2012 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.

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.

My vehicle is a 2012 Kia Forte EX. The vehicle experienced a corrosion-related brake line failure that affected braking performance and created a safety concern. The brake pedal became soft/sank, and the vehicle had unsafe braking behavior, requiring repair at a Kia dealership. The failed component was a brake line, which is a safety-critical part of the braking system. The repair was completed at customer expense after Kia declined goodwill or reimbursement assistance. Kia Customer Care case number: 2622663. My concern is that this does not appear to be ordinary wear only. This vehicle had prior Kia underbody corrosion campaign history under SC141, titled “Application of Additional Anti-Corrosion Material.” Kia confirmed to me that SC141 involved applying additional anti-corrosion/undercoating/cavity wax material to certain underbody components to help protect against corrosion. Kia also confirmed that SC141 was completed on my vehicle before the brake-line repair. Kia’s position is that SC141 did not cover brake lines or brake replacement, and that brake-line corrosion is normal maintenance/customer-pay because the vehicle is out of warranty. I understand Kia’s warranty position, but my complaint is about the safety issue and possible design-related corrosion vulnerability. The failed brake line appears to be routed in an underbody area exposed to corrosion risk, possibly near hardware, brackets, covers, or areas where salt/water can collect. In my view, this may represent a corrosion-trap design issue involving the routing/location of a safety-critical brake line, rather than simple routine maintenance. I am filing this complaint because corrosion-related brake line failure can result in reduced braking ability or loss of braking, and I believe this issue should be documented and reviewed for potential safety-defect trends involving this vehicle/platform.

NHTSA ID

11747944

Incident

Jun 9, 2026

Vehicle: 2012 Kia Forte Recall: NHTSA 23V-652 (Kia SC284) – HECU/ABS fuse recall My vehicle underwent this safety recall in 2025. The dealership replaced the HECU fuse. Immediately upon leaving the dealership after the recall repair, the same warning lights returned. I contacted the dealership immediately before fully leaving the area to report the issue. I also contacted Kia Corporate after the warning condition returned. Kia was aware the warning lights returned immediately after recall completion. I was advised if the vehicle later entered limp mode again, to contact Kia roadside assistance for towing support per prior guidance. The warning condition was not resolved by the recall repair. The brake warning light remained present, additional warning indicators later appeared, and the vehicle ultimately entered limp mode in January 2026, resulting in loss of reliable transportation and safety concerns. Due to this condition, I was forced to rely on a rental vehicle for an extended period at significant personal cost totaling several thousand dollars. I'm a single parent with a child requiring ongoing medical appointments, making reliable transportation essential. Kia only approved a limited "goodwill payment" of $191.40 for an earlier rental period, while refusing reimbursement for the substantially larger rental costs incurred after the recall failure and progression to limp mode. When the vehicle entered limp mode, I had to arrange towing because Kia assistance was not available as they closed out the recall. Kia is now requiring out-of-pocket diagnostic payment before determining whether the issue is related to Recall 23V-652, despite the warning condition returning immediately after recall repair and later progressing to limp mode consistent with the original failure symptoms. I am reporting a potentially ineffective recall remedy and unresolved recurrence of the safety condition addressed under Recall 23V-652.

NHTSA ID

11745725

Incident

Jan 17, 2026

There is a class action lawsuit concerning the airbag control unit not functioning properly leading to safety issues during a crash. The case is called ZF-TRW Airbag Control Unit Product Liabilty Litigation. Case number XXX My Kia Forte was on the list of recalled vehicles. I have been having electrical problems with my car and this may be the answer I have been looking for !! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11742145

Incident

Jun 4, 2026

The contact owns a 2012 Kia Forte. The contact stated that upon starting the vehicle, the vehicle made an abnormal knocking sound, and there was a burning oil odor coming from the vehicle. The check engine warning light was illuminated. The contact related the failure to NHTSA Campaign Number: 20V750000 (ENGINE); however, the contact was unable to schedule an appointment because the dealer was unreachable. The manufacturer was not contacted. The failure mileage was approximately 142,000.

NHTSA ID

11731572

Incident

Oct 16, 2025

Mileage

142,000 mi

While driving, the engine suddenly shut off without warning. The vehicle lost power in traffic, creating a safety risk. There were no warning signs before the failure. The oil level was properly maintained and oil changes were performed regularly. The dealership diagnosed the vehicle and stated that the engine needs to be replaced. The exact mechanical cause was not clearly explained to me.

NHTSA ID

11721956

Incident

Mar 3, 2026

Engine started screeching out of nowhere, sounded like something fell through, there was no warning of any kind, car was running seemingly fine prior to this, car was jolting and not going anymore and something also sounded as if it had popped, it started knocking and caught fire and was smoking, breaking down on the side of the road and has been in another state since this occurred just sitting at a hotel because we had to get a rental car. We did call Kia in Georgia to have this issue rectified as we had recently bought this vehicle and were unaware there was a recall on it, however we did some checking and the previous owner also let us know there is a recall for engine fire. I do have the papers for that. Kia advised us they would not be responsible, but Panama City fl Kia where we live were willing to look at that car prior to this incident and take care of the recall, the previous owner never went but now the car has caught fire whilst we were driving in it 7.5 hours away from our house out of town with our children in the car. We had to pull over off of the interstate because the car was on fire and get out on the side of the road and all of had to evacuate. I do believe that if we had been going any faster, we may have even became fatalities because the car locked up. It turned off actually as I was turning to to the exit and just coasted far enough to not be hit in the middle of the road. It was terrifying and we had to move fast and smoke was starting to come through, it started dropping oil everywhere just spilling out lv its almost like the entire underneath of the motor just dropped or something. I’m not quite sure but it was sudden and it has been absolutely miserable.

NHTSA ID

11705749

Incident

Nov 30, 2025

Back in July my car started jerking, stalling, and smoking. There was a recall 20v750 open for engine fires. The dealership check it out and said everything looked good. They installed a knock sensor related to the problem. Last week my car did it again leaving me stalled on the interstate at night. There is now a P1326 code for the knock sensor which confirms that there was a issue. However I'm being told that due to my mileage the warranty had expired and there isn't anything they can do.

NHTSA ID

11697284

Incident

Oct 25, 2025

The contact owns a 2012 Kia Forte. The contact stated that while driving at an undisclosed speed, there was a strong fuel odor coming from the vehicle, followed by a loss of motive power. The malfunction indicator light and ABS warning light were illuminated. The contact was able to restart the vehicle; however, the failure recurred. The vehicle was towed to the residence. The dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 100,000. The VIN was not available.

NHTSA ID

11694846

Incident

Oct 21, 2025

Mileage

100,000 mi

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.

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.)

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.

TECHNICAL SERVICE BULLETIN: PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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 (PI2002A, PI2002B and SC200**1) titled “Knock Sensor Detection System - ECU Logic Improvement”. 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).

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.