2012 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.

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.

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.

The contact owns a 2012 Kia Forte Koup. The contact stated that while the vehicle was being serviced, white smoke was coming from under the hood. While the independent mechanic was starting the vehicle, there was smoke coming from the vehicle. The mechanic turned off the vehicle. The contact stated that prior to the smoke on a separate occasion, while the contact's daughter was driving 30 MPH, the check engine warning light illuminated. The vehicle was towed to an independent mechanic who diagnosed that the engine had caused the battery, starter, and knock sensor to fail. The vehicle was repaired for the prior failures. The contact stated that after the most recent failure, the independent mechanic diagnosed that the engine had failed and damaged the battery, starter, and knock sensor. The independent mechanic replaced the battery, starter, and knock sensor. Additionally, the engine needed to be replaced. The contact related the failure to NHTSA Campaign Number: 20V750000 (Engine); but the VIN was not included. The manufacturer was not notified of the failure. The failure mileage was unknown.

NHTSA ID

11665926

Incident

May 2, 2025

TL* THE CONTACT OWNS A 2012 KIA FORTE KOUP. THE CONTACT STATED THAT THE CHECK ENGINE WARNING LIGHT WOULD ILLUMINATE INTERMITTENTLY FOR SEVERAL MONTHS. THE CONTACT STATED THAT THE ENGINE WAS PREVIOUSLY REPLACED. THE VEHICLE WAS TAKEN TO VALLEY KIA OF FONTANA (16272 S. HIGHLAND AVE, FONTANA, CA 92336) TO BE DIAGNOSED. THE CONTACT WAS INFORMED OF AN ENGINE DIAGNOSTIC CODE THAT WAS THE CAUSE FOR THE FAILURE. THE CONTACT STATED THAT THE CONSUMPTION VALVE WAS REPLACED HOWEVER, THE FAILURE RECURRED WITH THE CHECK ENGINE WARNING LIGHT ILLUMINATED, AND A KNOCKING SOUND COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN BACK TO THE SAME DEALER BUT WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 77,800.

NHTSA ID

11403758

Incident

Mar 2, 2020

Mileage

77,800 mi

WHILE DRIVING AT 70MPH ON THE HIGHWAY HEARD A TAPPING SOUND FROM THE ENGINE. TOWED TO THE KIA DEALERSHIP. MECHANIC FOUND THAT THE CONNECTING ROD BEARING FAILED, RUINING THE ENGINE (2.4L). QUOTED $6,000 FOR REPAIR. 82,000 MILES. ALL MAINTENANCE DONE ON TIME. DEALER AND KIA CORPORATE DENIED ANY HELP OR THAT THE 2.4L WAS DEFECTIVE AT MANUFACTURE.

NHTSA ID

11162833

Incident

Dec 17, 2018

Mileage

82,000 mi

WHILE DRIVING, ENGINE MADE A SOUND LIKE A TICKING NOISE THEN JUST BLEW. OIL ALL OVER THE ENGINE BAY AND GROUND. A LOT OF SMOKE COMING FROM UNDER THE HOOD. WOULD NOT START OR DO ANYTHING. GLAD IT DIDN'T CATCH FIRE WITH ALL THE OIL EVERYWHERE. HAD TO HAVE IT TOWED. TOOK IT TO MECHANIC, COME TO FIND OUT THE ENGINE HAD SEIZED UP. THIS HAPPEN WHILE DRIVING ON HIGHWAY. SPEED LIMIT 70. IT WAS LIKE THE ENGINE WENT BOOM. GLAD I WAS IN THE RIGHT LANE TO BE ABLE TO GET THE CAR OVER TO THE SIDE. LOST ALL POWER AND UNABLE TO CONTROL CAR. MECHANIC HAD TO ORDER AND WAITING ON USED ENGINE COMING FROM CALIFORNIA TO PUT INTO CAR. WILL COST 4000.00 FOR THIS REPAIR. STILL OWE ON THIS CAR TOO.

NHTSA ID

11140398

Incident

Oct 2, 2018

Mileage

114,620 mi

I HEARD A KNOCK COMING FROM THE ENGINE AND SUDDENLY THE CAR DIED WHILE DRIVING IN THE CITY THE CHECK ENGINE LIGHT CAME ON AND WOULD NOT START UP AGAIN BUT THE POWER WAS STILL ON FOR LIGHTS, ETC. I HAD TO HAVE IT TOWED TO THE REPAIR SHOP. I WAS TOLD THE ENGINE IS SHOT. AFTER RESEARCHING THE KIA FORTE I FOUND A LOT OF REVIEWS COMPLAINING OF THE SAME THING ON THE 2012 FORTE. NOW WITH THE RECALLS FOR THE OTHER KIA ENGINES WITH THE SAME OR SIMILAR ENGINE TYPES, THIS MAKE AND MODEL NEEDS TO BE INCLUDED!!!

