2010 Kia Forte Koup

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.

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.

The Office of Defects Investigation (ODI) opened PE18-003 on 3/16/18 to investigate incidents involving crashes, resulting in significant collision related damage, where the frontal airbags failed to deploy. ODI reviewed complaint data, available design, test, and field data on the model year (MY) 2011 Hyundai Sonata, MY 2012-2013 Kia Forte and Forte Koup vehicles. ODI also evaluated data from the automotive air bag system supplier, ZF-TRW (ZF), to review vehicles that may contain the same air bag control unit (ACU) used in the subject vehicles. Hyundai Motor America (HMA) issued recall No. 18V-137 for MY 2011-2013 Sonata and MY 2012 Sonata Hybrid vehicles. Kia Motors America (KMA) issued recall No. 18V-363 for MY 2010-2013 Kia Forte and Forte Koup, MY 2011-2013 Optima, MY 2011-2012 Optima Hybrid, and MY2011-2012 Sedona vehicles. The two recalls address vehicles containing ACUs manufactured without adequate circuit protection by installing a wire harness filter kit to prevent internal damage to the ACU. In the event of a crash, ACU damage may result in the disablement of the vehicle's airbags. Each respective manufacturer has mailed letters to affected vehicle owners informing them of the remedy and its availability. ODI plans to evaluate the susceptibility of the subject ACU to electrical signals, as well as other vehicle factors that can either lead to, or reduce the likelihood of, an electrical overstress event in other vehicles manufactured with the subject ZF ACU.Accordingly, this Preliminary Evaluation has been upgraded to an Engineering Analysis (EA19-001), to expand the scope of the investigation to include the Tier-one supplier and any manufacturers who installed the subject ACU in production vehicles. Additional information is available with the closing resume available at NHTSA.gov (see Associated Documents).The ODI complaints cited above can be viewed at www.NHTSA.gov under the following ODI identification numbers: 10781050, 10849839, 11099038, 11080341.

THESE VEHICLES ARE ABSOLUTELY DANGEROUS! I'VE BEEN IN THE AUTOMOTIVE BUSINESS MY ENTIRE CAREER FOR 15 YEARS WITH A LEVEL CERTIFICATIONS AND ASE'S. I STOPPED DRIVING THE VEHICLE DUE TO THE SIMPLE MATTER OF ANY ACCELERATION OVER 2900 RPM IT STARTS KNOCKING. I WILL NOT PUT MY FAMILY OR MYSELF IN THE DANGER OF DRIVING THIS VEHICLE ANY LONGER. IF SOMETHING WERE TO BREAK WHILE MAKING A LEFT TURN THE RESULTS COULD BE DEVASTATING! I'VE CONTACTED KIA MANY TIMES REGARDING THIS MATTER YET I'VE BEEN TOLD THAT KNOCKING HIS NORMAL THEY CALL IT A PING. I TOLD THEM I USE 91 OCTANE EVERY TIME I FILL SO THERE'S NO WAY OF PINGING FROM PRE DETONATION. THE VEHICLE IS ALWAYS MAINTAINED AND OIL CHANGES ARE ALWAYS DONE EARLY. AFTER BEING TOLD MANY TIMES THAT THE KIA 2010 IS NOT A PART OF THE RECALL I HAVE TAKEN MY OWN ACTION TO FIXING THE PROBLEM. UPON TEARDOWN I HAVE DISCOVERED ROD BEARING DAMAGE AND A OIL PAN FULL OF MINOR FLAKES FROM ROD MATERIAL. DUE TO ME KEEPING RPM SLOW I WILL HOPEFULLY BE ABLE TO REPLACE THE ROD BEARINGS WITHOUT FURTHER PROBLEMS BUT WHO KNOWS ON THIS MOTOR. I JUST WORRY ABOUT ALL THE PEOPLE THAT DRIVE NORMALLY AND COULD POTENTIALLY HAVE A MOTOR FAILURE AND POSSIBLE FIRE FROM A ROD BREAKING THROUGH THE BLOCK. I SURE HOPE KIA DOES SOMETHING BEFORE SOMEONE IS KILLED!

