Engine. Review the 496 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Electrical System. Review the 116 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Structure. Review the 91 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 reports44 fire reports22 injury reports

Electrical System complaints

116 reports

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41,100 miles · May 6, 2014

Electrical SystemEngineVehicle Speed Control

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AS I WAS DRIVING AT ABOUT 15-20MPH THE CAR SHUT OFF COMPLETELY AS I WAS MAKING A LEFT HAND TURN WITHOUT WARNING. THIS IS THE THIRD TIME AT DIFFERENT SPEEDS SINCE WE PURCHASED THE VEHICLE IN JANUARY 2014. WE HAVE TAKEN IT TO KIA DEALERSHIP FOR REPAIR, REGULAR OIL CHANGES AND MAINTENANCE. THEY WERE UNABLE TO FIND ANYTHING WRONG , READ ANY CODES WITH COMPUTER OR DUPLICATE THE PROBLEM. I AM VERY CONCERNED AS THIS IS OUR FAMILY CAR AND IT IS A DRIVING HAZARD NOT KNOWING WHEN IT WILL SHUT OFF WITH NO WARNING, NEXT TIME IT COULD BE IN THE MIDDLE OF THE INTERSECTION OR FREEWAY! WE PLAN ON TAKING BACK TODAY TO DEALERSHIP. *TR

NHTSA ODI #10586755

13,250 miles · Apr 30, 2014

Electrical SystemEngine

I WAS DRIVING IN TRAFFIC AND ALL OF A SUDDEN, THE CAR DIES. THE LIGHTS ON THE DASHBOARD ILLUMINATE. I HAD TO PUT THE CAR IN PARK, THEN TRIED STARTING THE CAR AGAIN. AFTER 2 TIMES, THE CAR TURNED BACK ON FINE. I BROUGHT THE CAR TO THE DEALER AND THERE COULDN'T REPLICATE THE PROBLEM AND DIDN'T FIND ANY COMPUTER CODES STORED. THI…

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NHTSA ODI #10585612

9,000 miles · Apr 26, 2014

Electrical SystemEnginePower Train

FIRST INCIDENT : AFTER A FULL STOP AT RED LIGHT, AS CAR TOOK OFF, ENGINE STALLED OUT. HAD TO TRY SEVERAL TIMES TO RESTART ENGINE. AFTER RESTARTED, THE CAR DROVE FINE. SECOND INCIDENT : AFTER SLOWING DOWN THE CAR TO ABOUT 3MPH AND REACCELERATING, ENGINE STALLED OUT. AFTER A FEW TRIES TO RESTART THE ENGINE, IT RESTARTED AND DRO…

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NHTSA ODI #10585106

31,000 miles · Apr 23, 2014

Electrical System

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04-21-2014 @ 5:30 AM. CAR WILL NOT START. NO ELECTRICAL PRESENT ON ANY SYSTEM-NOTHING. CALLED KIA ROADSIDE SERVICE AND THEY SUGGESTED A JUMPSTARTED WHICH WE DID AND THE CAR STARTED. I RAN THE CAR FOR AN HOUR OR SO WITH NO PROBLEMS. I TOOK IT TO A LOCAL GARAGE AND HAD THE BATTERY AND ALTERNATOR TESTED AND NO PROBLEMS WERE FOUND. I CALLED KIA DEALERSHIP AND DESCRIBED THE EVENTS TO THEM AND THEY STATED THAT IT WAS SIMPLY A DEAD BATTERY. NEXT MORNING (YESTERDAY), THE CAR WAS TOTALLY DEAD ONCE MORE. CALLED KIA ROADSIDE ASSISTANCE AND THEY WANTED TO JUMPSTARTED IT AGAIN. I REFUSED AND TOLD THEM TO SEND ME A TOW. THEY DID AND THE CAR WAS TAKEN TO THE CLOSEST KIA DEALERSHIP, 65 MILES AWAY. SEVERAL HOURS LATER I CALLED THE DEALERSHIP AND THEY STATED THAT IT WAS A DEAD BATTERY. THEY CHARGED THE BATTERY FOR 3-4 HOURS, TESTED THE CHARGING SYSTEM AND PRONOUNCED IT "FIXED". I LEFT IT AT THE DEALERSHIP AND PICKED IT UP THIS MORNING (TODAY). IT STARTED AND MY WIFE IS NOW DRIVING IT. I DO NOT BELIEVE IT WAS THE BATTERY AND I EXPECT IT TO HAPPEN AGAIN BUT THE DEALERSHIP'S SHOP WILL DO NO FURTHER INVESTIGATION. I'LL KEEP YOU INFORMED. *TR