NHTSA ID

11140289

Incident

Oct 4, 2018

Mileage

61,000 mi

WHILE DRIVING THIS CAR, I HEARD A KNOCK COMING FROM THE ENGINE!! I HAD IT TOWED TO A KIA DEALER AND WAS TOLD THAT I NEEDED A NEW ENGINE! THIS IS UNACCEPTABLE FOR CAR THAT IS ONLY 6 YEARS OLD AND ALL MAINTENANCE KEPT UP TO DATE!! I DID SOME CHECKING AND OTHER KIA ENGINES WITH SIMILAR OR SAME ENGINE TYPES HAVE BEEN RECALLED. THIS MAKE AND MODEL NEEDS TO INCLUDED!!

NHTSA ID

11124222

Incident

Aug 23, 2018

Mileage

127,000 mi

I WAS TURNING LEFT AND CAR CHUGGED BACK AND FORTH AND BURNING SMELL WITH A TON OF GRAY AND WHITE SMOKE POURING OUT OF BACK OF CAR. FOUGHT WITH KIA GOT A REBUILT ENGINE. 2 WEEKS LATER SAME PROBLEM. TOOK BACK TO A DIFFERENT DEALER AND FAULTY VALVE WAS NEVER REPLACED. HAPPENED AGAIN 3 WEEKS LATER. CAN'T FIND ANYTHING WRONG. HAPPENED AGAIN 3 WEEKS LATER AND THIS TIME SMOKE AND BURNING SMELL WAS SO INTENSE YOU COULDN'T SEE IN BACK OF CAR. DEALERSHIP SAID THAT I JUST NEED TO DRIVE IT MORE. I AM A MOTHER TO 3 YOUNG KIDS. THE CAR SMELLS LIKE IT'S GOING TO EXPLODE AND THE SMOKE ALONE IS DANGEROUS TO WHO IS BEHIND ME.

NHTSA ID

11120500

Incident

Nov 3, 2017

Mileage

45,000 mi

ON 7/23/2016(MILAGE 108000) I WAS DRIVING MY 2012 KIA FORTE SX KOUP TO WORK TRAVELING 70 MPH ON THE HIGHWAY. 2 MILES FROM WORK I BEGAN TO HEAR A LOUD KNOCKING SOUND . ARRIVING AT WORK I DID A QUICK ENGINE INSPECTION BUT COULD NOT FIND ANYTHING VISUALLY WRONG (LEAKS, SMOKE, LOOSE PARTS) LATER THAT MORNING I RETURNED TO MY CAR TO TEST THE ENGINE AND COULD HEAR THE SAME NOISE. I DECIDED IT WOULD BE BEST TO HAVE IT TOWED TO A MECHANIC. VEHICLE WAS NOT INSPECTED UNTIL 07/25/16. MECHANIC SAID THE ENGINE NEEDED TO BE REPLACED AFTER DISCOVERING A BAD ROD. MECHANIC ALSO CONTACTED KIA TO SEE IF BY CHANCE THEY WOULD OFFER AND EXTENDED WARRANTY, BUT KIA WOULD NOT REPAIR ENGINE SINCE IT HAD PASSED THE 100000 MILE WARRANTY. (JUST 8000 MILES OVER WARRANTY !!!!!!) MY WIFE AND I DECIDED TO BITE THE BULLET AND HAVE THE ENGINE REPAIRED. $4300 AND ONE WEEK LATER MY VEHICLE WAS RETURNED TO ME. I NOW SEE ALL OF THESE NEWS STORIES ABOUT KIA CATCHING FIRE AND OTHER HORROR STORIES ON THE NHTSA WEBSITE ABOUT THE SAME EXPERIENCE OTHERS HAVE GONE THROUGH . I AM EVEN MORE OUTRAGED THAT IT COULD STILL HAPPEN TO ME AND THE FACT THAT THERE IS A CURRENT RECALL FOR THE AIRBAGS AND SEAT BELTS BUT NOT THE ENGINE!!!!!!!!!!! PLEASE DO SOMETHING!!!!!!

NHTSA ID

11120443

Incident

Jul 25, 2016

Mileage

108,000 mi

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)

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.

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR & DECAL INSTALLATION (CS2311) - 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 15, which may not have been equipped with an immobilizer and whose Integrated Body Control Unit (IBU) / Body Control Module (BCM) are not able to receive the Anti-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 that are not equipped with an immobilizer, 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: OWNER NOTIFICATION - This document is the owner notification advising that Kia is now making steering wheel lock devices available directly to certain Kia vehicle owners. These devices can help deter a theft attempt. We are making this device available to customers free of charge and will ship it directly to customers who place orders within eighteen (18) months from the date of this letter.

TECHNICAL SERVICE BULLETIN: TRANSMISSION FLUID APPLICATION GUIDE - 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, refer to applicable vehicles in the chart starting on page 2.