2011 Kia Optima Hybrid

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.

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

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 contact owns a 2011 Kia Optima. The contact received notification of NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic); however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11627468

Incident

Sep 25, 2023

The contact owns a 2011 Kia Optima Hybrid. The contact stated while driving 50-60 MPH, there was smoke coming out from underneath the hood of the vehicle. The check engine warning light and other unknown warning lights were illuminated. The vehicle was taken to an independent mechanic, where the engine was cleaned and the spark plugs were replaced; however, the failure recurred while driving. The contact was able to pull into a parking lot and park the vehicle. The vehicle was towed to the residence. The vehicle was then towed to the local dealer and failed to restart. The dealer informed the contact that the vehicle could not be serviced because it was out of warranty. The vehicle was not diagnosed or repaired. The contact related the failure to NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic) and to Kia Campaign Number: SC200. The manufacturer was not notified of the failure. The failure mileage was approximately 131,000.

NHTSA ID

11596463

Incident

Jun 25, 2022

Mileage

131,000 mi

The contact owns a 2011 Kia Optima Hybrid. The contact stated that while operating the vehicle, the check engine warning light remained illuminated, and the message "Stop Vehicle" was displayed. The contact stated that the vehicle had stalled and shut off on several occasions. The vehicle was towed to the local dealer who was unable to determine the cause of the failure. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was 30,000.

NHTSA ID

11584874

Incident

Apr 24, 2022

Mileage

30,000 mi

The contact owns a 2011 Kia Optima Hybrid. The contact stated while the vehicle was parked, after starting the vehicle, the steering wheel became stiff. The “Steering Assist Fault” messages were displayed. The vehicle was taken to an independent mechanic where it was diagnosed that the steering gear had failed. The dealer was contacted for a second opinion, but a diagnostic test was not performed. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 70,000.

NHTSA ID

11582463

Incident

Apr 10, 2024

Mileage

70,000 mi

The contact owns a 2011 Kia Optima Hybrid. The contact received notification of NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic) however, the part to do the recall repair was not yet available. The local dealer was made aware of the issue and confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

NHTSA ID

11557251

Incident

Oct 1, 2023

WHILE DRIVING (IN FORWARD MOTION), WITHOUT ANY PRESSURE BEING APPLIED TO EITHER THE BRAKE OR PARKING BRAKE, THE VEHICLE BEGINS TO SLOW ITSELF RAPIDLY LOSING ACCELERATION.; A RUMBLE CAN BE HEARD THERE IS CONSISTENT BEEPING NOISE AND THE VEHICLE BEGINS TO VIBRATE SLIGHTLY. A YELLOW TRIANGLE WITH AN EXCLAMATION POINT AND THE WORDS CHECK BRAKE APPEARS IN THE DRIVERS DISPLAY; ATTEMPTS TO ACCELERATE INCREASES THE RPMS BUT THE VEHICLE CONTINUES TO SLOW RAPIDLY. NOT IDLE AS IF IT WERE NOT IN GEAR, BUT JUST AS IF THE DRIVER WAS BREAKING SUDDENLY. THE ONLY KNOWN METHOD OF CORRECTING THIS IS TO TURN THE VEHICLE OFF AND RESTART IT. HOWEVER, THIS STOPS WORKING AS A SOLUTION AFTER A FEW DAYS AND THE PROBLEM PERSISTS. WHEN THE VEHICLE RESTARTS YOU CAN FEEL THE BRAKE PEDAL RELEASE. THIS HAS OCCURRED RANDOMLY AT LEAST 20 TIMES IN THE PAST BEFORE UNTIL EVENTUALLY IT COULD NOT BE DRIVEN AT ALL. AT SPEEDS RANGING FROM 25 MPH ON NEIGHBORHOOD STREETS TO 70 MPH ON BUSY FREEWAYS. I SINCERELY FEAR THAT IF NOT CORRECTED IT WILL LEAD TO A (POTENTIALLY FATAL) VEHICLE COLLISION. I ALSO TOOK THE VEHICLE TO A NEAR-BY KIA DEALER SERVICE DEPARTMENT IN CA. AFTER MONTHS THE CAR WAS RETURNED AND IT CONTINUED TO HAVE THE SAME ISSUE WITHIN A DAYS. THEY WERE UNABLE TO DIAGNOSE OR DUPLICATE THE MALFUNCTION AS ALSO. I HAVE VIDEO OF THIS AS WELL. THIS NEEDS TO IMMEDIATELY BE CORRECTED AND THE TECHNICIANS NEED TO KNOW WHAT THE PROBLEM IS AND HOW TO FIX IT RATHER THAN EXPERIMENTING ON OWNERS VEHICLES FOR MONTHS OR WEEKS TO THEN RETURN IT WITHOUT RESOLUTION. WHY SHOULD I OR ANY OTHER KIA OWNER BEAR THE BURDEN OF THESE UNNECESSARY COSTS, INCONVENIENCE, AND EXTREMELY UNSAFE CONDITIONS. KIA NEEDS TO RESPOND I AM SURE OTHERS HAVE EXPERIENCED THIS SAME ISSUE AND SHOULD COME FORWARD IMMEDIATELY FOR THE SAFETY AND WELL BEING OF ALL. *TR

NHTSA ID

11232147

Incident

Jul 15, 2019

Mileage

98,000 mi

MY ACTIVE AIR FLAPP SYSTEM IS DEFAULTING AND TRANSMISSION GOING OUT. NOT TO MENTION THE HESITATION WHEN ACCELERATING

NHTSA ID

11204091

Incident

Apr 1, 2019

Mileage

130,000 mi

MY 2011 KIA OPTIMA HYBRID HAD AN ENGINE FAILURE, CAR KEPT STALLING SO BOUGHT A 300 DOLLAR BATTERY. WELL THE CAR STALLED AGAIN WHILE DRIVING, TOOK IT TO THE KIA SERVICE CENTER JUST TO TELL ME THE ENGINE WAS BLOWN. THERE'S BEEN SEVERAL CONSUMER COMPLAINTS ABOUT ENGINE FAILURE ON THESE VEHICLES SO WHATS TAKING LONG TO RECALL THESE ENGINE MISHAPS. CALLED CUSTOMER CARE AND WAS INFORMED WITH NO HELP WHATSOEVER. SEVERAL CONSUMERS HAVE COME OUT OF POCKET FOR THESE NEGLECTED ENGINE FAILURES AND NOTHING IS BEING DONE.

NHTSA ID

11203947

Incident

Apr 21, 2019

Mileage

91,000 mi

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).

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: PARTIAL REPAIR - ELECTRICAL A/C COMPRESSOR - 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 regarding partial repair of the Air Conditioning (A/C) compressor assembly on some 2011MY~ Optima Hybrid (TF HEV, JF HEV/PHEV), 2015MY~ Soul EV (PS EV), 2017MY~ Niro (DE HEV/PHEV/EV), 2022MY~ EV6 (CV), 2021MY~ Sorento (MQ4 HEV/PHEV), 2023MY~ Sportage (NQ5 HEV/PHEV), and 2023MY~ Niro (SG2 EV/HEV/PHEV) vehicles.

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.