOP. THINKING IT MAY JUST BE THE BRAKES THAT WERE GOING OUT, RETURNED VEHICLE TO THE SHOP. UPON INSPECTION THE SHOP FOUND THAT ALL 4 OF THE 13 INCH WHEELS HAD STRESS FRACTURES. THE FRONT 2 WERE THE WORST AS THEY HAD BEGUN TO SPLIT. WAS TOLD THAT THERE WAS A POSSIBLITY OF A FATAL CRASH HAD THIS NOT BEEN BROUGHT TO THERE ATTENTION WHEN IT WAS.*AK
WHILE DRIVING AT ANY SPEED CONSUMER HEARD A THUMPING SOUND COMING FROM THE REAR PASSENGER SIDE OF THE VEHICLE. UPON CLOSER INSPECTION RIGHT REAR WHEELS HAD SEVERE CRACKS IN THE WALLS. THE CRACKS WERE SUCH THAT ONE COULD ACTUALLY HOLD THE WHEELS TO THE LIGHT AND SEE THROUGH THEM. THE DEALER REPLACED THE BAD RIM UNDER WARRAN…
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WHILE DRIVING AT ANY SPEED CONSUMER HEARD A THUMPING SOUND COMING FROM THE REAR PASSENGER SIDE OF THE VEHICLE. UPON CLOSER INSPECTION RIGHT REAR WHEELS HAD SEVERE CRACKS IN THE WALLS. THE CRACKS WERE SUCH THAT ONE COULD ACTUALLY HOLD THE WHEELS TO THE LIGHT AND SEE THROUGH THEM. THE DEALER REPLACED THE BAD RIM UNDER WARRANTY AND KEPT THE BAD RIM. *AK
THE VEHICLES DRIVERS SIDE FRONT TIRE RIM DEVELOPED 14 INCH CRACKS ALL AROUND AND PIECES OF THE RIM WERE FALLING OFF. THE CONSUMER BELIEVES THE TIRE MAY FALL OFF. PLEASE DESCRIBE FURTHER. *NLM SON NOTIFIED OWNER AT @ 45K MILES THAT THERE WAS A STRANGE NOISE COMING FROM THE FRONT END OF THE VEHICLE AND HE THOUGHT THERE MIGHT …
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THE VEHICLES DRIVERS SIDE FRONT TIRE RIM DEVELOPED 14 INCH CRACKS ALL AROUND AND PIECES OF THE RIM WERE FALLING OFF. THE CONSUMER BELIEVES THE TIRE MAY FALL OFF. PLEASE DESCRIBE FURTHER. *NLM SON NOTIFIED OWNER AT @ 45K MILES THAT THERE WAS A STRANGE NOISE COMING FROM THE FRONT END OF THE VEHICLE AND HE THOUGHT THERE MIGHT BE A PROBLEM, PERHAPS WITH THE BRAKES. OWNER WENT FOR A RIDE WITH THE SON TO CONFIRM NOISE BUT OWNER COULD NOT HEAR IT. SHORTLY THEREAFTER, THE SON COMPLAINED TO HIS FATHER AGAIN ABOUT THE NOISE, STATING IT WAS NOW MUCH WORSE. OWNER TOOK VEHICLE FOR A TEST DRIVE AND HE COULD HEAR A LOUD GRINDING/CRACKING/POPPING NOISE FROM THE FRONT END. HE REMOVED THE FRONT DRIVER SIDE WHEEL TO INSPECT AND HE SAW LARGE CRACKS AT THE WHEEL HAT AREA ABOUT 2-3" ABOVE THE LUG HOLES ON THE WHEEL DISC. THERE WERE SEVERAL CIRCUMFERENTIAL CRACKS APPROXIMATELY 14 INCHES IN LENGTH ALMOST COMPLETELY CIRCLING THE WHEEL. WHEN HE REMOVED THE WHEEL LARGE PIECES OF THE WHEEL IN THE AREA OF THE CRACKS CRUMBLED AND FELL OUT ONTO THE GROUND. ALSO NOTICED FRONT PASSENGER SIDE WHEEL HAD SEVERAL 5" CRACKS IN SAME AREA. BOTH WHEELS WERE THE STANDARD EQUIPPED 13X5J STEEL WHEELS. NEITHER WHEEL HAD ANY SCRAPES, SCRATCHES, OR BENDS INDICATIVE OF ABUSE. REPORTED ISSUE TO DEALER AND MANUFACTURER, BOTH REFUSED TO PROVIDE ASSISTANCE BECAUSE VEHICLE NO LONGER COVERED UNDER WARRANTY. OWNER TOOK VEHICLE TO AN INDEPENDENT WHEEL SHOP WHERE HE PURCHASED 2 REPLACEMENT STEEL WHEELS.
