2014 Kia Optima Hybrid

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.

The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect.  During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment.  FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle.  Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW.  These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes.  An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time.   In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU.  This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners.  Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW.  The risk associated with the ASIC is equally shared among all OEMS involved in the investigation.  The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage.  There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation.  The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU.  If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC.  Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC.  All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled.  In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024.  With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.

During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Kia Optima, MY 2011-2014 Kia Sorento and MY 2010-2015 Kia Soul vehicles equipped with Theta II, Gamma, Nu and Lambda II engines (approximately 1.7 million vehicles). ODI also reviewed field and other data on other Kia vehicles (approximately 3.6 million additional vehicles) equipped with the same engines used in the above-mentioned vehicles.As a result of this PE, Kia has issued NHTSA Recalls 20V-750 and 21V-844 to address potential engine failures and fires in certain Kia vehicles equipped with various engine types.Additional information on these and other related recall actions is available in the downloadable version of this resume available at NHTSA.gov.In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure-related recalls mentioned above and conducted previously.See the EA21-003 Opening Resume available at NHTSA.gov for more information.Also available in the downloadable version of this resume is a list of the reference numbers for the 444 ODI reports, or Vehicle Owner Questionnaires (VOQs), cited above which ODI received through mid-November 2021.Note that the Manufacturer reports cited above are customer complaints received through March 2019.

While driving during colder weather the car will show HEV (hybrid system) warning and tell you to shut it off. I was in a construction zone with no where to pull over when the car died and lost all propulsion and brakes. This seems to be a common problem on KIA Optima hybrids from 2012-2015.

NHTSA ID

11710148

Incident

Dec 12, 2025

The contact owns a 2014 Kia Optima Hybrid. The contact stated while driving 40 MPH, the vehicle lost motive power with a battery management system (BMS) message displayed. The contact desperately depressed the brake pedal, but the pedal became firm, causing the contact to almost crash into another vehicle. The contact was able to pull into a parking lot, turned off and restarted the vehicle, but the BMS message and check engine warning was light illuminated. The dealer was contacted but the vehicle needed be diagnosed. The manufacturer was not contacted. The failure mileage was 84,000.

NHTSA ID

11503599

Incident

Jan 25, 2023

Mileage

84,000 mi

The contact owns 2014 Kia Optima Hybrid. The contact stated that while driving at undisclosed speeds, the "Check Hybrid System - Turn Off Engine" message displayed on the instrument panel and the vehicle stalled. On two occasions, the vehicle shifted to LIMP Mode. The vehicle was towed to the dealer and the engine was replaced twice. The manufacturer was notified of the failure and a case was filed. The vehicle was not repaired. The failure mileage was 58,997.

NHTSA ID

11501051

Incident

Sep 1, 2021

Mileage

58,997 mi

The contact owns a 2014 Kia Optima Hybrid. The contact stated while driving approximately 35 MPH, the engine seized without warning. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 140,000. The contact stated that the dealer and the manufacturer were notified but refused to help with the issue.

NHTSA ID

11472409

Incident

Jun 29, 2022

Mileage

140,000 mi

The contact owns a 2014 Kia Optima Hybrid. The contact stated that while driving at an unknown speed, the hybrid system malfunctioned. The contact stated that during the failure the vehicle decelerated and lost motive power. The contact stated that several unknown warning lights were illuminated. The contact stated that the vehicle was taken to the dealer and remained with the dealer. The vehicle was not repaired. The contact stated that the manufacturer was notified of the failure. The approximate failure mileage was 75,000. Error message comes up on the dashboard.

NHTSA ID

11469000

Incident

Jun 13, 2016

Mileage

75,000 mi

The contact owns a 2014 Kia Optima. The contact stated that while driving approximately 60 MPH, the vehicle decelerated with the "check hybrid battery and check engine" warning lights displayed. The vehicle was towed to the local dealer who diagnosed that the engine was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 122,000.

