2011 Kia Optima

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) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involving crashes, from which 69 subject Hyundai-Kia vehicles were inspected by Hyundai/Kia dealer technicians, Hyundai/Kia engineers, and/or third-party representatives.ODI found the inspections identified no vehicle defects related to the ETC system.Of the 220 crash-involved reports, 13 Event Data Recorder (EDR) records were downloaded successfully and 11 of those indicated driver error: (i.e.) pedal misapplication.A condition where the accelerator pedal is mistakenly applied instead of the brake pedal when the driver wants to stop the vehicle.In addition, ODI reviewed a scientific journal paper published in Forensic Science International in 2016 by Mr. Park et al ., as well as related test videos. ODI does not believe there is any evidence of uncontrollable SUA occurrences in any of the tests reviewed. NHTSA's Office of Vehicle Safety Compliance (OVSC) reviewed the allegations regarding the potential noncompliance with Federal Motor Vehicle Safety Standard No. 124.Based on the information provided, the Agency concludes there is insufficient information for us to determine if a possible non-compliance exists.Finally, both Hyundai and Kia informed ODI that all their vehicles manufactured after 2012 were equipped with an ETC management system, in which the engine speed will go to idle when the system sees signals from both the brake pedal and accelerator pedal at the same time; this is commonly known as the brake-throttle override system.After thoroughly assessing the material submitted by the petitioner, information already in NHTSA's possession, information submitted by Hyundai and Kia in response to an Information Request letter, and the potential risks to safety implicated by the petitioner's allegation, NHTSA does not believe that a formal investigation is warranted. After full consideration of appropriate factors, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA?s reasons for denial of the petition will be published.

The vehicle's engine had previously been replaced once under Kia's Theta II engine recall/warranty program approximately five years prior to this incident. On the date of failure, the replacement engine catastrophically failed while the vehicle was in operation, resulting in the engine developing a hole in the engine block and becoming inoperable. Prior to the failure, the vehicle exhibited a "check engine" warning and symptoms consistent with connecting rod bearing failure. Diagnostic trouble codes P1326 and P0303 were present upon inspection at an authorized Kia dealership. The failure occurred at approximately 198,000 miles. This is the second engine failure on this vehicle, both consistent with the known Theta II engine defect involving premature bearing wear and connecting rod failure that has been the subject of prior NHTSA recalls and a related class action settlement. The failure created a risk of sudden loss of engine power while driving, which can pose a safety hazard in traffic. The vehicle was inspected by the authorized Kia dealership, which confirmed the hole in the engine block and the diagnostic codes noted above. The engine and related repair estimate are available for inspection upon request. A warranty claim for repair coverage was submitted and denied by the manufacturer, citing insufficient maintenance documentation, despite this being the vehicle's second occurrence of the same underlying defect.

NHTSA ID

11752542

Incident

Feb 12, 2026

About six months ago, I lost the heated steering wheel functionality in my steering wheel, then from there, I slowly lost functionality like cruise control, and the most recent now my airbag and horn do not work. If you press on the horn, it is silent, and the airbag light has been illuminated consistently for the last couple of months. I had this issue diagnosed and it came up with the codes of B1346. And B1481. After some research, these issues are the result of a bad clock, spring and cause the airbag and horn not to work. Additionally, this issue is known to this model the 2011 Kia Optima, and has been recalled in most production cases of this vehicle, but my vehicle is not included. I received a quote for $876 from a dealership to get this corrected, but it should be included in the recall.

NHTSA ID

11749934

Incident

Jun 1, 2026

The contact owns a 2011 Kia Optima. The contact stated that while the vehicle was parked in a parking lot, he noticed the vehicle started smoking heavily from under the hood, and shortly thereafter, the vehicle fully ignited into flames. The vehicle was occupied during the fire. The contact stated that he noticed smoke emerging from the driver-side section of the hood. Furthermore, the contact noted that the power door locks failed to unlock automatically, requiring him to manually unlock the door to exit the vehicle safely. The color of the smoke started off light and quickly turned black. The contact stated he noticed a burning electrical odor during the fire. The fire started at underneath the hood, and stayed in the engine bay. No property damage. The location of the fire was the engine compartment. The fire was extinguished by the local fire dept by water. A Fire Department report was not filed. No police report was filed. The vehicle was totaled. No injuries occurred. The vehicle was towed to a independent auto shop. The dealer was not notified of the failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage on the odometer was 219,000, but the vehicle had a previous engine replacement.

NHTSA ID

11742198

Incident

Jun 3, 2026

I have replaced the headlights in my 2011 Kia Optima multiple times but no matter what without the brights on, the road is not at all illuminated making it impossible to see at night. When you look at the car head on the lights look as if they would be incredibly bright, but I believe due to faulty reflective lining on the interior of the headlight housing, even though the bulb may shine brightly, it does not get reflected properly onto the surface of the road causing serious safety concerns.

