2011 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.

MY CAR ACCELERATES ON ITS OWN. FULLY STOPPED, MY CAR IS ON 1000RPMS, I WILL BE DRIVING AT A CONSTANT SPEED AND MY RPM SHOOTS ALL THE WAY UP.

NHTSA ID

11185115

Incident

Jul 16, 2018

Mileage

75,000 mi

ONE MORNING I STARTED THE CAR AND THE "CHECK ENGINE" LIGHT CAME ON. THE CAR ALSO MADE A KNOCKING/TICKING SOUND THAT WAS NOT USUAL AND THE ENGINE HAD AN ABNORMAL SOUND TO IT WHEN STATIONED AND IN MOTION. IT PROGRESSIVELY GOT WORSE, ESPECIALLY AS IT WAS DRIVEN TO THE DEALER RIGHT AFTER THE LIGHT CAME ON. WE BROUGHT IT INTO THE DEALER WE BOUGHT IT FROM AND FOUND OUT THAT THE LIGHT WAS FOR A CODE ABOUT THE INTAKE MANIFOLD (BUTTERFLY) VALVES NOT OPENING/CLOSING PROPERLY. IT LATER ENDED UP BEING COMPLETE INTERNAL ENGINE FAILURE DUE TO THE CONNECTING ROD BEARING FAILING. THE CAR REQUIRED A COMPLETELY NEW ENGINE BECAUSE OF THIS. IT ONLY HAD 82,000 MILES ON IT WHEN THE PROBLEM OCCURRED. IT ALSO HAD PROBLEMS STARTING OCCASIONALLY BEFORE THE CHECK ENGINE LIGHT CAME ON. THE DEALERSHIP ALSO FOUND THAT THE VEHICLE CONTROL MODULE (VCM) WAS BAD AND NEEDED TO BE REPLACED AS WELL AT THE SAME TIME OF THE ENGINE FAILURE.

NHTSA ID

11183518

Incident

Feb 18, 2019

Mileage

82,000 mi

HELLO, LONG STORY SHORT, KIA HAS FAULTY AIRBAGS I HAVE A VERY PREGNANT WIFE. THEY HAVE YET TO DIE RIGHT BY THE CUSTOMER AND OFF SAFE VEHICLES TO REPLACE THESE UNTIL A FIX IS FOUND. I WENT TO KIA IN TURNERSVILLE NJ TO HAVE A HUB ASSEMBLY REPLACED. AT THIS TIME I REQUESTED THE TECHNICIAN TO RUN THE VIN FOR AN AIRBAG RECALL I SAW ONLINE, THIS WAS IN JUNE. HE CAME BACK SAYING HE CHECKED AND IT IS ALL CLEAR AND I ASKED HIM TO CHECK AGAIN MAINLY BECAUSE SHE IS 8 MONTHS PREGNANT. ONCE AGAIN TOLD IT WAS CLEAR. TODAY I RECEIVED SOMETHING IN THE MAIL FROM KIA REGARDING MY PREGNANT FINANCES AIRBAG IN FACT BEING RECALLED. SHE HAS BEN DRIVING LIKE THIS FOR TWO MONTHS AND WASN'T LIED TO AND MADE TO FEEL COMFORTED THAT ALL WAS FINE! I CALLED AGAIN TODAY AND WAS TOLD THERE WASN'T ANYHTING TO BE DONE YET AND MY WIFE WILL BE FINE JUST DRIVE CAREFULLY AND THE AIRBAG IS FINE PROBABLY. SO WE HAVE A FAULTY VEHICLE WE HAVE PAID FOR YEARS AND NOW OWN AND CANNOT FEEL SAFE DRIVING ANYWHERE. IN MY OPTION KIA AND HYUNDAI SHOULD HANDLE THIS IN THE SAME MANNER HONDA DID AND HONOR THE CUSTOMER WITH RENTALS UNTIL THE ISSUE IS RESOLVED. IF NOT I AM SURE A LARGE SCALE LAWSUIT WILL ENSUE BECAUSE THIS IS NOT BEING HANDLED CORRECTLY. THE DEALERSHIP ALSO MENTIONED THAT THEY STILL HAVE NO KNOWLEDGE OF A RECALL UNTIL AFTER THE CONSUMER, ANOTHER BOLD FACE LIE FROM KIA. SOMETHING MUST BE DONE

