2019 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) 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.

I have a 2019 Kia Optima S with the 2.4L engine and 117,000 miles. The vehicle has diagnostic codes P1326 and POOOB. The check-engine light is continuously flashing, the engine is knocking, and the vehicle has lost acceleration and will not go over approximately 65 mph. I believe this may be related to the KSDS connecting-rod bearing issue under Kia campaign PI1805.

NHTSA ID

11775414

Incident

Oct 2, 2026

2019 Kia Optima EX, 1.6L turbo, 7-speed dual-clutch transmission. Second owner, purchased August 2019 at Jeff Wyler near Cincinnati, Ohio, not Certified Pre-Owned. Transmission was previously replaced under warranty in my first year of ownership. In spring 2026 I reported rough low-speed shifting. The dealer performed a DCT fluid service and software reset on April 27, 2026, $478.72. That shifting issue was not resolved immediately, but it eventually went away. Kia Consumer Assistance Case #26051125 replied on May 22, 2026 that the dealer was unable to duplicate any issue and the transmission was operating normally. On September 30, 2026, at about 70,000 miles, the transmission failed and the car stopped in the middle of the road in my community. It would not engage first gear and was diagnosed as a mechanical failure of the odd gear fork. No crash, no injury. It was towed to Ourisman Chantilly Kia. Replacement parts were $4,094.67 on October 11, 2026 and labor was $3,180.46 on October 20, 2026, total $7,275.13. Two transmissions have failed by about 70,000 miles. The September odd gear failure may or may not be related to the earlier shifting issue. I am filing this as a defect and safety complaint, not a reimbursement request. I authorize NHTSA to share my contact details with Kia.

NHTSA ID

11774915

Incident

Sep 30, 2026

Car smelled of what seemed like motor oil while driving. Parked, saw white smoke, and confirmed an engine fire. I was clearly in life threatening danger, especially with a full tank of gas. Fire developed rapidly into a roaring blaze. Entire front of car melted. Car is currently being investigated by manufacturer and cause is unknown. No warning lamps illuminated.

NHTSA ID

11770217

Incident

Oct 2, 2026

VEHICLE SHUT OFF WHILE DRIVING AT 40MPH, ENGINE SEIZED ,WILL NOT CRANK .SUSPECTED CONECTING ROD BEARING FAILURE UNDER SAFETY RECALL SC200, I CALL KIA 18003334542 DENIED RECALL REPAIR AND BEARING CLEARANCE TEST STATING VEHICLE IS REBUILT TITLE. FEDERAL SAFETY RECALL CANNOT BE DENIED DUE TO REBUILT TITLE PER NHTSA .REQUESTING RECALL REMEDY.

NHTSA ID

11769928

Incident

Oct 8, 2026

On XXX, Towbin Kia Service (Henderson, NV) officially diagnosed my 2019 Kia Optima (VIN: [XXX], Mileage: 118,325) with a critical component failure: "LOW PRESSURE FUEL PUMP IS LEAKING FROM TOP HAT" (Invoice #XXX). Despite documenting a severe, volatile raw fuel leak that presents an immediate fire and explosion hazard, the dealership refused to keep the vehicle. They explicitly released this active safety hazard back to me. The service department even arranged a third-party Lyft ride to transport my children and me to the dealership to pick up the leaking car and force us to drive it home. The vehicle is currently parked outside my residence, actively leaking raw fuel and filling the cabin with toxic gas fumes. It is entirely un-driveable and a public safety threat. Kia Corporate must immediately bypass standard dealership timelines, authorize a flatbed tow to retrieve this fire hazard, and directly provide an emergency corporate rental vehicle line (Enterprise/Hertz) for my family's safety today. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11768086

Incident

Sep 29, 2026

The vehicle experienced a sudden and severe loss of engine power while being driven on the interstate at highway speeds. The vehicle lost the ability to accelerate normally beyond approximately 60 mph, the Check Engine Light began flashing rapidly, and the vehicle entered “Limp Home Mode.” This sudden loss of power occurred in heavy traffic and created an immediate risk of a high-speed rear-end collision. The vehicle was subsequently inspected by an authorized Kia dealership service center. Diagnostic testing confirmed DTC P1326 (Knock Sensor Detection System). The dealership performed the manufacturer’s Bearing Clearance Test (BCT), and the dealership paperwork documents a “NO PASS BCT” result. The dealership paperwork also documents that Service Campaign SC340 (Theta II 2.4L GDI ECM Software Upgrade) was performed on the vehicle. Despite the documented P1326 condition and the manufacturer’s “NO PASS BCT” result, the dealership is refusing to provide the engine replacement as a covered repair and has instead quoted approximately $9,000 for the engine replacement. I am requesting that NHTSA review this matter because the vehicle experienced a sudden loss of power at highway speeds, followed by a documented “NO PASS BCT” result from the manufacturer’s diagnostic procedure. The vehicle remains an unresolved safety concern. I am also requesting review of whether Kia is properly applying the applicable P1326/BCT engine-replacement procedure and associated coverage to this vehicle. The vehicle and all diagnostic and service paperwork are available for inspection upon request.