MY VEHICLE STARTED MAKING A HORRIBLE NOISE IN THE FRONT. IT SOUNDED LIKE THE BRAKES WERE DIGGING INTO THE ROTOR SO I FIGURED I NEEDED A BRAKE JOB. WHEN I REMOVED THE WHEELS I LOOKED AT MY BRAKES AND THEY WERE FINE, I THEN LOOKED AT MY WHEEL AND NOTICED A VERY LARGE CRACK ALL THEY WAY AROUND. I WENT THE DEALERSHIP WHERE I PURC…
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MY VEHICLE STARTED MAKING A HORRIBLE NOISE IN THE FRONT. IT SOUNDED LIKE THE BRAKES WERE DIGGING INTO THE ROTOR SO I FIGURED I NEEDED A BRAKE JOB. WHEN I REMOVED THE WHEELS I LOOKED AT MY BRAKES AND THEY WERE FINE, I THEN LOOKED AT MY WHEEL AND NOTICED A VERY LARGE CRACK ALL THEY WAY AROUND. I WENT THE DEALERSHIP WHERE I PURCHASED MY VEHICLE AND THEY REFUSED TO DO ANYTHING SINCE IT WAS OUT OF WARRANTY. THEY INSISTED THAT WHEN I HAD NEW TIRES PUT ON THAT THEY MUST OF USED TOO MUCH FORCE AND CRACKED THE RIMS. I WENT TO THE TIRE PLACE WHERE I HAD JUST RECENTLY PURCHASED TIRES AND THEY SAID THERE WAS NO WAY THEY COULD HAVE DONE IT, BUT PUT MY CAR UP ON THE RACKS AND CHECKED THE REST OF MY WHEELS. COME TO FIND THE OTHER THREE RIMS WERE CRACKED AS WELL. I TOOK MY CONCERNS TO THE SERVICE MANAGER OF THE AUTOMOTIVE NETWORK I PURCHASED MY CAR FROM AND HE AGREED THAT IT WAS A SAFETY ISSUE AND REPLACE ALL FOUR WHEELS WITH BRAND NEW ONES FROM KIA.*AK
I HAVE A 2001 KIA RIO, MANUAL TRANSMISSION. AT 32000 MILES THE LEFT FRONT RIM CRACKED, AND WAS REPLACED UNDER WARRANTY. I HAD THE RIGHT FRONT CRACK AT 62000 MILES. KIA DID NOT CONSIDER THIS A DEFECT, SO I HAD TO PURCHASE A NEW RIM FOR 98.00, AND HAVE IT MOUNTED AT ADDITIONAL COST. I SPOKE WITH THE DEALER, AND KIA DIRECTLY AB…
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I HAVE A 2001 KIA RIO, MANUAL TRANSMISSION. AT 32000 MILES THE LEFT FRONT RIM CRACKED, AND WAS REPLACED UNDER WARRANTY. I HAD THE RIGHT FRONT CRACK AT 62000 MILES. KIA DID NOT CONSIDER THIS A DEFECT, SO I HAD TO PURCHASE A NEW RIM FOR 98.00, AND HAVE IT MOUNTED AT ADDITIONAL COST. I SPOKE WITH THE DEALER, AND KIA DIRECTLY ABOUT THIS BEING A SAFETY CONCERN. KIA'S RESPONSE WAS SINCE IT WAS OUT OF WARRANTY, THEY WOULD ONLY COVER MANUFACTURING DEFECTS. THE 13 INCH STEEL RIM HAS NO DAMAGE WHICH WOULD HAVE CAUSED THE TEAR IN THE STEEL; CIRCUMFERENCE WITH THE LUG BOLT HOLES. *NLM
WHILE DRIVING THE DRIVER HEARD A NOISE FROM THE REAR END OF THE VEHICLE. THE NOISE IS AS A RESULT OF THE LEFT REAR WHEEL CRACKING THROUGH THE MIDDLE. PLEASE PROVIDE MORE DETAILS. TS
CONSUMER IS REPORTING PREMATURE WEAR OF THE ENGINE MOUNTS AND A RATTLING NOISE COMING FROM THE ENGINE AREA,WHILE IDLING OR DRIVING. DEALER NOTIFIED AND HAD REPLACED THEM. NLM THE CONSUMER HAS TRADED THIS VEHICLE IN DUE TO ALL OF THE MECHANICAL PROBLEMS AND IS REQUESTING HER MONEY BACK BECAUSE WHEN SHE HAD TAKEN THE VEHICLE TH…
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CONSUMER IS REPORTING PREMATURE WEAR OF THE ENGINE MOUNTS AND A RATTLING NOISE COMING FROM THE ENGINE AREA,WHILE IDLING OR DRIVING. DEALER NOTIFIED AND HAD REPLACED THEM. NLM THE CONSUMER HAS TRADED THIS VEHICLE IN DUE TO ALL OF THE MECHANICAL PROBLEMS AND IS REQUESTING HER MONEY BACK BECAUSE WHEN SHE HAD TAKEN THE VEHICLE THE DEALER, THEY DIDN'T REPAIR THE PROBLEM WHICH WAS TO BE COVERED BY WARRANTY. THE VEHICLE HAS NO POWER AND VERY POOR SHIFTING. THE ABS AND CHECK ENGINE LIGHT IS ON. THE LEFT FRONT MIRROR IS NOT WORKING. THE SPARK PLUGS ARE FAULTY/BREAKING DOWN. THE INNER/OUTER BEARING WITH SEALS ON LEFT REAR AND RIGHT REAR-REPLACED, AND THE RIGHT REAR HUB ASSEMBLY-REPLACED DUE TO OVER TIGHTENING OF THE SPINDLE NUT. THERE'S A NOISE IN THE TIRE(S) THE DEALER PERFORMED A RECALL THAT REPLACED THE COOLER HOSE. *SCC
Official recalls
305V159000 · Wheels
Apr 20, 2005
CERTAIN PASSENGER VEHICLES MAY HAVE A MANUFACTURING FLAW THAT COULD CAUSE THE WHEELS TO CRACK UNDER LONG TERM DRIVING FATIGUE. IF CRACKS OCCUR, WHEEL NOISE AND VIBRATION WILL RESULT AND BECOME PROGRESSIVELY WORSE OVER TIME.