NHTSA ID

11414806

Incident

May 1, 2018

Mileage

70 mi

I WAS DRIVING ON ROUTE 77 IN CHARLOTTE AT APPROXIMATELY 60 MPH. WHILE DRIVING, MY WHEEL HAD A STRUCTURAL FAILURE. I RETRACED MY ROUTE AND DO NOT SEE ANYTHING ON THE ROUTE (I.E. MAJOR OBSTACLE). REGARDLESS, THIS FAILURE IS COMPLETELY UNACCEPTABLE. I HAVE HAD OTHER CARS IN THE PAST AND HAVE RUN OVER SUBSTANTIAL ROAD DEBRIS AND NEVER HAD THE WHEEL ALMOST COME OFF OF THE CAR.

NHTSA ID

11205683

Incident

May 3, 2019

Mileage

125,000 mi

I RECENTLY TOOK MY CAR TO HAVE THE MOST RECENT RECALL WITH THE AIR BAG FIXED. AFTER THE REPAIR OCCURRED, THE AIR BAG LIGHT CAME ON. I TOOK THE CAR BACK TO THE DEALERSHIP TO SEE IF A MALFUNCTION OCCURRED DURING THE REPAIR. THE DEALERSHIP SERVICE DEPARTMENT TOLD ME THE AIR BAG MODULE AND CLOCK SPRING NEEDED TO BE REPLACED AT MY EXPENSE.

NHTSA ID

11165023

Incident

Jan 7, 2019

I HAD A 2010 KIA FORTE KOUP THAT CAUGHT ON FIRE 5/29/18 WHILE GOING DOWN A HIGHWAY APPROXIMATELY 55 MILES/HR. BEFORE THE FIRE BEGAN, THERE WAS SOME KNOCKING IN THE ENGINE AND ALL POWER WENT OUT, INCLUDING POWER STEERING AND BRAKES. I WAS ABLE TO GET IT TO THE SIDE OF THE ROAD AND POPPED THE HOOD TO SEE FLAMES COMING OUT OF THE ENGINE. I IMMEDIATELY CALLED THE FIRE DEPARTMENT. THEY DIDN'T MAKE IT IN TIME, AND THE WHOLE CAR WAS A COMPLETE LOSS. I HAVE ALWAYS KEPT UP WITH THE OIL CHANGES AND HAVING ALL FLUIDS CHECKED AND FILLED AS NEEDED. I HAVE HAD ALL RECALLS DONE AS THEY BECAME AVAILABLE. THE FIRE WAS IN THE FRONT OF THE CAR AND GAVE NO WARNING BEFORE THE POWER STEERING AND BRAKES WENT OUT. ALL WE COULD DO IS EVACUATE THE CAR, GET AS FAR AWAY FROM IT AS POSSIBLE, AND CALL 911. IT WAS DEVOURED WITHIN MINUTES WITH FLAMES, AND IS NOW A COMPLETE LOSS. I HAVE CONTACTED KIA INTERNATIONAL (CASE #12745414) WHO TOLD ME THAT THE MANUFACTURER'S WARRANTY WAS EXPIRED, SO THERE WAS NOTHING THAT THEY COULD DO. I ALSO PURCHASED AN EXTENDED WARRANTY FROM CNA NATIONAL, BUT THEY CLAIMED THAT THEY WEREN'T RESPONSIBLE FOR MECHANICAL ISSUES.

NHTSA ID

11151192

Incident

May 29, 2018

Mileage

131,000 mi

THE SEAT BELTS WILL NOT AUTOMATICALLY ROLL BACK INTO THE DOOR FRAME OF THE CAR AFTER TAKING THEM OFF. YOU HAVE TO JERK THE BELT UP AND DOWN CLOSE TO TWENTY TIMES TO GET THEM TO RETRACT. ALSO, I'VE NOTICED THAT THE CRUISE CONTROL DOESN'T FUNCTION LIKE NORMAL. IT ONLY WORKS ONCE IN A WHILE. I HAVE TO TRY TO SET MY SPEED MANY TIMES IF IT EVER GETS IT TO WORK. THESE ISSUES HAVE BEEN GOING ON FOR MONTHS NOW.

NHTSA ID

11105081

Incident

Jul 2, 2018

Mileage

102,000 mi

I WAS DRIVING ON THE INTERSTATE DOING ABOUT 65 MPH WHEN SUDDENLY I HEARD A VERY LOUD BOOM. NO OTHER CARS WERE NEAR ME WHEN THE BOOM HAPPENED AND I THOUGHT I JUST RAN OVER SOMETHING. A FEW MINUTES LATER MY WIFE OPENED UP THE SUNROOF SLIDING COVER AND WE SAW THAT THE SUNROOF HAD SHATTERED. THE WHOLE SUNROOF GLASS LOOKED LIKE A SPIDERWEB AND THERE WAS NOT ANY IMPACT MARKS WHERE SOMETHING COULD HAVE HIT THE GLASS.

