NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
392 reports74,000 miles · Jul 3, 2017
Engine
DRIVING DOWN THE ROAD AT APPROXIMATELY 45-50 MPH AND THE ENGINE BEGAN KNOCKING. LOST ALL POWER TO THE CAR. A FEW MOMENTS LATER, THE CAR STOPPED COMPLETELY IN THE MIDDLE OF A BUSY INTERSECTION. I GOT OUT OF THE CAR AND PUSHED IT INTO A GAS STATION PARKING LOT. THE CAR WOULD CRANK BUT THE KNOCKING OF THE ENGINE WAS BECOMING WORSE.…
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DRIVING DOWN THE ROAD AT APPROXIMATELY 45-50 MPH AND THE ENGINE BEGAN KNOCKING. LOST ALL POWER TO THE CAR. A FEW MOMENTS LATER, THE CAR STOPPED COMPLETELY IN THE MIDDLE OF A BUSY INTERSECTION. I GOT OUT OF THE CAR AND PUSHED IT INTO A GAS STATION PARKING LOT. THE CAR WOULD CRANK BUT THE KNOCKING OF THE ENGINE WAS BECOMING WORSE. I HAD THE CAR TOWED TO A SHOP WHERE THE PROBLEM WAS DIAGNOSED AS "ROD KNOCK" WHICH IS CAUSED BY A FAULTY MOTOR, ALLOWING METAL SHAVINGS TO ENTER AND BLOCK THE FLOW OF OIL TO THE MOTOR. NOT WANTING TO BELIEVE THAT I WAS GOING TO HAVE TO PAY $5,000 TO REPLACE THE ENGINE, I GOT A SECOND OPINION FROM A KIA DEALERSHIP IN MY HOME TOWN. NOT ONLY DID THEY CONFIRM WHAT THE INITIAL MECHANIC HAD DIAGNOSED, BUT WERE VERY RUDE WHEN ASKING US TO "REMOVE OUR CAR FROM THEIR PARKING LOT BECAUSE UNLESS WE WERE GOING TO PAY THEM TO FIX IT, IT HAD NO BUSINESS BEING THERE." ALL OIL CHANGES HAVE BEEN DONE REGULARLY AND I HAVE DOCUMENTATION FOR THEM ALL. OUR VEHICLE HAD 74,000 MILES ON IT AND WAS KEPT IN EXCELLENT CONDITION. AS OF NOW, KIA HAS DONE NOTHING TO EXPLAIN WHY NOTHING HAS BEEN DONE ABOUT OUR PROBLEM, AS WELL AS MANY OTHERS WHO HAVE HAD THIS SAME PROBLEM.
NHTSA ODI #11002799
98,800 miles · Jun 23, 2017
Engine
ONE DAY ME AND MY WIFE WERE DRIVING AROUND THE CITY RUNNING SOME ERRANDS WHEN I NOTICED A SOUND COMING FROM THE ENGINE AREA. SO I ADMEDIATLY HEADED HOME. WHEN I ARRIVED I OPENED THE HOOD OF MY 2012 KIA SPORTAGE TO HEAR A KNOCKING SOUND. AFTER CONFIRMING THE SOUND WAS MY ENGINE I CALL KIA TELLING THEM WHAT WAS GOING ON, THEY MADE…
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ONE DAY ME AND MY WIFE WERE DRIVING AROUND THE CITY RUNNING SOME ERRANDS WHEN I NOTICED A SOUND COMING FROM THE ENGINE AREA. SO I ADMEDIATLY HEADED HOME. WHEN I ARRIVED I OPENED THE HOOD OF MY 2012 KIA SPORTAGE TO HEAR A KNOCKING SOUND. AFTER CONFIRMING THE SOUND WAS MY ENGINE I CALL KIA TELLING THEM WHAT WAS GOING ON, THEY MADE ME A APPOINTMENT DATE AND TOLD ME TO CALL MY EXTENDED WARRANTY COMPANY TO NOTIFY THEM OF THE