Consequence & remedy
Consequence: IF THE CRACK IS SEVERE, THE WHEEL COULD SEPARATE FROM THE VEHICLE AND POSSIBLY RESULT IN LOSS OF VEHICLE CONTROL AND A CRASH.
Remedy: DEALERS WILL REPLACE ALL FOUR WHEELS FREE OF CHARGE. THE RECALL BEGAN ON JUNE 22, 2005. OWNERS MAY CONTACT KIA AT 1-800-333-4542.
04V179000 · Fuel System, Gasoline:delivery
Apr 9, 2004
ON CERTAIN PASSENGER VEHICLES, THE FUEL INTAKE NIPPLE OF THE FUEL DISTRIBUTOR IS SUBJECT TO FRACTURE OR CRACKING DURING REMOVAL OF THE QUICK CONNECT COUPLING SECURING THE MAIN FUEL TUBE ASSEMBLY TO THE FUEL INTAKE NIPPLE, OR WHEN FORCE IS ACCIDENTALLY APPLIED TO THE INTAKE NIPPLE DURING THE VEHICLE ASSEMBLY PROCESS OR DURING ENGINE COMPARTMENT REPAIRS.
Consequence & remedy
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL DISTRIBUTOR AND MAIN FUEL TUBE ASSEMBLIES. THE RECALL BEGAN JUNE 18, 2004. OWNERS SHOULD CONTACT KIA AT 1-800-333-4542.
03V352000 · Fuel System, Gasoline
Sep 24, 2003
ON CERTAIN PASSENGER VEHICLES, FUEL LEAKS MAY DEVELOP AT THE FUEL DISTRIBUTOR ASSEMBLY BECAUSE OF QUALITY DEVIATIONS.
Consequence & remedy
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT AND REPLACE THE FUEL DISTRIBUTOR AND FUEL CONNECTOR ASSEMBLIES. OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING THE FIRST QUARTER OF 2004. OWNERS SHOULD CONTACT KIA AT 1-800-333-4542.
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
6EA04020 · Steel Wheel Fracture
Opened Jul 22, 2004 · Closed Apr 28, 2005
Status: closed (inferred from source dates) · Wheels; Wheels:hubcap/cover
ON MARCH 24, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-030) TO INVESTIGATE ALLEGED STEEL WHEEL FRACTURES IN CERTAIN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE SUBJECT VEHICLES ARE EQUIPPED WITH WHEELS MANUFACTURED FROM MAY 12 THROUGH OCTOBER 17, 2000.WHEELS WERE MANUFACTURED DURING THIS PERIOD USING A TOOL (RING DIE) THAT HAD IMPROPER SURFACE TREATMENT.THIS ALLOWED TOOL DAMAGE TO DEVELOP WITH ACCUMULATED USE AND RESULTED IN AN IRREGULAR SHAPED STAMPING ON THE WHEEL DISC AT THE HAT AREA.THE IRREGULAR SHAPED HAT AREA CREATES A STRESS RISER THAT MAY LEAD TO THE FORMATION OF CRACKS.ODI IS AWARE OF 40 NON-DUPLICATIVE CONSUMER REPORTS ALLEGING WHEEL FRACTURE, 6 OF WHICH ALLEGED WHEEL SEPARATION INCIDENTS ON THE SUBJECT VEHICLES.AS OF MARCH 31, 2005, KIA MOTORS AMERICA, INC. (KIA) HAS PAID 535 WARRANTY CLAIMS FOR THE REPLACEMENT OF ONE OR MORE WHEELS ON THE SUBJECT VEHICLES DUE TO FRACTURE.BY LETTER DATED APRIL 18, 2005, KIA HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NTHSA RECALL NO. 05V-159) TO REPLACE DEFECTIVE WHEELS IN APPROXIMATELY 24,119 SUBJECT VEHICLES.KIA WILL REPLACE ALL FOUR STEEL WHEELS FREE OF CHARGE.THE ACTION TAKEN BY KIA IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Additional source detail variants (2)
Wheels:hubcap/cover
