2012 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.

Electriconic braking moduel with "Check Brake" indication light and"Hybrid System Warning! and vehicle will come to a stop and warning flights will flash until you turn off the vehicle sit for 10-20 minutes. Brakes will not work and vehicle loses power. Battery has been replaced and large 140 fuse in trunk of vehicle and no improvement. KIA states no recall on my vehicle, but my vehicle has had to have recall repairs done on it regardless of not being listed on this site. I need to know what to do. Vehicle is reliable otherwise. Right now, its risky to drive.

NHTSA ID

11751228

Incident

Apr 11, 2026

The contact owns a 2012 Kia Optima Hybrid. The contact stated that while attempting to drive uphill and on gravel with the Electric Drive Mode activated, the vehicle failed to move forward. The contact pressed the button to deactivate the Electric Drive Mode, but the vehicle failed to respond. The contact released the accelerator pedal until the vehicle responded as needed. The vehicle was taken to an unknown dealer, where the contact was informed that no cause for the failure was found. Additionally, the contact received notification of NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic), and a recall repair appointment was scheduled with the dealer. The contact stated that while driving out of the driveway at 5 MPH, the message "Emergency - Pull Over - System Failure Warning" was displayed. The contact pulled back into the driveway and parked the vehicle. The contact stated that the vehicle was unsafe to drive and could not be driven to the dealer for the recall repair because the dealer was 2 hours away. The dealer was not notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was contacted and denied towing assistance. The failure mileage was approximately 60,000.

NHTSA ID

11629816

Incident

Dec 10, 2022

Mileage

60,000 mi

The contact owns a 2012 Kia Optima Hybrid. The contact stated the engine was previously replaced under an unstated NHTSA recall. The contact stated that five months after the repair, the malfunction indicator warning light was illuminated. The vehicle was towed to a local dealer where it was diagnosed that the replaced engine was defective and affected the high hybrid battery. 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 manufacturer was contacted and offered to replace the engine and the high hybrid battery; however, the vehicle remained at the local dealer because parts were not yet available. The failure mileage was unknown.

NHTSA ID

11591281

Incident

Jul 24, 2022

The contact owns a 2012 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 contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that when the vehicle was parked, the check engine warning light illuminated with the “Hybrid - No Driving Mode” message displayed. The vehicle was not taken to a dealer or independent mechanic. The dealer was made aware of the failure but confirmed that parts were not yet available. The vehicle was not repaired. The manufacturer was made aware of the failure but confirmed that parts were not yet available. The failure mileage unavailable. VIN tool confirms parts not available.

NHTSA ID

11588569

Incident

Apr 17, 2024

The contact owns a 2012 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 contact stated while driving 40 MPH, the check engine warning light and several unknown warning lights were illuminated. Additionally, the contact stated that a message indicating that the Hybrid System failure was displayed. The contact stated that the failure recurred while driving. The contact parked and turned off the vehicle. The contact stated that upon starting the vehicle later, the check engine warning light remained illuminated. Additionally, the contact stated that while sitting on the rear seats, the rear seats were significantly hot because the hybrid battery was underneath the rear seats. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure, but no assistance was provided. The failure mileage was approximately 132,000. VIN tool confirms parts not available.

NHTSA ID

11571974

Incident

Dec 31, 2023

Mileage

132,000 mi

The contact owns a 2012 Kia Optima. The contact stated while driving 60 MPH, the vehicle independently decelerated and failed to exceed 20 MPH. No warning lights were illuminated. The contact stated that the vehicle had started to overheat. The contact referenced NHTSA Campaign Number: 20V750000 (Engine). The vehicle was towed to an independent mechanic and the contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer and dealer were not notified of the failure. The failure mileage was 160,000.

NHTSA ID

11563805

Incident

Jan 31, 2023

Mileage

160,000 mi

The contact owns a 2012 Kia Optima Hybrid. The contact received notification of NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic). The contact stated that the ABS and check engine warning light was illuminated. The vehicle was towed to a friend's residence. The vehicle was not diagnosed or repaired. 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 failure mileage was approximately 160,000.

NHTSA ID

11560070

Incident

Dec 14, 2023

Mileage

160,000 mi

The contact's wife owns a 2012 Kia Optima Hybrid. The contact stated while driving 30 MPH, the vehicle shuddered, and there was an abnormal ticking sound coming from the engine. There was no warning light illuminated. The contact veered to the side of the road and the vehicle was towed to the residence. The vehicle was then towed to the dealer, where it was diagnosed and determined that the engine had failed. The dealer informed the contact that the engine needed to be replaced; however, due to the mileage on the vehicle, the repair was not covered under warranty. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 180,000.

NHTSA ID

11544157

Incident

Jul 29, 2023

Mileage

180,000 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.