SITUATION AND GET AUTHORIZATION TO DO AN INSPECTION. SO I DID AND THEY TOLD ME TO TAKE IT IN WHILE THEY INVESTIGATE. AS A COUPLE DAYS PASSED I TOOK MY CAR IN AN IMMEDIATELY THEY KNEW WHAT THE PROBLEM WAS AND GUARANTEED ME KIA WOULD HANDLE THE PROBLEM. AS THREE WEEKS WENT BYE I CALLED THE WARRANTY COMPANY TO SEE WHAT WAS TAKING SO LONG AND THEY BEGAN TO SAY THAT THE REASON FOR THE PROBLEM WAS MY FAULT DUE TO LACK OF MAINTENANCE AND IF I WANTED THE ENGINE FIXED IT WOULD COST $8000. I REFUSED REPAIRS AND WENT TO RECOVER MY VEHICLE. AS I DROVE AWAY IN MY VEHICLE I NOTICED THEY GAVE IT BACK MAKING A LOUDER KNOCKING. AS I PROCEEDED TO GO HOME MY CAR SUDDENLY STALLED IN THE MIDDLE OF THE STREET WITH TRAFFIC BEHIND ME. THE CAR WOULD NOT TURN ON ANYMORE. I PUSHED IT TO THE SIDE OF THE ROAD WERE I HAD TO CALL FOR A TOW TRUCK TO TAKE IT HOME WERE MY VEHICLE HAS BEEN FOR THE LAST TWO MONTHS.. KIA AND THE EXTENDED WARRANTY COMPANY STILL REFUSING TO DO ANY REPAIRS WITHOUT ME PAYING $8000 FOR A NEW ENGINE.
NHTSA ODI #11000764
59,918 miles · Jun 12, 2017
Engine
TL* THE CONTACT IS AN ATTORNEY WHOSE CLIENT OWNS A 2012 KIA SPORTAGE. WHILE THE CLIENT'S WIFE WAS DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER (RICK CASE KIA SUNRISE 14500 W SUNRISE BLVD, SUNRISE, FL 33323), BUT THE FAILURE COULD NOT BE REPLICATED. THE FAILURE RECURRED. THE VEHICLE WAS…
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TL* THE CONTACT IS AN ATTORNEY WHOSE CLIENT OWNS A 2012 KIA SPORTAGE. WHILE THE CLIENT'S WIFE WAS DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER (RICK CASE KIA SUNRISE 14500 W SUNRISE BLVD, SUNRISE, FL 33323), BUT THE FAILURE COULD NOT BE REPLICATED. THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO THE DEALER AGAIN AND THE FAILURE RECURRED AS THE DEALER DROVE THE VEHICLE. IT WAS DIAGNOSED THAT THE CRANKSHAFT AND CRANK POSITION SENSORS FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE CONTACT SPOKE TO THE DEALER WHO STATED THAT IF NO WARNING INDICATORS ILLUMINATED, THEY COULD NOT ASSIST. THE FAILURE RECURRED ONCE AGAIN. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V224000 (ENGINE) AND TOOK THE VEHICLE BACK TO RICK CASE KIA FOR AN ENGINE INSPECTION. THE DEALER PERFORMED AN OIL CHANGE, REPLACED THE DIPSTICK, AND STATED THAT THE VEHICLE PASSED PER KIA'S SPECIFICATIONS. THE FAILURE HAD NOT RECURRED AT THE TIME OF THE COMPLAINT. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE CONTACT SHOULD MAKE AN APPOINTMENT WITH THE DEALER. THE APPROXIMATE FAILURE MILEAGE WAS 59,918.