ON MARCH 24, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-030) TO INVESTIGATE ALLEGED STEEL WHEEL FRACTURES IN CERTAIN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE SUBJECT VEHICLES ARE EQUIPPED WITH WHEELS MANUFACTURED FROM MAY 12 THROUGH OCTOBER 17, 2000.WHEELS WERE MANUFACTURED DURING THIS PERIOD USING A TOOL (RING DIE) THAT HAD IMPROPER SURFACE TREATMENT.THIS ALLOWED TOOL DAMAGE TO DEVELOP WITH ACCUMULATED USE AND RESULTED IN AN IRREGULAR SHAPED STAMPING ON THE WHEEL DISC AT THE HAT AREA.THE IRREGULAR SHAPED HAT AREA CREATES A STRESS RISER THAT MAY LEAD TO THE FORMATION OF CRACKS.ODI IS AWARE OF 40 NON-DUPLICATIVE CONSUMER REPORTS ALLEGING WHEEL FRACTURE, 6 OF WHICH ALLEGED WHEEL SEPARATION INCIDENTS ON THE SUBJECT VEHICLES.AS OF MARCH 31, 2005, KIA MOTORS AMERICA, INC. (KIA) HAS PAID 535 WARRANTY CLAIMS FOR THE REPLACEMENT OF ONE OR MORE WHEELS ON THE SUBJECT VEHICLES DUE TO FRACTURE.BY LETTER DATED APRIL 18, 2005, KIA HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NTHSA RECALL NO. 05V-159) TO REPLACE DEFECTIVE WHEELS IN APPROXIMATELY 24,119 SUBJECT VEHICLES.KIA WILL REPLACE ALL FOUR STEEL WHEELS FREE OF CHARGE.THE ACTION TAKEN BY KIA IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Wheels
ON MARCH 24, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-030) TO INVESTIGATE ALLEGED STEEL WHEEL FRACTURES IN CERTAIN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE SUBJECT VEHICLES ARE EQUIPPED WITH WHEELS MANUFACTURED FROM MAY 12 THROUGH OCTOBER 17, 2000.WHEELS WERE MANUFACTURED DURING THIS PERIOD USING A TOOL (RING DIE) THAT HAD IMPROPER SURFACE TREATMENT.THIS ALLOWED TOOL DAMAGE TO DEVELOP WITH ACCUMULATED USE AND RESULTED IN AN IRREGULAR SHAPED STAMPING ON THE WHEEL DISC AT THE HAT AREA.THE IRREGULAR SHAPED HAT AREA CREATES A STRESS RISER THAT MAY LEAD TO THE FORMATION OF CRACKS.ODI IS AWARE OF 40 NON-DUPLICATIVE CONSUMER REPORTS ALLEGING WHEEL FRACTURE, 6 OF WHICH ALLEGED WHEEL SEPARATION INCIDENTS ON THE SUBJECT VEHICLES.AS OF MARCH 31, 2005, KIA MOTORS AMERICA, INC. (KIA) HAS PAID 535 WARRANTY CLAIMS FOR THE REPLACEMENT OF ONE OR MORE WHEELS ON THE SUBJECT VEHICLES DUE TO FRACTURE.BY LETTER DATED APRIL 18, 2005, KIA HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NTHSA RECALL NO. 05V-159) TO REPLACE DEFECTIVE WHEELS IN APPROXIMATELY 24,119 SUBJECT VEHICLES.KIA WILL REPLACE ALL FOUR STEEL WHEELS FREE OF CHARGE.THE ACTION TAKEN BY KIA IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
PE04030 · Steel Wheel Fracture
Opened Mar 24, 2004 · Closed Jul 22, 2004
Status: closed (inferred from source dates) · Wheels; Wheels:hubcap/cover
ON MARCH 24, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STEEL WHEEL FRACTURES IN CERTAIN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE SUBJECT VEHICLES ARE EQUIPPED WITH WHEELS MANUFACTURED BETWEEN MAY 12 AND OCTOBER 18, 2000.WHEELS WERE MANUFACTURED DURING THIS PERIOD USING A TOOL (RING DIE) THAT HAD IMPROPER SURFACE TREATMENT.THIS ALLOWED TOOL DAMAGE TO DEVELOP WITH ACCUMULATED USE AND RESULTED IN AN IRREGULAR SHAPED STAMPING ON THE WHEEL DISC AT THE HAT AREA.THE IRREGULAR SHAPED HAT AREA CREATES A STRESS RISER THAT MAY LEAD TO THE FORMATION OF CRACKS.ODI IS AWARE OF 30 NON-DUPLICATIVE CONSUMER REPORTS ALLEGING WHEEL FRACTURE AND 3 ALLEGED WHEEL SEPARATION INCIDENTS ON THE SUBJECT VEHICLES.KIA HAS PAID 576 WARRANTY CLAIMS FOR WHEEL REPLACEMENT ON THE SUBJECT VEHICLES.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA04-020) TO FURTHER STUDY THE SCOPE AND SAFETY CONSEQUENCES OF THIS ISSUE.
