2016 Kia Optima

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) 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 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.

My Kia experienced catastrophic engine failure while I was driving on the freeway, creating an extremely frightening and dangerous situation. The sudden loss of engine power put my safety and the safety of surrounding motorists at risk, as I was traveling at freeway speeds when the engine gave out. Leading up to the failure, my vehicle experienced excessive oil consumption despite regular maintenance. I was repeatedly adding oil between scheduled oil changes. Previous repairs, including replacement of spark plugs and a thermostat, did not resolve the underlying issue. Following the engine failure, a Kia dealership reported a cracked engine valve and multiple severely damaged or melted spark plugs, including spark plugs that had recently been replaced. These findings raise serious concerns about progressive internal engine damage and a potentially defective engine. Despite my concerns regarding known Kia engine defects and possible connecting rod bearing issues, the dealership stated it could not perform the bearing clearance test due to the condition of the valves. My case was never submitted to Kia Techline for further investigation. I was initially instructed to provide oil change and maintenance records for consideration of engine replacement assistance, only to later be told that excessive oil consumption was not relevant to my claim. I am extremely concerned that a potentially defective engine experienced progressive damage before suddenly failing on the freeway, placing my life and others at risk. I am requesting that NHTSA investigate this failure and determine whether it is related to known Kia engine defects or an unresolved safety issue affecting other vehicles.

NHTSA ID

11776030

Incident

Sep 13, 2026

My engine is making a knock sound coming from the bottom end of motor I was driving it and no warning or anything it just started knocking

NHTSA ID

11775539

Incident

Nov 3, 2026

Component: Power Window / Door Description: All four power window regulators failed on my 2016 Kia Optima SXL within 16 months - from June 2025-Oct 2026. The failure mode is identical on all four doors: the plastic drum gear in the regulator separates or breaks, causing the window glass to drop into the door and become completely inoperable. The vehicle had 113,867 miles on it at the time of the first failure. This is a known design defect, not wear-and-tear. Kia issued Technical Service Bulletin BOD300 (March 2021) specifically addressing "Window Regulator Drum Gear Replacement" for 2016-2017MY Optima (JFa) vehicles produced September 1, 2015 through July 31, 2016. The bulletin confirms the drum gear separates or breaks. Despite this, Kia has not issued a safety recall. Safety risk: In a collision, intact side windows are an occupant ejection restraint. A window that has fallen into the door removes that protection and increases the risk of occupant ejection. Side curtain airbags deploy through the window frame (FMVSS 208). A window that is detached or lowered can interfere with proper airbag deployment, negating a Federal Motor Vehicle Safety Standard protection. In an emergency (fire, submersion), the driver and passengers cannot lower a window to create an escape path. Evidence of systemic defect: All four regulators failed (not one or two), within a short timeframe, demonstrating a design-level failure rather than isolated component wear. Kia's own TSB BOD300 confirms the root cause (drum gear separation/breakage). This complaint is filed in connection with existing NHTSA investigations PE21004 and EA22002 regarding this exact defect. I paid $3,734.64 out of pocket to have all four regulators replaced. I opted out of the Le Beau v. Kia America class action settlement and retain my individual claims. I am requesting that NHTSA evaluate this as a safety defect warranting a recall.

NHTSA ID

11773122

Incident

Jun 11, 2025

Concerning my Optima KIA's OEM front windshield. At certain times of the day when the sunlight is shining on a certain angle it is difficult to see through the windshield due to the glare which creates a visual impairment. There were a quite a few instance's where I almost got into serious accidents. With my observation the glass looks like there are thousands of microscopic pits like a light sandblasting embedded within the lamination and not the surface of the glass. It seems prominent at night also. This seems like a manufacture defect. This puts a safety risk for me and others. The dealer and manufacture will not do anything about it do to out of warranty. This appeared about a year ago and has gotten worse.