NHTSA ODI #10994480
103,000 miles · Jun 4, 2017
Engine
WHILE DRIVING ON A HIGHWAY, THE ENGINE OF THE CAR BEGAN TO MAKE A LOUD KNOCKING SOUND. AFTER THE NOISE STARTED, THE ENGINE POWER WAS SEVERELY REDUCED. THE CAR FAILED TO ACCELERATE AS NORMAL. AT THE FIRST STOPLIGHT AFTER EXITING THE HIGHWAY, THE ENGINE STALLED. IT STARTED AGAIN, AND STALLED AGAIN AT THE NEXT LIGHT BUT WE WERE ABL…
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WHILE DRIVING ON A HIGHWAY, THE ENGINE OF THE CAR BEGAN TO MAKE A LOUD KNOCKING SOUND. AFTER THE NOISE STARTED, THE ENGINE POWER WAS SEVERELY REDUCED. THE CAR FAILED TO ACCELERATE AS NORMAL. AT THE FIRST STOPLIGHT AFTER EXITING THE HIGHWAY, THE ENGINE STALLED. IT STARTED AGAIN, AND STALLED AGAIN AT THE NEXT LIGHT BUT WE WERE ABLE TO GET IT SAFELY TO A PARKING LOT AT AN AUTOMOTIVE SERVICE CENTER. AT NO TIME, DID THE CHECK ENGINE LIGHT EVER ILLUMINATE INDICATING THAT THERE MAY BE A PROBLEM BEFORE OR DURING THIS ISSUE. THE CAR WAS INSPECTED THE NEXT DAY AND THE SHOP RECOMMENDED ENGINE REPLACEMENT. CAR WAS TOWED TO A KIA DEALERSHIP AND UPON THEIR INSPECTION, IT WAS DETERMINED THAT THE KNOCKING NOISE WAS COMING FROM THE CRANKSHAFT WHICH CAUSED "EXCESSIVE METAL THROUGHOUT THE ENGINE". TOTAL ENGINE REPLACEMENT WAS NECESSARY. THE CAR HAD APPROXIMATELY 103,000 MILES AT THE TIME. KIA CORPORATE OFFERED NO FINANCIAL ASSISTANCE SINCE CERTIFIED PRE-OWNED WARRANTY EXPIRED AT 100,000 MILES. THE TOTAL COST OF THE ENGINE REPLACEMENT WAS $5,037.93 WHICH HAD TO BE PAID OUT OF POCKET.
NHTSA ODI #10993062
103,000 miles · Jun 1, 2017
Engine
ENGINE KNOCKED AS I SPED UP ON HIGHWAY THEN CAR DIED AND ENGINE AND OIL LIGHTS CAME ON AS I PULLED ONTO AN OFF-RAMP CAR WILL NO LONGER START OR RUN HAD TO BE TOWED DIAGNOSED AS FAILED ENGINE
NHTSA ODI #10992670
92,943 miles · May 31, 2017
EngineUnknown Or Other
YESTERDAY WHEN I WAS DRIVING MY CHECK ENGINE LIGHT CAME ON. SO I TOOK IT TO PEPBOYS THAT SAID THE CODE WAS 791. THEN, CALLED THE DEALERSHIP AND MECHANICS TO FIND OUT ABOUT IT. MOST PEOPLE THAT PART SHOULD NOT HAD WENT BAD. THIS CODE IS FOR THE BUTTERFLY FLIPS IN THE INTAKE MANOFOLD.