Additional source detail variants (2)
Wheels:hubcap/cover
ON MARCH 24, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STEEL WHEEL FRACTURES IN CERTAIN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE SUBJECT VEHICLES ARE EQUIPPED WITH WHEELS MANUFACTURED BETWEEN MAY 12 AND OCTOBER 18, 2000.WHEELS WERE MANUFACTURED DURING THIS PERIOD USING A TOOL (RING DIE) THAT HAD IMPROPER SURFACE TREATMENT.THIS ALLOWED TOOL DAMAGE TO DEVELOP WITH ACCUMULATED USE AND RESULTED IN AN IRREGULAR SHAPED STAMPING ON THE WHEEL DISC AT THE HAT AREA.THE IRREGULAR SHAPED HAT AREA CREATES A STRESS RISER THAT MAY LEAD TO THE FORMATION OF CRACKS.ODI IS AWARE OF 30 NON-DUPLICATIVE CONSUMER REPORTS ALLEGING WHEEL FRACTURE AND 3 ALLEGED WHEEL SEPARATION INCIDENTS ON THE SUBJECT VEHICLES.KIA HAS PAID 576 WARRANTY CLAIMS FOR WHEEL REPLACEMENT ON THE SUBJECT VEHICLES.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA04-020) TO FURTHER STUDY THE SCOPE AND SAFETY CONSEQUENCES OF THIS ISSUE.
Wheels
ON MARCH 24, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STEEL WHEEL FRACTURES IN CERTAIN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE SUBJECT VEHICLES ARE EQUIPPED WITH WHEELS MANUFACTURED BETWEEN MAY 12 AND OCTOBER 18, 2000.WHEELS WERE MANUFACTURED DURING THIS PERIOD USING A TOOL (RING DIE) THAT HAD IMPROPER SURFACE TREATMENT.THIS ALLOWED TOOL DAMAGE TO DEVELOP WITH ACCUMULATED USE AND RESULTED IN AN IRREGULAR SHAPED STAMPING ON THE WHEEL DISC AT THE HAT AREA.THE IRREGULAR SHAPED HAT AREA CREATES A STRESS RISER THAT MAY LEAD TO THE FORMATION OF CRACKS.ODI IS AWARE OF 30 NON-DUPLICATIVE CONSUMER REPORTS ALLEGING WHEEL FRACTURE AND 3 ALLEGED WHEEL SEPARATION INCIDENTS ON THE SUBJECT VEHICLES.KIA HAS PAID 576 WARRANTY CLAIMS FOR WHEEL REPLACEMENT ON THE SUBJECT VEHICLES.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA04-020) TO FURTHER STUDY THE SCOPE AND SAFETY CONSEQUENCES OF THIS ISSUE.
EA03015 · Fuel Rail Leakage
Opened Aug 28, 2003 · Closed Apr 30, 2004
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings; Fuel System, Gasoline:fuel Injection System; Fuel System, Gasoline:fuel Injection System:fuel Rail
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Additional source detail variants (10)
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:delivery
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:delivery
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:fuel Injection System:fuel Rail
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:fuel Injection System:fuel Rail
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:fuel Injection System
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:fuel Injection System
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline
ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
PE03016 · Engine Compartment Fires
Opened Apr 15, 2003 · Closed Aug 28, 2003
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings; Fuel System, Gasoline:fuel Injection System; Fuel System, Gasoline:fuel Injection System:fuel Rail; Fuel System, Gasoline:fuel Injection System:injectors
KIA HAS IDENTIFIED 22 NON-CRASH ENGINE COMPARTMENT FIRES OF ANY OR UNSPECIFIED CAUSE ON THE SUBJECT VEHICLES.NINE FIRES (OF WHICH 4 WERE ALSO REPORTED TO ODI) ARE IDENTIFIED AS BEING DUE TO A FUEL SYSTEM LEAK ORIGINATING BETWEEN THE FIREWALL AND THE FUEL INJECTOR RAIL (P/N 0K30E 13 150) IN THE PASSENGER SIDE AREA OF THE ENGINE COMPARTMENT.THE REMAINING FIRES WERE DUE TO VARIED OR UNKNOWN CAUSES.ALL 9 FIRES CAUSED BY A FUEL SYSTEM LEAK SUSTAINED SEVERE AND TOTAL DAMAGE.ANALYSIS INDICATES THAT 1 FIRE WAS CAUSED BY A FAILED QUICK CONNECT BETWEEN THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE (P/N 0K32A 13 49XB) AND THE RIGID LINE MOUNTED TO THE FIREWALL; 5 FIRES WERE CAUSED BY A FAILURE OF THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE ITSELF OR ITS RELATED CONNECTORS; THE REMAINING 3 FIRES WERE CAUSED BY UNSPECIFIED FUEL LEAKS IN THE VICINITY OF THE FUEL INJECTOR RAIL, FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE, AND THE RIGID LINE MOUNTED TO THE FIREWALL.KIA REPORTS THAT NEITHER THE FUEL INJECTOR RAIL NOR THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE HAS BEEN SUBSTANTIALLY MODIFIED SINCE THEIR INTRODUCTION IN THE 2001 MODEL YEAR.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA03-015) SO THAT ODI MAY COLLECT ADDITIONAL INFORMATION AND CONDUCT FURTHER STUDY OF THIS ISSUE.