NHTSA ODI #10584445

22,000 miles · Feb 7, 2014

Electrical SystemEngine

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I HAVE A 2013 KIA SORENTO THAT I BOUGHT BRAND NEW WITH ONLY 8 MILES ON IT. I WAS AT A STOP LIGHT AND MY CAR LUNGED FORWARD AS IF SOMEONE HIT US FROM BEHIND BUT THERE WAS NO ONE THERE. SO WHEN THE LIGHT TURNED GREEN WE STARTED TO GO AND NOTICED WE HAD NO POWER AND THE CHECK ENGINE LIGHT WAS ON. WE WERE ABLE TO GET TO THE SIDE OF THE ROAD AND TURN OFF THE CAR AND CALLED AAA AND THE DEALERSHIP TELLING THEM WHAT HAPPENED. SO ONCE IT GOT THERE THE SERVICE TECH AND IT PROBABLY WAS THE COMPUTER AND IT NEEDED TO BE UPDATED . I STAYED THERE FOR ABOUT 1 HOUR WHILE THEY DID THE UPDATE AND THEN THEY TEST DROVE IT AND THE CHECK ENGINE LIGHT CAME BACK ON. SO THEN THEY SAID IT WAS THE THROTTLE BODY SO THEY REPLACED IT AND TEST DROVE IT AGAIN AND THE CHECK ENGINE LIGHT CAME ON AGAIN. SO THEY FOUND THAT IT WAS THE PCM . NOT TOTALLY SURE WHAT THAT IS. HE SAYS IT WAS 1500$ PART IN THE COMPUTER THAT WAS MALFUNCTIONING . BUT THEY HAD MY CAR FOR A WEEK DOING THE REPAIRS AND NOW IS RUNNING GOOD. THEY ALSO HAVE ME A RENTAL CAR. SO IN ALL THE DEALERSHIP DID A GOOD JOB FIXING MY CAR AND WOULDN'T STOP UNTIL IT WAS FIXED RIGHT. *TR

NHTSA ODI #10563372

17,500 miles · Dec 17, 2013

Electrical SystemEngine

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I WAS STOPPED IN THE LEFT TURN LANE WAITING FOR TRAFFIC TO PASS SO THAT I COULD PULL INTO A SHOPPING CENTER PARKING LOT WHEN SUDDENLY EVERYTHING SHUT OFF. I HAD FIRST NOTICED THE RADIO HAD SHUT OFF AND THEN I REALIZED THAT THE ENTIRE ENGINE HAD SHUT DOWN AS I COULD NOT MOVE THE VEHICLE. AFTER PUTTING THE VEHICLE IN PARK AND TURNING THE IGNITION OFF AND THE RESTARTING IT, I WAS ABLE TO RESUME DRIVING. AS THIS WAS THE DAY BEFORE THANKSGIVING, I WAS NOT ABLE TO TAKE THE CAR TO THE DEALERSHIP UNTIL THE SATURDAY AFTER THANKSGIVING. SIMILAR TO OTHERS HERE WHO HAVE MADE COMPLAINTS, THE AUTOMOTIVE TECHNICIANS AT THE DEALERSHIP WERE NOT ABLE TO FIND ANYTHING WRONG WITH THE CAR EVEN AFTER TEST DRIVING IT AND HAVING IT CONNECTED TO THE COMPUTER. THE PROBLEM HAS NOT OCCURRED SINCE TAKING IT TO THE DEALERSHIP. I THOUGHT THAT MAYBE THIS WAS JUST A FLUKE THING UNTIL I READ ALL OF THE COMPLAINTS HERE. KIA REALLY NEEDS TO FIND OUT WHAT THE ISSUE IS WITH THESE VEHICLES BEFORE SOMEONE GETS SERIOUSLY INJURED OR KILLED. *TR