NHTSA ID

11096819

Incident

May 18, 2018

Mileage

150,000 mi

MY SEAT BELT DRIVER SIDE WILL NOT CLICK INTO THE BUCKLE WHICH MAKES IT HARD NOT BE PULLED OVER AND VERY UNSAFE. AS WELL AS, MY LIGHTS ON THE INSIDE OF THE CAR DO NOT TURN OFF THEY ARE ALWAYS ILLUMINATED ONCE STARTING THE CAR. MY BRAKE LIGHTS GO OUT EVERY SO OFTEN, AS WELL AS A FEW OTHER ELECTRICAL PROBLEMS. ALSO MY BRAKES SOMETIMES WON'T COME UP OFF THE FLOOR OR WILL STAY IN THE UPRIGHT POSITION EVEN WHILE BEING PRESSED. THIS IS INCREDIBLY UNSAFE.

NHTSA ID

11090426

Incident

Apr 27, 2018

Mileage

150,000 mi

ENGINE FAILURE DUE TO METAL FLAKES IN ENGINE (SAME AS RECENT RECALL ON OTHER MODELS). NO LIGHTS OR INDICATORS PRESENT, ENGINE WAS MAKING ABNORMAL NOISES AND TOOK CARE IN BEFORE A CATASTROPHIC INDECENT.

NHTSA ID

11080384

Incident

Mar 1, 2018

Mileage

108,000 mi

PRODUCT IMPROVEMENT CAMPAIGN: OWNER RENOTIFICATION (PI2102 FLIGHT #501) - This document is the owner renotification advising that Kia is conducting an important Product Improvement Campaign to perform a software update on 2010-2011 MY Kia Forte and Forte Koup vehicles equipped with 2.4-liter MPI engines to protect the engine from excessive connecting rod bearing damage. The update will be done free of charge and will only involve the addition of newly developed computer software for the Engine Control Unit (“ECU”).

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information to install a Theft Deterrent Ignition Cylinder Protector on certain 2010-2022MY Kia vehicles outlined on page 20, which may not have been equipped with an immobilizer and whole Integrated Body control Unit (IBU) / Body Control Module (BCM) did receive the Ant-Theft Software Logic upgrade under CS2301/02/03/04/05/06/07/08/09 TSBs. In an effort to help prevent thefts of Kia vehicles, a protective cover will be permanently affixed to the ignition cylinder. This Theft Deterrent Ignition Cylinder Protector prevents the removal of the key lock cylinder thereby preventing access to the ignition tumbler.

PRODUCT IMPROVEMENT CAMPAIGN: OWNER RENOTIFICATION (PI2102) - This document is the owner renotification advising that Kia is conducting a Product Improvement Campaign to perform a software update on 2010-2011 MY Kia Forte and Forte Koup vehicles equipped with 2.4-liter MPI engines to protect the engine from excessive connecting rod bearing damage. The update will be done free of charge and will only involve the addition of newly developed computer software for the Engine Control Unit (“ECU”).

TECHNICAL SERVICE BULLETIN: PRODUCT IMPROVEMENT CAMPAIGN: SUBSEQUENT REPAIR ACTION: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z) - This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information related to the Technical Service Bulletin previously published in (PI2102) titled “Knock Sensor Detection System - ECU Logic Improvement” for 2010-2011MY Forte and Forte Koup (TD)vehicles equipped with Theta 2.4L MPI engine, produced from February 24, 2009 through May 31, 2011. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below return to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).

PRODUCT IMPROVEMENT CAMPAIGN: OWNER RENOTIFICATION (PI2102) - This document is the owner renotification advising that Kia is conducting This bulletin provides information related to the Technical Service Bulletin previously published in (PI2101) titled “Knock Sensor Detection System - ECU Logic Improvement” for 2011MY Sorento (XMa) vehicles equipped with Theta 2.4L MPI engine, produced from October 24, 2009 through June 24, 2011. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below return to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).

This bulletin provides information relating to the correct transmission fluid type and fill quantity requirement for each Kia model. A flush is required ONLY when a transmission is replaced.