Additional source detail variants (6)
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
KIA HAS IDENTIFIED 22 NON-CRASH ENGINE COMPARTMENT FIRES OF ANY OR UNSPECIFIED CAUSE ON THE SUBJECT VEHICLES.NINE FIRES (OF WHICH 4 WERE ALSO REPORTED TO ODI) ARE IDENTIFIED AS BEING DUE TO A FUEL SYSTEM LEAK ORIGINATING BETWEEN THE FIREWALL AND THE FUEL INJECTOR RAIL (P/N 0K30E 13 150) IN THE PASSENGER SIDE AREA OF THE ENGINE COMPARTMENT.THE REMAINING FIRES WERE DUE TO VARIED OR UNKNOWN CAUSES.ALL 9 FIRES CAUSED BY A FUEL SYSTEM LEAK SUSTAINED SEVERE AND TOTAL DAMAGE.ANALYSIS INDICATES THAT 1 FIRE WAS CAUSED BY A FAILED QUICK CONNECT BETWEEN THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE (P/N 0K32A 13 49XB) AND THE RIGID LINE MOUNTED TO THE FIREWALL; 5 FIRES WERE CAUSED BY A FAILURE OF THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE ITSELF OR ITS RELATED CONNECTORS; THE REMAINING 3 FIRES WERE CAUSED BY UNSPECIFIED FUEL LEAKS IN THE VICINITY OF THE FUEL INJECTOR RAIL, FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE, AND THE RIGID LINE MOUNTED TO THE FIREWALL.KIA REPORTS THAT NEITHER THE FUEL INJECTOR RAIL NOR THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE HAS BEEN SUBSTANTIALLY MODIFIED SINCE THEIR INTRODUCTION IN THE 2001 MODEL YEAR.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA03-015) SO THAT ODI MAY COLLECT ADDITIONAL INFORMATION AND CONDUCT FURTHER STUDY OF THIS ISSUE.
Fuel System, Gasoline:delivery
KIA HAS IDENTIFIED 22 NON-CRASH ENGINE COMPARTMENT FIRES OF ANY OR UNSPECIFIED CAUSE ON THE SUBJECT VEHICLES.NINE FIRES (OF WHICH 4 WERE ALSO REPORTED TO ODI) ARE IDENTIFIED AS BEING DUE TO A FUEL SYSTEM LEAK ORIGINATING BETWEEN THE FIREWALL AND THE FUEL INJECTOR RAIL (P/N 0K30E 13 150) IN THE PASSENGER SIDE AREA OF THE ENGINE COMPARTMENT.THE REMAINING FIRES WERE DUE TO VARIED OR UNKNOWN CAUSES.ALL 9 FIRES CAUSED BY A FUEL SYSTEM LEAK SUSTAINED SEVERE AND TOTAL DAMAGE.ANALYSIS INDICATES THAT 1 FIRE WAS CAUSED BY A FAILED QUICK CONNECT BETWEEN THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE (P/N 0K32A 13 49XB) AND THE RIGID LINE MOUNTED TO THE FIREWALL; 5 FIRES WERE CAUSED BY A FAILURE OF THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE ITSELF OR ITS RELATED CONNECTORS; THE REMAINING 3 FIRES WERE CAUSED BY UNSPECIFIED FUEL LEAKS IN THE VICINITY OF THE FUEL INJECTOR RAIL, FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE, AND THE RIGID LINE MOUNTED TO THE FIREWALL.KIA REPORTS THAT NEITHER THE FUEL INJECTOR RAIL NOR THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE HAS BEEN SUBSTANTIALLY MODIFIED SINCE THEIR INTRODUCTION IN THE 2001 MODEL YEAR.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA03-015) SO THAT ODI MAY COLLECT ADDITIONAL INFORMATION AND CONDUCT FURTHER STUDY OF THIS ISSUE.
