2011 Kia Forte

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.

The contact owned a 2011 Kia Forte. The contact stated that while the vehicle was parked and unoccupied, a bystander went into the contact's place of employment and stated that there was a fire inside the vehicle in the parking lot. The contact became aware that his vehicle was the one on fire. No warning lights were illuminated prior to parking the vehicle. The cause of the failure was unknown. The contact's wife attempted to extinguish the fire with a fire extinguisher but was unable to extinguish the fire. The contact called the Fire Department, and the firemen were able to extinguish the fire and were required to remove the dashboard in order to extinguish it. The Fire Department filed a report. A Police report was filed. The contact stated that his wife sought medical attention for smoke inhalation. The contact was notified that the VIN was included in NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic). The manufacturer was not notified of the failure. The failure mileage was approximately 300,000.

NHTSA ID

11754070

Incident

Jul 31, 2026

Mileage

300,000 mi

The contact owns a 2011 Kia Forte. The contact stated that while driving 45 MPH, the TPMS, red brake light, and several unknown warning lights were illuminated. The contact stated that the vehicle was jumping and jerking during acceleration and deceleration. After restarting the vehicle, there was resistance while accelerating, and the jerking persisted. The contact stated that the failures started one week after the vehicle was repaired under NHTSA Campaign Number: 23V652000 (SERVICE BRAKES, HYDRAULIC). The vehicle was driven to an independent mechanic but was not diagnosed. The vehicle was then driven to a dealer, but was not repaired. The manufacturer was notified of the failure. The failure mileage was 273,000.

NHTSA ID

11720801

Incident

Feb 25, 2026

Mileage

273,000 mi

See attached document for complaint.

NHTSA ID

11714989

Incident

Dec 7, 2025

The contact owns a 2011 Kia Forte. The contact stated that while driving at an undisclosed speed, there was smoke coming from under the hood, and the check engine warning light illuminated. In addition, the contact noticed a burning odor in the interior of the vehicle. The vehicle was taken to an independent mechanic, where it was diagnosed with a failed pollution control system. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. In addition, the contact stated that the vehicle was taken for the State Inspection, and the vehicle failed the inspection due to a failed pollution system. The contact received notification of NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic). The contact stated that the failure described in the recall notification indicated a possible engine fire. The dealer was made aware of the failure; however, the contact was informed that the repair was not covered under the recall. The manufacturer was made aware of the failure; however, the contact was informed that parts were not yet available for the recall repair. The failure mileage was approximately 85,000.

NHTSA ID

11708830

Incident

Nov 5, 2023

Mileage

85,000 mi

The centered high mounted brake light overheated during normal vehicle operation. The plastic bulb socket and housing melted, causing the bulb to dislodge and fall into the interior of the vehicle. The bulb was extremely hot and burned holes through an interior fabric item that was stored in the rear cargo area for less than 15 minutes. There was no collision or modification involved. This created a potential fire hazard inside the vehicle. No warning lights or dashboard messages appeared prior to the incident. The cause of overheating is unknown. The damaged bulb, socket, and surrounding components were available for inspection at the time of the incident.

NHTSA ID

11703885

Incident

Dec 8, 2025

The contact owns a 2011 Kia Forte. The contact stated that while driving at an undisclosed speed, the contact noticed an unusual ticking sound and smoke coming from under the hood. In addition, the contact stated that several unknown warning lights illuminated. The vehicle was driven to the shoulder of the road. The contact inspected the vehicle and noticed smoke that was coming from the HECU fuse box. The vehicle was towed to the dealer. The contact stated that the vehicle had been at the dealer for three weeks without any communication from the dealer. The contact was unsure if the vehicle had been inspected or not. The contact received a recall notification, NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic). The manufacturer was not made aware of the failure. The failure mileage was unknown.

NHTSA ID

11694817

Incident

Sep 23, 2025

I just bought this car with 79873 miles on it it now has 81853 miles and its making a ticking noise.I been looking over the engine and wondering why my check engine light doesn't come on when I left my gas cap off.I bought this car from a used car dealership..I been doing some research on this type engine and most of them have me recalled.

NHTSA ID

11694631

Incident

Oct 1, 2025

WCS Sensor Defect B1322-20 - Airbag Code WCS Communication Error B1324-20 - Airbag Code Door Ajar Lamp Circuit Failure B1323-20 - Airbag Code

NHTSA ID

11691517

Incident

Sep 29, 2025

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 20, 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.

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”).

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)

PITSTOP: TECHNICAL OPERATIONS: EXTERNAL DAMAGE TO ULTRASONIC SENSOR: This Pitstop provides information related to Parking Distance Warning (PDW) alerts and repairs involving ultrasonic sensors. The PDW system alerts the driver while parking, by calculating distance based on the difference in signal transmission and reception times between the vehicle (ultrasonic sensor) and an object. The membrane film of the ultrasonic sensor is used for object detention and can be damaged by stone chips or foreign substances while driving. Damage to the cover of the ultrasonic sensor can also lead to damage to the internal circuit. As a result of this external damage, the PDW system may not receive the proper signal from the ultrasonic sensor. In some cases, the system may cause a false alarm, no alert, or phantom warnings by a “Warning Lamp’ to be displayed on the cluster. The ultrasonic sensor membrane film should be always inspected for external damage and if any part replacement should be treated as a general repair, not as a warranty claim repair for this concern. (Please note that this Pitstop only applies to models/trims that are equipped with the ultrasonic sensors.)

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: TRANSMISSION FLUID APPLICATION GUIDE - 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 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, and the transmission oil cooler is transferred to the new transmission.