NHTSA ID

11741618

Incident

Mar 23, 2024

The contact owns a 2011 Kia Optima. The contact stated that the vehicle caught fire while driving at 60 MPH on the expressway. No warning lights illuminated. The contact had some wires replaced prior to the failure. There were no reported injuries, air bag deployment or crash. The driver was able to pull over safely. The fire department was able to extinguish the fire. A police report was filed. The vehicle was towed to a tow lot. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was called but there was no answer. The failure mileage was approximately 35,000. The VIN was not available.

NHTSA ID

11732339

Incident

Apr 18, 2026

Mileage

35,000 mi

I am submitting a complaint regarding my 2011 Kia Optima (VIN: [XXX] ), which is currently experiencing significant engine issues and is undrivable. This issue is currently being reviewed under Kia Case #XXX. This vehicle is part of the Theta II engine group that has been the subject of recalls, service campaigns, and extended warranty coverage due to known engine defects, including rod bearing failure and potential engine seizure. The vehicle has also received the Knock Sensor Detection System (KSDS) update associated with these known issues. My vehicle is currently at the dealership and has been there since March 10, 2026. It is not drivable, and I have been without transportation during this time. The dealership has diagnosed the issue as oil consumption; however, Kia has denied coverage, stating that oil consumption is not related to rod bearing failure. Kia has not confirmed whether a full internal engine inspection was performed to rule out rod bearing damage, nor have they confirmed that a Techline engineering review has been conducted. Given the known history of engine defects in this model, I am concerned that the current condition may be related to internal engine failure that has not been properly evaluated. Oil consumption can be a precursor or symptom of internal engine damage, and I do not believe the issue has been fully or adequately diagnosed. Additionally, my vehicle has an open safety recall related to potential engine compartment fire risk, which further raises concerns about the safety and reliability of this vehicle. I am requesting that this issue be reviewed as a potential safety-related defect, as the vehicle is undrivable and may be at risk for sudden engine failure or fire. I am also concerned that the manufacturer is relying solely on a dealership-level assessment without a thorough engineering evaluation of a known defect condition. Thank you for your review of this matter. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11729896

Incident

Mar 3, 2026

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 while driving, the vehicle failed to exceed 60 MPH with the accelerator pedal depressed. No warning light was illuminated. The local dealer advised the contact that the vehicle could not be repaired due to a lack of maintenance records. 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. The failure mileage was approximately 160,000.

NHTSA ID

11727293

Incident

Jan 15, 2026

Mileage

160,000 mi

While driving the Kia on the highway (in the passing lane on Route 93, Boston, MA), the hood of the car flew open and shattered the windshield. Prior to getting into the vehicle, there was no notification, warning light/display, that alerted to the hood or anything else not being 'closed', no rattling of the hood either. The hood blocked my entire vision with the exception of a small area below, where I miraculous got over to the breakdown lane without causing any accident. When I got out of the car, the hood was bent and the second latch was loose. It did not hold its shape. Called the police and the insurance company, the car was deemed a total loss. This incident occurred on January 31, 2026 at 10:05AM. The conditions were dry and sunny. The state trooper said that this incident could have had serious safety consequences to the driver and others since no one expects a hood to fly open, block visibility...this highway is a busy road and could have impacted several other vehicles on the road. We no warning lamps/message- this was traumatic- this put the safety of the driver and the public at great risk.

NHTSA ID

11717872

Incident

Jan 31, 2026

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - 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) did 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, 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.

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - 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 whole Integrated Body control Unit (IBU) / Body Control Module (BCM) did receive the Ant-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, 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.

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - This bulletin provides information to install a Theft Deterrent Ignition Cylinder Protector on certain 2010-2022MY Kia vehicles outlined on page 19, which may not have been equipped with an immobilizer and whose Integrated Body Control Unit (IBU) / Body Control Module (BCM) did 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, 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: OWNER NOTIFICATION (CS2312) - This document is the owner notification advising that Kia is conducting Customer Satisfaction Campaign. A software upgrade that addresses the social media theft method has been made available to owners of eligible Kia model vehicles free of charge at authorized Kia dealers since 2023. In addition to the anti-theft software, a new zinc-reinforced ignition cylinder protector hardware upgrade has been developed and can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Because the subject Kia vehicles were not factory-equipped with an engine immobilizer and were previously eligible for the software upgrade, these vehicles are 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 17, 2025 through February 27, 2026)

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: EXCESSIVE OIL CONSUMPTION NU/GAMMA/THETA/KAPPA ENGINES - 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 on diagnosing and/or repairing some 2011-2024MY vehicles (refer to the table on pages 9 and 10 for applicable models and engine), which may exhibit a symptom of excessive oil consumption.