Fuel System, Gasoline:fuel Injection System:fuel Rail
KIA HAS IDENTIFIED 22 NON-CRASH ENGINE COMPARTMENT FIRES OF ANY OR UNSPECIFIED CAUSE ON THE SUBJECT VEHICLES.NINE FIRES (OF WHICH 4 WERE ALSO REPORTED TO ODI) ARE IDENTIFIED AS BEING DUE TO A FUEL SYSTEM LEAK ORIGINATING BETWEEN THE FIREWALL AND THE FUEL INJECTOR RAIL (P/N 0K30E 13 150) IN THE PASSENGER SIDE AREA OF THE ENGINE COMPARTMENT.THE REMAINING FIRES WERE DUE TO VARIED OR UNKNOWN CAUSES.ALL 9 FIRES CAUSED BY A FUEL SYSTEM LEAK SUSTAINED SEVERE AND TOTAL DAMAGE.ANALYSIS INDICATES THAT 1 FIRE WAS CAUSED BY A FAILED QUICK CONNECT BETWEEN THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE (P/N 0K32A 13 49XB) AND THE RIGID LINE MOUNTED TO THE FIREWALL; 5 FIRES WERE CAUSED BY A FAILURE OF THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE ITSELF OR ITS RELATED CONNECTORS; THE REMAINING 3 FIRES WERE CAUSED BY UNSPECIFIED FUEL LEAKS IN THE VICINITY OF THE FUEL INJECTOR RAIL, FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE, AND THE RIGID LINE MOUNTED TO THE FIREWALL.KIA REPORTS THAT NEITHER THE FUEL INJECTOR RAIL NOR THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE HAS BEEN SUBSTANTIALLY MODIFIED SINCE THEIR INTRODUCTION IN THE 2001 MODEL YEAR.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA03-015) SO THAT ODI MAY COLLECT ADDITIONAL INFORMATION AND CONDUCT FURTHER STUDY OF THIS ISSUE.
Fuel System, Gasoline:fuel Injection System:injectors
KIA HAS IDENTIFIED 22 NON-CRASH ENGINE COMPARTMENT FIRES OF ANY OR UNSPECIFIED CAUSE ON THE SUBJECT VEHICLES.NINE FIRES (OF WHICH 4 WERE ALSO REPORTED TO ODI) ARE IDENTIFIED AS BEING DUE TO A FUEL SYSTEM LEAK ORIGINATING BETWEEN THE FIREWALL AND THE FUEL INJECTOR RAIL (P/N 0K30E 13 150) IN THE PASSENGER SIDE AREA OF THE ENGINE COMPARTMENT.THE REMAINING FIRES WERE DUE TO VARIED OR UNKNOWN CAUSES.ALL 9 FIRES CAUSED BY A FUEL SYSTEM LEAK SUSTAINED SEVERE AND TOTAL DAMAGE.ANALYSIS INDICATES THAT 1 FIRE WAS CAUSED BY A FAILED QUICK CONNECT BETWEEN THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE (P/N 0K32A 13 49XB) AND THE RIGID LINE MOUNTED TO THE FIREWALL; 5 FIRES WERE CAUSED BY A FAILURE OF THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE ITSELF OR ITS RELATED CONNECTORS; THE REMAINING 3 FIRES WERE CAUSED BY UNSPECIFIED FUEL LEAKS IN THE VICINITY OF THE FUEL INJECTOR RAIL, FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE, AND THE RIGID LINE MOUNTED TO THE FIREWALL.KIA REPORTS THAT NEITHER THE FUEL INJECTOR RAIL NOR THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE HAS BEEN SUBSTANTIALLY MODIFIED SINCE THEIR INTRODUCTION IN THE 2001 MODEL YEAR.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA03-015) SO THAT ODI MAY COLLECT ADDITIONAL INFORMATION AND CONDUCT FURTHER STUDY OF THIS ISSUE.