NHTSA ID

11119780

Incident

Jun 20, 2018

Mileage

94,000 mi

MY CAR BROKE DOWN IN DECEMBER 2015, WHEN I TOOK IT TO THE KIA SERVICE DEPARTMENT AND THEY FIX IT. I PAID OVER 1000 USD. 2 MONTHS LATER THERE WAS A SAFETY RECALL FOR THE SAME REASON MY CAR BROKE DOWN COUPLE MONTS BEFORE THAT RECALL. UNTIL THIS DAY I HAVE TRIED TO GET MY MONEY BACK AND THEY DONT WANT TO GIVE ME A REFUND EVEN THOUGH IT WAS A FACTORY DEFECT. I WAS DRIVING ON THE FREEWAY WHEN THE CAR STOPPED COMPLETELEY DUE TO THE HOSE OF THE TRANSMISION FLUID. 04/01/2021: ODI # CHANGED FROM 11054837 TO 11054367 AS PART OF ROUTINE DATA CLEANUP.

NHTSA ID

11054367

Incident

Dec 23, 2015

Mileage

15 mi

CHECK ENGINE LIGHT ON 20000 MILES CODE# P200A INTAKE MANIFOLD SENSOR

NHTSA ID

11035252

Incident

Jan 1, 2016

Mileage

20,000 mi

UPON ENTERING A HIGHWAY, A KNOCK OCCURRED AND AS RPM DROPPED THE KNOCKING SUBSIDED. NEXT DAY AND CHECK ENGINE LIGHT TURNED ON AND WHILE WHILE IN MOTION ON A CITY STREET, VEHICLE STALLED AND RPM DROP TO ZERO. CAR WOULD NOT TURN ON AN ENGINE WOULD NOT TURN OVER. MECHANIC STATED THAT THE ENGINE "LOCKED UP"

NHTSA ID

11021604

Incident

Sep 3, 2017

Mileage

100,500 mi

I TOOK THE CAR IN TO HAVE A COOLANT LINE RECALL INSTALLED. THE SERVICE MANAGER AND LATER A MECHANIC REMARKED THAT THE ENGINE HAD A SERIOUS "KNOCK" AND BOTH MENTIONED THAT THE ENGINE EITHER NEEDED TO BE REBUILT OR REPLACED. IT ONLY HAS 81K MILES. SUBSEQUENTLY, WHEN I ASKED ABOUT POSSIBLE TRADE IN VALUE I WAS INFORMED THEY WOULD ONLY GIVE ME $500. NOW I SEE THERE ARE RECALLS IN MOTION FROM BOTH HYUNDAI AND KIA FOR THIS EXACT PROBLEM WHICH COULD EVENTUALLY CAUSE THE VEHICLE TO STALL DURING OPERATION. THERE WAS NO MENTION OF THE RECALL AFFECTING THE FORTE VERSION, BUT IT DOES HAVE THE 2.0 LITER ENGINE WHICH IS INCLUDED IN AN UPCOMING RECALL.

NHTSA ID

10972326

Incident

Mar 24, 2017

Mileage

81,000 mi

WHEN I'M DRIVING MY CAR IT JERKS FEELS LIKE IT'S GOING TO TURN OFF AND THE ENGINE LIGHT COME ON. 2011 KIA FORTE KOUP.. UPDATED 04/13/17 *BF *CN

NHTSA ID

10971856

Incident

Nov 26, 2016

Mileage

300 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.

CUSTOMER SATISFACTION CAMPAIGN: POSTCARD OWNER RENOTIFICATION (CS2311) - This document is the owner renotification advising that Kia is conducting Customer Satisfaction Campaign. Kia has developed a new zinc-reinforced ignition cylinder protector hardware upgrade and can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Prior notifications stated that this modification had to be performed by July 1, 2025, but the subject vehicles are now eligible until March 31, 2027, to have the ignition cylinder protector installed—if requested—at no cost through an authorized Kia dealership. (Mailing of these notifications to vehicle owners will be completed from December 19, 2025 through December 31, 2025)

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).