NHTSA ODI #10556294

40,000 miles · Dec 12, 2013

Electrical SystemEngine

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ABOUT 6 MONTHS AGO WHEN MY RADIO TURNED OFF AND WOULDN'T TURN BACK ON. I TOOK IT INTO THE DEALERSHIP AND THEY SAID THAT IT MUST HAVE BEEN A ONE TIME THING BECAUSE THEY WE NOT ABLE TO DUPLICATE THE PROBLEM AGAIN. I WENT WITH IT AS THIS IS THE 3RD KIA I HAVE OWNED. ON 12/5/13 I WENT TO TURN MY CAR ON AND IT DIDN'T START, I WAITED A FEW SECONDS TRIED AGAIN AND SHE STARTED. THE VERY NEXT DAY 12/6/13 I DROVE TO LA WITH MY SON AND ON MY WAY BACK DOWN (90 MILES AWAY FROM HOME) THE RADIO WENT OUT AGAIN AND MY CAR FELT VERY SLUGGISH. I COULDN'T CALL MY HUSBAND AS MY BLUETOOTH IS CONNECTED TO MY RADIO AND I WAS ALREADY ON THE ROAD WHEN THE RADIO WENT OUT AGAIN. NOW TODAY 12/11/13 I WAS DRIVING ON THE FREEWAY TO A DOCTORS APPOINTMENT. AS SOON AS I GET OFF THE FREEWAY I AM AT A STOP SIGN, I STOP. WHEN IT IS MY TURN TO GO IS WHEN MY CAR DECIDES TO COMPLETELY SHUT DOWN! ALL THE LIGHTS FLICKERED, THE RADIO WENT OUT AND MY CAR WAS STILL STUCK IN DRIVE, ON A SLIGHT HILL. I IMMEDIATELY PUT MY HAZARD LIGHTS ON, PUT THE EMERGENCY BREAK ON AS I DIDN'T WANT MY CAR TO ROLL BACKWARDS. AFTER TRYING TO RESTART MY CAR ABOUT 4 TIMES I WAS FINALLY ABLE TO PUT THE CAR IN PARK AND RESTART THE CAR. BUT SHE WAS SHAKING THE ENTIRE TIME UNTIL I FINALLY PARKED THE CAR AND WENT TO MY APPT. I PURCHASED THIS CAR FOR SAFETY AS I HAVE NEVER HAD A PROBLEM WITH ANY OF MY OTHER KIA'S. I WILL BE TAKING IT IN TO THE DEALERSHIP TOMORROW AND SEE WHAT THEY SAY. AFTER READING ALL OF THESE COMPLAINTS FROM PEOPLE WITH THE SAME EXACT ISSUE I AM LOOKING AT KIA TO RECALL THIS CAR. THEY SHOULDN'T WAIT UNTIL A FATALITY OCCURS TO RECTIFY THIS ISSUE. I LIVE THE CALIFORNIA SO AFTER 3 TIMES FOR THE SAME REASON IT WILL FALL UNDER THE LEMON LAW BUT MY CONCERN IS THE SAFETY OF EVERYONE ELSE ESPECIALLY MY 3 CHILDREN THAT I AM CONSTANTLY TRANSPORTING, AND MYSELF ON MY 140 MILE DRIVE DAILY. PLEASE RECALL THIS VEHICLE! *TR