NHTSA ID

11458764

Incident

Mar 5, 2022

Mileage

122,000 mi

ON 6/07/19 WHILE TRAVELLING TO WORK ON THE HIGHWAY, TRAVELLING ABOUT 65 MPH, THE DASH DISPLAY READ CHECK HYBRID SYSTEM, AND SUDDENLY SHUT DOWN. ENGINE STOPPED RUNNING, STEERING WHEEL BEGAN STIFFENING, I COASTED FROM THE PASSING LANE TO THE RIGHT LANE AND THEN TO THE SHOULDER WITHOUT INCIDENT AND WAS ABLE TO SAFELY PARK THE CAR. KIA FAILED TO PROVIDE ROADSIDE ASSISTANCE SINCE THE CAR HAS OVER 60,000 MILES(ACTUALLY HAS 95,000 MILES), HOWEVER I AM STILL UNDER THE 10YR/100,000 MILES WARRANTY. THE CAR WAS TOWED TO THE KIA DEALERSHIP VIA MY INSURANCE COVERAGE. AFTER THE ASSESSMENT I WAS TOLD I HAD A BLOWN MAIN HYBRID FUSE. CHARGED $201.24 TO REPLACE THE FUSE. I PRESENT THIS AS A SAFETY ISSUE BECAUSE HAD I BEEN ON A MAJOR HIGHWAY WITH MY GRANDCHILDREN IN THE MIDDLE OF TRAFFIC, THERE WOULD BE NO WAY POSSIBLE TO REACH A LANE SHOULDER WITHOUT POSSIBLE HARM OR DEATH. ACCORDING TO KIA'S OWN "TECHNICAL OPERATIONS NOTICE - PS515(REV 2, 02/28/2019" DATED AUGUST 2017), THEY ARE FULLY AWARE OF THIS PROBLEM. THE BATTERY FUSE IS TO BE REPLACED FROM A 125 AMP TO A 150 AMP. THIS FUSE IS PART OF THE SAFETY PLUG LOCATED IN THE TRUNK. AS A OWNER I SHOULD HAVE BEEN WARNED OF THIS POSSIBLY HAPPENING TO THE CAR AND GIVEN THE OPTION TO HAVE THIS FUSE REPLACED....AT KIA'S EXPENSE. FOR THOSE STILL DRIVING THIS YEAR AND MAKE OPTIMA HYBRID,PLEASE BE AWARE OF THIS OCCURRENCE. THE 125 AMP HV BATTERY FUSE SHOULD BE REPLACED WITH THE NEWER 150 AMP HV BATTERY FUSE(PART #375F2 4R150. SEE KIA'S PITSTOP: TECHNICAL OPERATIONS NOTICE #PS515. UNFORTUNATELY MY COMMUNICATION WITH KIA PROVED FRUITLESS.

NHTSA ID

11228890

Incident

Jun 7, 2019

Mileage

95,000 mi

I WAS TRAVELING ON THE FREEWAY WHEN THE DASHBOARD READ 'HEV SYSTEM WARNING. PULL OVER AND SHUT OFF VEHICLE.' ENGINE THEN SHUT OFF. AFTER NEARLY BEING HIT BY A SEMI-TRUCK, I COASTED FROM THE CARPOOL TO THE OFF RAMP EXIT. THE VEHICLE WAS ABLE TO TRAVEL AT APPROXIMATELY 5-15MPH AND MADE IT HOME SAFELY. I TOWED MY VEHICLE TO THE CITRUS VALLEY MOTORS IN THE CITY OF ONTARIO. THEY RAN DIAGNOSTICS STATING IT WAS A FUSE IN THE ENGINE AND IT WILL COST ME $686.97. KIA RELEASED INFORMATION TO THE PUBLIC STATING THEY KNOW THE 125 FUSE AMP FOR THE HYBRID SYSTEMS WAS THE WRONG SIZE WHICH CAN CAUSE A 'BLOW OUT' TURNING THE ENGINE OFF WHILE DRIVING. KIA STAYED THEY NEEDED TO REPLACE IT WITH THE 150 AMP FUSE IN ORDER TO SUSTAIN THE POWER TO THE ENGINE. I CALLED KIA EXPRESSING MY CONCERN UNDER THE FEDERAL POLICY 'LEMON LAW.' KIA TOLD ME 'YOUR WARRANTY IS EXPIRED BY 3 WEEKS. WE CAN NOT GIVE YOU ASSISTANCE.' MY VEHICLE SITS IN THE SHOP WITH A WRONG SIZE FUSE AND WANT ME TO PAY FOR THE CORRECT SIZE THAT SHOULD HAVE BEEN PLACED IN THEIR IN THE FIRST PLACE.

NHTSA ID

11220953

Incident

Jun 14, 2019

Mileage

87,000 mi

VOLUNTARY SERVICE CAMPAIGN: OWNER RENOTIFICATION (SC269 FLIGHT #401) - This document is the owner renotification advising that Kia is conducting a Voluntary Service Campaign to inspect and, if necessary, replace the high-voltage fuse in 2013-2016 MY Optima Hybrid vehicles.

PRODUCT IMPROVEMENT CAMPAIGN: OWNER RENOTIFICATION (PI2104 FLIGHT 501) - This document is the owner renotification advising that Kia is conducting a Product Improvement Campaign to perform a software update on 2014-2016 MY Optima Hybrid 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”).

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 (PI2104) - This document is the owner renotification advising that Kia is conducting a Product Improvement Campaign to perform a software update on 2014-2016 MY Optima Hybrid 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.

VOLUNTARY SERVICE CAMPAIGN: OWNER RENOTIFICATION (SC269) - This document is the owner renotification advising that Kia conducting a Voluntary Service Campaign to inspect and, if necessary, replace the high-voltage fuse in 2013-2016 MY Optima Hybrid vehicles.