NHTSA ODI #10992507
106,000 miles · May 27, 2017
Engine
DRIVING DOWN THE FREEWAY AT 80MPH (SPEED LIMIT IN IDAHO), RPMS STARTED TO REV OVER 6K, HEARD A TICKING SOUND, THEN A VERY LOUD BANG, FOLLOWED BY A BIG PUFF OF BLACK SMOKE, ALL IN THE SPAN OF AROUND 20 SECONDS. CAR DIED ON THE FREEWAY, HAD TO COAST TO GET IN EMERGENCY LANE. THEN THE CHECK ENGINE LIGHT CAME ON. THERE WAS NO INDICA…
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DRIVING DOWN THE FREEWAY AT 80MPH (SPEED LIMIT IN IDAHO), RPMS STARTED TO REV OVER 6K, HEARD A TICKING SOUND, THEN A VERY LOUD BANG, FOLLOWED BY A BIG PUFF OF BLACK SMOKE, ALL IN THE SPAN OF AROUND 20 SECONDS. CAR DIED ON THE FREEWAY, HAD TO COAST TO GET IN EMERGENCY LANE. THEN THE CHECK ENGINE LIGHT CAME ON. THERE WAS NO INDICATION OF ENGINE ISSUES UNTIL IT WAS FAR TOO LATE. THANKFUL THE CARS BEHIND ME WERE PAYING ATTENTION OR I WOULD HAVE BEEN IN AN AWFUL ACCIDENT WITH AN 18 WHEELER. MECHANIC FOUND THAT ENGINE HAD THROWN A ROD AND PUT A HOLE IN THE ENGINE BLOCK. 106K MILES ON THE VEHICLE, DID NOT EXPECT TO HAVE ENGINE FAILURE THIS EARLY. THIS VIN IS NOT PART OF THE CURRENT RECALL, I BELIEVE IT SHOULD BE, AS IT HAS BEEN PROPERLY MAINTAINED AND SHOULD NOT HAVE FAILED ON THE FREEWAY WITH NO INDICATION OF PROBLEMS UNTIL IT WAS TOO LATE.
NHTSA ODI #10991919
99,992 miles · May 22, 2017
Engine
CRUISING ALONG AT FREEWAY SPEED, 75 MPH, VEHICLE MOMENTARILY LOST POWER AS IF IT WAS GOING TO STALL OR DOWN SHIFT. UPON RESUMING SPEED, HEARD A TAPPING NOISE AND A LOUD BANG, SAW SMOKE COMING OUT THE BACK OF THE VEHICLE AND OBJECTS TOSSED OUT. SAW A VEHICLE FOLLOWING IN MY LANE, SWERVE AS IF AVOIDING AN OBJECT BUT DID NOT STOP. …
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CRUISING ALONG AT FREEWAY SPEED, 75 MPH, VEHICLE MOMENTARILY LOST POWER AS IF IT WAS GOING TO STALL OR DOWN SHIFT. UPON RESUMING SPEED, HEARD A TAPPING NOISE AND A LOUD BANG, SAW SMOKE COMING OUT THE BACK OF THE VEHICLE AND OBJECTS TOSSED OUT. SAW A VEHICLE FOLLOWING IN MY LANE, SWERVE AS IF AVOIDING AN OBJECT BUT DID NOT STOP. COASTED TO THE SIDE OF THE FREEWAY, NOTICED A TRAIL OF OIL. UPON PARKING, CHECKED UNDERNEATH THE ENGINE COMPARTMENT, NOTICED OIL DRIPPING AND METAL PIECES, AND WHAT APPEARED TO BE A HOLE IN THE OIL PAN. VEHICLE WAS TOWED TO A DEALERSHIP AND WAS TOLD, A COUPLE OF DAYS LATER, THAT THE VEHICLE MAY BE SUBJECT TO A RECALL FOR SIMILAR DEFECTS. DOING AN ONLINE QUERY, I NOTICED THAT THE 2.4 ENGINE FOR THIS MODEL WAS NOT A PART OF THE RECALL CAMPAIGN, ALTHOUGH OTHER MODELS WITH THE 2.4 ENGINE WERE. FORTUNATELY, IT APPEARS THAT NO FOLLOWING VEHICLES WERE HIT WITH ANY OF THE DEBRIS COMING OFF THE VEHICLE. UPON CHECKING THE SIDE OF THE FREEWAY, I PICKED UP WHAT APPEARED TO BE A PIECE OF THE ENGINE'S CONNECTING ROD. HAD THIS PIECE HIT A FOLLOWING VEHICLE, IT COULD'VE RESULTED IN PROPERTY DAMAGE OR UNKNOWN INJURIES TO ITS OCCUPANTS.