NHTSA ODI #10555776

1,000 miles · Oct 20, 2013

Electrical SystemEngine

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WE PURCHASED THE 2013 KIA SORENTO AWD 2/2013 W/300 MILES ON IT. AT THE END OF APRIL, WE WENT TO DEATH VALLEY (ROUND TRIP WAS APPROX 350 MILES.). WHEN WE RETURNED TO TOWN, WE STOPPED AT THE GROCERY STORE TO PICK UP SUPPER SUPPLIES. AFTER SHUTTING THE VEHICLE OFF, BEING IN THE STORE FOR APPROX. 30 MINUTES, & THEN CAME BACK OUT, WHEN WE TURNED THE VEHICLE ON, IT SOUNDED AS THOUGH IT WAS ONLY HITTING ON HALF THE CYLINDERS. WE IMMEDIATELY CUT THE VEHICLE OFF, WAITED A COUPLE OF MINUTES, AND THEN TURNED IT BACK ON. IT SEEMED FINE. WE FIGURED IT WAS PROBABLY A FLUKE. RIGHT AFTER THIS HAPPENED THOUGH, I NOTICE A HUGE DECREASE IN MY FUEL MILEAGE. BEFORE THIS HAPPENED, I WAS GETTING 18/19 MPG/CITY AND 24-34 MPG/HWY (DEPENDING ON HOW FAR I WENT, OUT TO DEATH VALLEY W/NO STOPS, WE GOT 34). NOW I WAS LUCKY TO GET 13/14 MPG/CITY AND 16-18 MPG/HWY. WE TOOK IT TO THE KIA GARAGE, BUT THERE WASN'T MUCH THEY COULD DO BECAUSE IT WASN'T THROWING ANY CODES. WE SUFFERED WITH PAYING MORE FOR GAS FOR 6 MONTHS UNTIL WE WENT FOR AN OIL CHANGE IN OCT AND THE DEALERSHIP TOLD US THERE WAS AN "ECM" UPDATE. AFTER THEY SHARED WITH US THAT IT COULD POTENTIALLY HELP W/THE FUEL MILEAGE, I WAS ECSTATIC! IT WENT RIGHT BACK UP TO WHERE IT HAD BEEN PREVIOUSLY! THEN, THE THING WITH THE IGNITION HAPPENED AGAIN! ONLY WORSE THIS TIME, JUST A FEW DAYS AGO! MY FUEL MILEAGE WENT BACK DOWN TO WHAT I SHARED ABOVE. WE TOOK IT BACK TO THE DEALERSHIP AND AFTER THEM TRYING ALL DAY TO REPLICATE WHAT HAPPENED (WHICH TOOK MONTHS FOR IT TO HAPPEN W/US), THEY FINALLY DID THE UPDATE, AGAIN. MY FUEL MILEAGE IS BACK UP TO WHERE IT SHOULD BE. I WANT TO BE HAPPY, BUT I AM CONCERNED THIS WILL HAPPEN YET AGAIN. THERE HAVE BEEN TO OTHER NOTICEABLE ISSUES THAT I HAVE SHARED IN OTHER SECTIONS. ONE ABOUT VIBRATION WHILE IN NEUTRAL/PARK & ONE ABOUT THE VEHICLE NOT STARTING AFTER PRESSING THE IGNITION BUTTON. *TR

NHTSA ODI #10548594

8,500 miles · Sep 16, 2013

Electrical SystemSuspension

RADIO AND CAMERA SYSTEM SUDDENLY STOPS WORKING. WHEN YOU TURN ON THE AIR CONDITIONER COMES A STRONG ODOR AS "SILICONE" THIS HAPPENS THE FIRST TIME THAT I TURN ON THE AIR CONDITIONER IN THE DAY. THE VEHICLE IS VERY UNSTABLE AND VERY SENSITIVE TO UNEVEN ROADS. SHAKES A LOT AND MOVES A LOT. I WORRY ABOUT YOUNG CHILDREN AND THEIR HE…

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NHTSA ODI #10543793

11,786 miles · Aug 31, 2013

Electrical SystemEngine

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I WAS APPROACHING A RED LIGHT AND APPLIED THE BRAKES QUICKLY AS I WAS GOING TOO QUICKLY TO STOP AT THE STOP LINE IF I HAD NOT. I WAS ONLY GOING ABOUT 20-25 MPH. AS I APPLIED THE BRAKES THE CAR SHUT OFF. I WAS UNABLE TO PLACE THE CAR IN PARK FOR A COUPLE OF MINUTES AND THE CAR DID NOT RESPOND AT ALL. AFTER I BLOCKED TRAFFIC FOR A COUPLE OF LIGHT CHANGES AND CARS WERE HONKING, I WAS ABLE TO PLACE CAR ON PARK AND RESTART IT. IT HAS NOT HAPPENED SINCE. I RECENTLY NOTICED A HIGH PITCHED BUT VERY LOW SOUND WHILE DRIVING AT FIRST I WASN'T SURE WHERE IT WAS COMING FROM. I AM DUE FOR AN OIL CHANGE SO I WILL LET THE DEALERSHIP KNOW WHEN I TAKE IT IN SOON. *JS

NHTSA ODI #10538251

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.

20V750000 · Engine

Dec 2, 2020

Kia Motors America (Kia) is recalling certain 2012-2013 Sorento, 2012-2015 Forte and Forte Koup, 2011-2013 Optima Hybrid, 2014-2015 Soul, and 2012 Sportage vehicles. An engine compartment fire can occur while driving.

Consequence & remedy

Consequence: An engine compartment fire increases the risk of injury.

Remedy: Kia will notify owners, and dealers will inspect the engine compartment for fuel and/or engine oil leaks, perform an engine test and make any repairs, including engine replacement, as necessary, free of charge. In addition, Kia dealers will update the Knock Sensor Detection System (KSDS) software, free of charge. The recall began January 27, 2021. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC200.

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.

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.

