2014 Kia Forte Koup

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.

I HAVE THE FORTE KOUP SX TGDI TRIM. I WAS DRIVING ON FREEWAY AT 75-80 MPH. I NOTICED I WAS NOT ABLE TO GAIN ENOUGH SPEED TO PASS SLOWER TRAFFIC. ALSO NOTICED THAT ONCE SPEED SLOWED TO 65-70 MPH THE WAS NO POWER WHEN TRYING TO ACCELERATE. HOWEVER THE CAR STILL WAS ABLE TO REGAIN SPEED AND MAINTAIN ONCE DESIRED SPEED WAS REACHED. I THEN HEARD A NOISE WHEN ACCELERATING. IT SOUNDED AS IF SOMETHING WAS BINDING UP. I ASSUMED IT WAS THE TURBO. I PULLED OFF AN EXIT SHUT THE CAR OFF. I LET THE CAR SIT FOR A MINUTE AND THEN STARTED IT. THE ENGINE SEEMED TO BE LOUDER THAN NORMAL. I PUT THE CAR IN DRIVE AND COULD HEAR THE NOISE IN THE TURBO AGAIN BUT IT WAS NOT AS IF SOMETHING WAS BINDING IT WAS IT WAS LOUD AIR. I DROVE APPROX. 1 BLOCK AND NOTICED SMOKE. I PULLED OVER SHUT THE CAR OFF AND LOOKED UNDER THE HOOD WALKED AROUND THE CAR DID NOT SEE ANY SMOKE FROM ANYWHERE. TURNED THE CAR BACK ON, NO SMOKE, ENGINE WAS QUIETER, DROVE ANOTHER BLOCK AND BEGAN BILLOWING BEHIND THE CAR THE ENGINE AT THIS POINT CAME ON. PULLED INTO A PARKING LOT SHUT THE CAR OFF AND DID A WALK AROUND. WHITE SMOKE WAS COMING FROM BOTH EXHAUST PIPES. HAD CAR TOWED TO KIA DEALERSHIP. THEY HAVE HAD THE CAR OVER A MONTH. SPOOL ON TURBO FLEW OFF AND OIL WAS SUCKED THROUGH EXHAUST. THE NO WARNING LIGHTS HAS BEEN EXPLAINED TO THE FAILURE OF O2 SENSORS, TURBO SPOOL, AND SOME PART OTHER BEING OFF BALANCE TO ALL HAPPENING SIMULTANEOUSLY. AFTER A MONTH A PICKED THE CAR UP AND HAVE APROX 80 MILES AND THE ENGINE LIGHT IS ON. DEALERSHIP SERVICE SAID T IS FROM OIL BURN OFF AND NOTHING TO CLEAR IT. MY DISPLAY FOR REAR CAMERA IS NOT WORKING AND NO ETA FOR PART TO BE AVAILABLE.

NHTSA ID

11109934

Incident

Jun 5, 2018

Mileage

65,000 mi

VOLUNTARY SERVICE CAMPAIGN: OWNER RENOTIFICATION (SC238 Flight #501) - This document is the owner renotification advising that Kia is conducting a Voluntary Service Campaign to inspect and, if necessary, replace brake line(s) in certain 2014-2017 MY Forte and Forte Koup vehicles that were originally sold in or are currently registered in states where heavy amounts of road salt are used. In addition, an anti-corrosion material will be applied to the underbody components for added protection.

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)

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - This bulletin provides information to install a Theft Deterrent Ignition Cylinder Protector on certain 2010-2022MY Kia vehicles outlined on page 19, which may not have been equipped with an immobilizer and whose Integrated Body Control Unit (IBU) / Body Control Module (BCM) did 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, 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 (CS2312) - This document is the owner notification advising that Kia is conducting Customer Satisfaction Campaign. A software upgrade that addresses the social media theft method has been made available to owners of eligible Kia model vehicles free of charge at authorized Kia dealers since 2023. In addition to the anti-theft software, a new zinc-reinforced ignition cylinder protector hardware upgrade has been developed and can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Because the subject Kia vehicles were not factory-equipped with an engine immobilizer and were previously eligible for the software upgrade, these vehicles are 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 17, 2025 through February 27, 2026)

VOLUNTARY SERVICE CAMPAIGN: SALT-STATE: OWNER RENOTIFICATION (SC238) - This document is the owner renotification advising that Kia conducting Voluntary Service Campaign to inspect and, if necessary, replace brake line(s) in certain 2014-2017 MY Forte and Forte Koup vehicles that were originally sold in or are currently registered in states where heavy amounts of road salt are used. In addition, an anti-corrosion material will be applied to the underbody components for added protection.