NHTSA ID

11767635

Incident

Sep 15, 2026

On December 26, 2023, this vehicle received a complete engine assembly replacement at an authorized dealership under a manufacturer warranty repair order. Following the engine overhaul, the vehicle developed a severe, raw gasoline smell entering the passenger cabin through the climate control AC vents while sitting at an idle.The vehicle was brought back to Kia Store East on September 10, 2026, specifically to report this volatile safety issue. On September 17, 2026, the dealership technician explicitly duplicated and confirmed the raw fuel odor coming from the engine area in writing. Despite confirming the gasoline smell, the dealership is refusing to perform a manual high-pressure fuel system pressure-drop test to isolate the physical vapor leak. Instead, they have listed a high-pressure Fuel Pipe Assembly (Part # 35305 2GGA0) on a customer-pay estimate paired with an unrelated $1,819.12 timing cover oil seal repair.The dealership is claiming the failure is out of warranty and is holding the vehicle while forcing daily rental car fees onto me, refusing to isolate the active fuel leak unless I authorize the out-of-pocket repair. The vehicle currently sits un-repaired at the dealership as an active cabin fire and occupant chemical exposure hazard that the manufacturer and dealer refuse to properly diagnose or cover under repair workmanship guidelines.

NHTSA ID

11766628

Incident

Sep 10, 2026

My car was parked when my Kia Optima Panoramic sunroof exploded. It was between 8:00-8:30 a.m. Friday XXX. It sounded like an explosion. I was sleeping and the explosion woke me up. The sunroof was closed and the car was parked. We r not aware of anything coming in contact with the sunroof. Actually the sunroof exploded from inside the car. The broken glass was pointed upwards. I’m concerned that this is a serious hazard if it occurs while I was driving it would have caused a serious accident or even a death. I notified KIA Customer Care Center. XXX Case # XXX. I also sent them a letter concerning the event with photos. I have found information that other reported KIA panoramic sunroof failures and concerned that this may be part of a bigger problem. Customer Care rep [XXX] told me to take the car to a dealer. Cannot see me for 3 weeks and charge $209.99. Called customer care again talked to Risha, told me not to take to dealer and not pay anything. Then wait for someone to get back to me. That was XXX. If I haven’t had any contact from Kia I’m supposed to call back XXX. Still waiting. I am asking NHTSA to document this incident and review whether there is a safety- related defect or pattern involving panoramic sunroofs on KIA vehicles, including the 2019 KIA OPTIMA. Car is 7 years olds an 72,400 mi. The warranty is 5yrs -60,000. Please include this complaint in NHTSA’s records concerning the 2019 Kia Optima and Panoramic sunroof failures. I authorized NHTSA to share my complaint and identifying vehicle information with Kia if that is necessary to investigate the issue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11766544

Incident

Sep 18, 2026

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER NOTIFICATION (SC367) - This document is the owner notification advising that Kia is conducting an important Voluntary Emissions Service Campaign to improve the emissions software logic in the Electronic Control Module (ECM) to ensure compliance with emissions regulations for 2019-2020 MY Optima vehicles manufactured from May 21, 2018, through June 1, 2020, equipped with the 1.6L T-GDI engine.

SC367_STKR: VOLUNTARY EMISSIONS SERVICE CAMPAIGN COMPLETION LABEL/STICKER

TECHNICAL SERVICE BULLETIN: VOLUNTARY EMISSIONS SERVICE CAMPAIGN: This bulletin provides information to upgrade the Electronic Control Module ‘ECM’ system software for certain 2019-2020 MY Optima vehicles manufactured from May 21, 2018, through June 1, 2020, equipped with the 1.6L T-GDI engine to ensure compliance with emissions. Kia has become aware that the subject vehicles may have been produced with engine calibrations that can cause the vehicle to release air pollutants that exceed Federal and California standards. These standards were established to protect the public’s health and welfare from the dangers of air pollution.

SC367_POC: PROOF OF CORRECTION CARD

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: DEALER PARTS AND SERVICE MANAGER MEMO (SC367) - This document is the announcement to dealer Parts and Service managers advising that Kia is conducting an important Voluntary Emissions Service Campaign to improve the emissions software logic in the Electronic Control Module (ECM) to ensure compliance with emissions regulations for 2019-2020 MY Optima vehicles manufactured from May 21, 2018, through June 1, 2020, equipped with the 1.6L T-GDI engine.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: DEALER PRINCIPAL MEMO (SC367) - This document is the announcement to the dealer principals advising that Kia is conducting an important Voluntary Emissions Service Campaign to improve the emissions software logic in the Electronic Control Module (ECM) to ensure compliance with emissions regulations for 2019-2020 MY Optima vehicles manufactured from May 21, 2018, through June 1, 2020, equipped with the 1.6L T-GDI engine.