Fuel System, Gasoline:fuel Injection System
KIA HAS IDENTIFIED 22 NON-CRASH ENGINE COMPARTMENT FIRES OF ANY OR UNSPECIFIED CAUSE ON THE SUBJECT VEHICLES.NINE FIRES (OF WHICH 4 WERE ALSO REPORTED TO ODI) ARE IDENTIFIED AS BEING DUE TO A FUEL SYSTEM LEAK ORIGINATING BETWEEN THE FIREWALL AND THE FUEL INJECTOR RAIL (P/N 0K30E 13 150) IN THE PASSENGER SIDE AREA OF THE ENGINE COMPARTMENT.THE REMAINING FIRES WERE DUE TO VARIED OR UNKNOWN CAUSES.ALL 9 FIRES CAUSED BY A FUEL SYSTEM LEAK SUSTAINED SEVERE AND TOTAL DAMAGE.ANALYSIS INDICATES THAT 1 FIRE WAS CAUSED BY A FAILED QUICK CONNECT BETWEEN THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE (P/N 0K32A 13 49XB) AND THE RIGID LINE MOUNTED TO THE FIREWALL; 5 FIRES WERE CAUSED BY A FAILURE OF THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE ITSELF OR ITS RELATED CONNECTORS; THE REMAINING 3 FIRES WERE CAUSED BY UNSPECIFIED FUEL LEAKS IN THE VICINITY OF THE FUEL INJECTOR RAIL, FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE, AND THE RIGID LINE MOUNTED TO THE FIREWALL.KIA REPORTS THAT NEITHER THE FUEL INJECTOR RAIL NOR THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE HAS BEEN SUBSTANTIALLY MODIFIED SINCE THEIR INTRODUCTION IN THE 2001 MODEL YEAR.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA03-015) SO THAT ODI MAY COLLECT ADDITIONAL INFORMATION AND CONDUCT FURTHER STUDY OF THIS ISSUE.
Fuel System, Gasoline
KIA HAS IDENTIFIED 22 NON-CRASH ENGINE COMPARTMENT FIRES OF ANY OR UNSPECIFIED CAUSE ON THE SUBJECT VEHICLES.NINE FIRES (OF WHICH 4 WERE ALSO REPORTED TO ODI) ARE IDENTIFIED AS BEING DUE TO A FUEL SYSTEM LEAK ORIGINATING BETWEEN THE FIREWALL AND THE FUEL INJECTOR RAIL (P/N 0K30E 13 150) IN THE PASSENGER SIDE AREA OF THE ENGINE COMPARTMENT.THE REMAINING FIRES WERE DUE TO VARIED OR UNKNOWN CAUSES.ALL 9 FIRES CAUSED BY A FUEL SYSTEM LEAK SUSTAINED SEVERE AND TOTAL DAMAGE.ANALYSIS INDICATES THAT 1 FIRE WAS CAUSED BY A FAILED QUICK CONNECT BETWEEN THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE (P/N 0K32A 13 49XB) AND THE RIGID LINE MOUNTED TO THE FIREWALL; 5 FIRES WERE CAUSED BY A FAILURE OF THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE ITSELF OR ITS RELATED CONNECTORS; THE REMAINING 3 FIRES WERE CAUSED BY UNSPECIFIED FUEL LEAKS IN THE VICINITY OF THE FUEL INJECTOR RAIL, FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE, AND THE RIGID LINE MOUNTED TO THE FIREWALL.KIA REPORTS THAT NEITHER THE FUEL INJECTOR RAIL NOR THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE HAS BEEN SUBSTANTIALLY MODIFIED SINCE THEIR INTRODUCTION IN THE 2001 MODEL YEAR.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA03-015) SO THAT ODI MAY COLLECT ADDITIONAL INFORMATION AND CONDUCT FURTHER STUDY OF THIS ISSUE.
EA02009 · Air Bag Non Deploy
Opened Jul 2, 2002 · Closed Jul 2, 2003
Status: closed (inferred from source dates) · Air Bags
THIS INVESTIGATION IDENTIFIED A TOTAL OF 82 REPORTS ALLEGING NON-DEPLOYMENT OF THE DUAL FRONT AIR BAGS.OF THE 82 REPORTS, ONLY ONE INCIDENT, THE FATAL CRASH THAT WAS THE BASIS FOR OPENING THE INVESTIGATION, HAS BEEN IDENTIFIED AS A MODERATE TO SEVERE CRASH IN WHICH THE AUTOMOTIVE RESTRAINT CONTROLLER ISSUED A COMMAND TO DEPLOY BUT THE AIR BAGS DID NOT DEPLOY.A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES. SEE ATTACHED SUMMARY REPORT
PE02022 · Air Bag NON-DEPLOYMENT Frontal Crash
Opened Feb 12, 2002 · Closed Jul 2, 2002
Status: closed (inferred from source dates) · Air Bags
IN ADDITION TO THE DECEMBER 2001 FATAL CRASH REPORTED TO ODI THAT PROVIDED THE BASIS FOR OPENING PE02-022, KIA PROVIDED ODI 29 ADDITIONAL REPORTS OF ALLEGATIONS OF NON-DEPLOYMENT OF THE AIR BAG IN A CRASH.NO ADDITIONAL FATAL CRASHES ARE REPORTED.AN ENGINEERING ANALYSIS HAS BEEN OPENED TO CONDUCT FURTHER ANALYSIS OF THE SUBJECT VEHICLE'S AIR BAG SYSTEM.