NHTSA ID

11771350

Incident

Aug 1, 2025

Severe engine defect (Theta II 2.4L GDI). Sudden total loss of power, metallic knocking, severe oil consumption, and imminent catastrophic failure while driving, creating a high safety risk. Vehicle is currently out of service in [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11770266

Incident

Aug 14, 2026

I am reporting a serious safety concern involving my 2016 Kia Optima, purchased from CarMax in 2024 and financed through CarMax Auto Finance. On or about October 5, 2026, I returned to my parked vehicle and discovered extensive black soot/smoke residue throughout the interior. Wiring and interior components appeared melted or burned. The vehicle had not been involved in a collision. Based on the damage, I believe an electrical or wiring failure may have caused the fire, although the exact cause has not yet been confirmed. The vehicle was inspected by police and the tow operator, and it was determined to be a total loss. An insurance claim has been filed, and the vehicle should be available for inspection if requested. This vehicle also had a significant history of mechanical problems. Since shortly after I purchased it, it experienced severe oil consumption/oil loss, requiring multiple visits to CarMax and multiple 1,000-mile oil-consumption tests. I also experienced repeated spark plug and coil pack problems requiring repairs/replacements. The exact component that failed is currently UNKNOWN. I have not yet had Kia inspect the vehicle or confirm the cause of the fire. This incident created a serious safety risk because the vehicle appears to have caught fire while parked. If this had occurred while I was driving or while my children were inside the vehicle, the fire could have caused serious injury or death. I do not recall receiving a specific warning message immediately before discovering the damage. The vehicle did, however, have its history of ongoing mechanical problems described above. I am requesting that NHTSA investigate whether an electrical, wiring, or other safety defect could have caused this vehicle fire and whether other Kia Optima owners may be at risk.

NHTSA ID

11769490

Incident

Oct 6, 2026

3 times windows different ones has stopped rolling up/down. 3 motors purchased and installed.

NHTSA ID

11767467

Incident

Sep 19, 2023

The contact owns a 2016 Kia Optima. The contact stated that while driving 25 MPH, the vehicle shut off without warning. Soon after the failure, the engine caught fire; however, the fire dissipated independently. The insurance agent was contacted and arrived at the scene to inspect the vehicle. The contact was initially informed that the vehicle was safe to drive; however, the engine failed to start after several attempts. Due to the failure, the vehicle was towed to a dealer where a mechanic discovered that the knock sensor was inoperable and had caused the fire. The contact was informed that the vehicle was included in NHTSA Campaign Number: 18V907000 (Fuel System, Gasoline, Engine) and the vehicle was repaired under the recall. Nearly a month after the repair, the vehicle started consuming oil with the master warning light displayed. The vehicle was taken back to the dealer for an inspection; however, no fault was found with the vehicle. The manufacturer was notified of the failure, and the contact was referred to the dealer. After another inspection, the dealer agreed to replace the engine; however, the failure recurred after the repair.

NHTSA ID

11766692

Incident

Dec 10, 2025

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.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: THETA II 2.4L GDI EMISSIONS: ECM LOGIC IMPROVEMENT (SC340 REVISION 5) - 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 upgrade the Electronic Control Module ‘ECM’ system software for certain 2016-2020MY Optima, 2016-2020MY Sorento, 2017-2022MY Sportage vehicles equipped with 2.4L Theta II engines listed in the table below. Kia has become aware that certain 2016-2022MY vehicles equipped with 2.4L Theta II engines may have engine calibrations that were not optimized for emissions standards under certain specific conditions. These calibrations may cause the vehicle to release air pollutants which exceed Federal and California standards. These standards were established to protect your health and welfare from the dangers of air pollution.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER NOTIFICATION (SC340 FLIGHT 104 ) - This document is the owner notification advising that Kia is conducting a Voluntary Emissions Service Campaign to improve the emissions software logic in the Electronic Control Module (ECM) for certain 2016-2020 MY Optima vehicles equipped with 2.4L Gas Direct Injection (GDI) engines to ensure compliance with emissions regulations.

TECHNICAL SERVICE BULLETIN: VOLUNTARY EMISSIONS SERVICE CAMPAIGN: THETA II 2.4L GDI EMISSION SECM LOGIC IMPROVEMENT (SC340 REV 4) - 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 upgrade the Electronic Control Module ‘ECM’ system software for certain 2016-2022MY vehicles equipped with 2.4L Theta II engines listed in the table below. Kia has become aware that certain 2016-2022MY vehicles equipped with 2.4L Theta II engines may have engine calibrations that were not optimized for emissions standards under certain specific conditions. These calibrations may cause the vehicle to release air pollutants which exceed Federal and California standards. These standards were established to protect your health and welfare from the dangers of air pollution.

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.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER NOTIFICATION (SC340 FLIGHT 103 / JF) - This document is the owner notification advising that Kia is conducting a Voluntary Emissions Service Campaign to improve the emissions software logic in the Electronic Control Module (ECM) for certain 2016-2020 MY Optima vehicles equipped with 2.4L Gas Direct Injection (GDI) engines to ensure compliance with emissions regulations.