15V626000 · Power Train:automatic Transmission

Oct 6, 2015

Kia Motors America (Kia) is recalling certain model year 2011-2013 Kia Sorento vehicles manufactured October 19, 2009, to January 31, 2013. In the affected vehicles, if excessive force is applied to the gear shift lever, the brake-shift interlock mechanism may chip or crack allowing the transmission being able to be shifted out of "Park" without the brakes being depressed. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 114, "Theft Protection."

Consequence & remedy

Consequence: Without requiring the brake to be pressed, the vehicle may be unintentionally shifted out of Park, allowing it to roll, which may result in a crash.

Remedy: Kia will notify owners, and dealers will replace the brake-shift interlock mechanism, free of charge. The recall began on November 9, 2015. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC124.

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.

PE20008 · Headlight Failure

Opened Jun 1, 2020 · Closed Jan 25, 2022

Status: closed (inferred from source dates) · Exterior Lighting; Exterior Lighting:headlights; Exterior Lighting:headlights:bulbs

The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) based on seventy-four Vehicle Owner Questionnaires (VOQs) reporting headlight failures on model year (MY) 2011-2013 KIA Sorento vehicles.In its response to ODI's June 25, 2020, information request letter (portions of which were submitted under request for confidentiality), Kia Motor America (Kia) provided design details of the headlight system showing that each headlight circuit is independently powered by the Smart Junction Box (SJB), a power control module. Kia claimed that the design minimizes the chance of both headlights failing simultaneously due to a headlight connector defect, a component located downstream of the SJB. Kia also advised that the SJB contains a safety feature designed to monitor power consumption for each headlight circuit; if excessive current is being demanded by either headlight the SJB will open the circuit (i.e., stop supplying current). Lastly Kia presented testing showing that the maximum headlight connector temperature achieved prior to the SJB opening the circuit was below the autoignition temperature of the plastic material the connector housing is made of, which Kia maintains eliminates the potential for a fire originating from an electrically overheated headlight connector. In its review of all available data, ODI determined that the majority of both VOQ and Kia customer complaints (1,339 reports in total) involved the loss or dimming of a single low beam headlight assembly caused primarily by a poor or overheated connector terminal located at the headlight. In some cases the failures were momentary in nature (i.e., flickering) with the headlights coming back on without driver intervention. A minority of VOQs and Kia complaints (the 196 Other reports) alleged simultaneous (and persistent) loss of both low beam headlights, and in most cases the driver was able to take an action (e.g., toggle the headlight switch, or use the ON rather than the AUTO setting on the headlight switch) to reinstate the low beam headlights. The high beam headlights were not seen to be affected and were available for drivers to use as alternate lighting.ODI did not identify any crashes or injuries, nor any fire incidents caused by a headlight related defect. While some VOQ and Kia reports alleged or indicated a fire occurrence, the incidents were found to involve melting or smells/odors due to thermal overheating of the plastic headlight connector housing, rather than an open flame fire.ODI notes that in April 2019, Kia initiated a 10 years/unlimited mileage warranty extension program to replace the headlight connector for MY 2011-2013 Sorento vehicles.Based on this analysis, a safety-related defect has not been identified at this time, and ODI is closing the investigation. This does not constitute a finding by the Agency that a safety-related defect is not present; the Agency will take further action if warranted by additional information received.The reference (ODI) numbers for the VOQs cited above are included in the downloadable version of this closing resume available at NHTSA.gov.

Additional source detail variants (3)