NHTSA ODI #10991094
122,000 miles · May 9, 2017
Engine
WHILE DRIVING MY 2012 KIA SPORTAGE ABOUT 30 MPH ON A COUNTY ROAD, THERE WAS A LOUD KNOCKING FROM THE ENGINE, THE CHECK ENGINE LIGHT CAME ON AND THE CAR STALLED. IT HAS BEEN DIAGNOSED AS A CRANK BEARING ISSUE. THERE IS A RECALL ON 2012 KIA SPORTAGE ALONG WITH OTHER KIAS AND HYUNDAI. THE RECALL IS FOR 2.4 LITER ENGINES IN THE OPTI…
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WHILE DRIVING MY 2012 KIA SPORTAGE ABOUT 30 MPH ON A COUNTY ROAD, THERE WAS A LOUD KNOCKING FROM THE ENGINE, THE CHECK ENGINE LIGHT CAME ON AND THE CAR STALLED. IT HAS BEEN DIAGNOSED AS A CRANK BEARING ISSUE. THERE IS A RECALL ON 2012 KIA SPORTAGE ALONG WITH OTHER KIAS AND HYUNDAI. THE RECALL IS FOR 2.4 LITER ENGINES IN THE OPTIMA AND THE SORRENTO BUT ONLY FOR THE 2.0 IN THE SPORTAGE. WHY IS THIS? I HAVE A 2.4 LITER ENGINE AND THERE ARE OBVIOUSLY ISSUES WHICH LED TO THE RECALL BUT IT WON'T BE COVERED. THE SAME SAFETY ISSUE THAT IS IN THE 2.0 IS IN THE 2.4 AND IT NEEDS TO RECALLED IN THE SPORTAGE JUST LIKE IT IS IN THE OTHER 2 MODELS.
NHTSA ODI #10984458
63,000 miles · Apr 30, 2017
Engine
MY PARTNER WAS DRIVING 50 MPH TO WORK ON A LOCAL HIGHWAY WHEN SUDDENLY THE VEHICLE LOST POWER. NO INDICATOR LIGHTS HAD COME ON. THERE WAS ONLY A SLIGHT TAPPING SOUND FROM UNDER THE HOOD. SHE WAS ABLE TO DRIFT THE VEHICLE TO THE SIDE OFF THE ROAD. WHEN SHE TRIED TO RESTART THE VEHICLE IT WOULD NOT START. THE VEHICLE WAS TOWE…
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MY PARTNER WAS DRIVING 50 MPH TO WORK ON A LOCAL HIGHWAY WHEN SUDDENLY THE VEHICLE LOST POWER. NO INDICATOR LIGHTS HAD COME ON. THERE WAS ONLY A SLIGHT TAPPING SOUND FROM UNDER THE HOOD. SHE WAS ABLE TO DRIFT THE VEHICLE TO THE SIDE OFF THE ROAD. WHEN SHE TRIED TO RESTART THE VEHICLE IT WOULD NOT START. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS PURCHASED AND A DIAGNOSTIC TEST REVEALED A CEASED UP ENGINE. THE VEHICLE HAD PERIODICAL OIL CHANGES AS REQUIRED TO KEEP A VEHICLE IN GOOD RUNNING ORDER AND AT THE TIME HAD OIL IN IT. AT NO TIME WAS THERE ANY LEAKS OR DRIPS OR SIGNS ON PAVEMENT WHERE THE VEHICLE WAS PARKED OF ANY OIL LEAKAGE. WE WERE TOLD THE ENGINE WOULD NEED TO BE REPLACED.
NHTSA ODI #10981480
Official recalls
5Sep 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.
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.
Feb 15, 2019
Kia Motors America (Kia) is recalling certain 2011-2012 Kia Sportage vehicles. The engine oil pan may leak and, if not addressed, the loss of oil may result in engine damage.
Consequence & remedy
Consequence: A damaged engine can increase the risk of a fire or it can cause an engine stall, increasing the risk of a crash.
Remedy: Kia has notified owners, and dealers will replace the oil pressure switch with an improved one, free of charge. In addition, dealers will inspect the oil pan for any oil leaks, replacing it if necessary, free of charge. The recall began July 3, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia's number for this recall is SC174.
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
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: 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
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: 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.
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.
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
4AQ23002 · 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.
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
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.
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.
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