Exterior Lighting:headlights:bulbs

Exterior Lighting:headlights

Exterior Lighting

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

EA14002 · Panoramic Glass Sunroof Breakage

Opened May 12, 2014 · Closed Jan 15, 2021

Status: closed (inferred from source dates) · Visibility:sun/moon Roof Assembly

The investigation focused on spontaneous breakage (fracture) of the panoramic sunroof (sunroof) on MY 2011-2013 Kia Sorento vehicles. The sunroof is constructed of tempered glass (often referred to as ?safety glass?), which, when broken, crumbles into granular chunks rather than splintering into jagged shards. The failure summary above shows NHTSA reports identified by the Office of Defects Investigation (ODI), and reports submitted by Kia from start of production of the subject MY 2011-2013 Kia Sorento through October 8, 2019, the date of ODI's last request for Kia data.Reports of sunroof failures typically occurred while the vehicle was in motion and often described a loud noise when the fracture occurred. If the sunshade is closed when the sunroof fractures, the particles are contained, otherwise the particles can drop into the passenger compartment.Reported injuries generally were minor in nature, such as nicks and cuts that often occurred when complainants were cleaning-up glass particles post-incident. No crash incidents have been identified, and complaints display a declining trend since 2014.During EA14-002, ODI requested and obtained failure data for the subject vehicles, the MY 2014 Sorento (which used a similar sunroof from a different supplier), and other peer Kia products (Optima and Sportage).ODI also requested and obtained failure data for peer vehicles produced by Hyundai, Ford, Nissan, and Volkswagen and failure reports through a General Order NHTSA issued to 13 OEMs (including Kia) in April 2016.This produced a significant volume of data upon which ODI bases this closing. NHTSA's Vehicle Research and Test Center (VRTC) also conducted testing on the subject sunroofs in an attempt to better understand potential hazards.In its responses to ODI, Kia states it has continuously monitored sunroof failure allegations throughout this investigation, and that the only consistently identified cause is external impact from foreign objects. Kia notes that the sunroof complies with the applicable Federal Motor Vehicle Safety Standards for glazing, and that it has not identified a manufacturing defect or assembly process error despite significant investigative efforts. Kia maintains that the field data supports its conclusion that an unreasonable risk to motor vehicle safety does not exist, citing a comparatively moderate failure rate, low injury risk posed by tempered glass, and the lack of an identified defect mechanism. Kia further notes it has received no reports of crashes due to driver distraction related to roof failure events, nor is NHTSA aware of any such reports.NHTSA's April 2016 General Order requested data on vehicles with panoramic glass sunroofs greater than 0.5 square meters in area. The response identified 97 distinct models produced over 11 model years totaling some 10 million vehicles. Over 4,000 sunroof fractures were reported (none of which alleged a crash due to driver distraction) forming a high to low frequency continuum by model.While the subject vehicles were at the high end of the spectrum, they were not the highest.Through its analysis of the information obtained to date, ODI has not identified sufficient evidence of a safety-related defect in the subject sunroof. This includes the absence of any suggestive trends by region, seasonality, date of production, or vehicle age, together with the minor nature of the alleged injuries and the lack of crash allegations in the subject or any of the peer vehicles. Accordingly, the investigation is closed. ODI will take further actions if warranted by new evidence. The reference numbers for the ODI failure reports cited above, as well as additi

PE13035 · Panoramic Sunroof Breakage

Opened Oct 21, 2013 · Closed May 21, 2014

Status: closed (inferred from source dates) · Visibility:sun/moon Roof Assembly

On October 21, 2013 the Office of Defects Investigation (ODI) opened PE13-035 in order to further examine claims that the sunroof would spontaneously break on 2011-2013 Kia Sorento vehicles.The majority of these claims occurred while the vehicle was in motion.Glass shattering while driving may distract the driver, and the resulting glass particles which enter the passenger compartment may injure occupants.To date, ODI has received a total of 26 reports of sunroof breakage on the subject vehicles. Of those, 24 occurred while the vehicle was in motion.There were also four (4) injury incident reports for minor cuts/scratches. Kia submitted a total of 123 field incidents related to sunroof breakage in response to ODI's information request. Of this number, ODI identified 78 unique vehicle identification numbers (VINs), with 9 matching ODI complaint vehicles.Sixty of the submitted reports occurred while the vehicle was in motion.Fourteen (14) of the submitted reports alleged minor cuts/scratches from falling glass.Kia also submitted a total of 101 warranty and goodwill claims for sunroof replacement, of which 86 unique VINs were identified.Kia stated in its response that their field inspections identified only one potential cause for the sunroof breakage - external impacts from rocks or other foreign objects encountered while the vehicle was in motion.In the other instances, no evidence of a defect was found, however, Kia's inspection results were inconclusive as to a cause for the breakage.Kia advises that the Sorento sunroofs also have a greater surface area than many other vehicles, potentially making them more susceptible to road debris strikes.While ODI recognizes that the Sorento may be more at risk due to its larger impact area, the rate of ODI reported incidents is concerning.Thus, the investigation has been upgraded toan Engineering Analysis (EA14-002) to further analyze the scope, frequency, and consequence of these failures.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10345933, 10410440, 10432904, 10453957, 10466987, 10478778, 10492886, 10502219, 10508983, 10514388, 10531972, 10534883, 10553341, 10555931, 10556212, 10562460, 10562516, 10563779, 10564555, 10567351, 10568629, 10572959, 10575487, 10583122, 10583626, 10584650

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