2020 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.

Driving car on highway Car would not accelerate Stalled engine loud noise all lights are on now

NHTSA ID

11774311

Incident

Oct 28, 2026

On October 25, 2026, while traveling eastbound on US Highway 74 near Bryson City, North Carolina, my 2020 Kia Optima 2.4L GDI experienced a sudden and substantial loss of engine power while driving through mountainous terrain. The check-engine light began flashing, and the vehicle entered what appeared to be reduced-power or limp mode. The engine remained running, but acceleration and available engine power were significantly reduced. This created a serious safety concern due to the mountainous highway conditions and surrounding traffic. I immediately pulled over at the first safe opportunity and did not continue driving the vehicle. My partner, who was approximately six months pregnant, was traveling with me. We remained stranded along the roadside for approximately three hours awaiting assistance, approximately 202 miles from home. Diagnostic trouble code P1326 was subsequently identified. There were no noticeable knocking, rattling, or ticking noises before or after the incident. The oil-pressure warning light did not illuminate. After the incident, the engine oil level was checked and found to be between the minimum and maximum dipstick markings. Timestamped photographs were taken during the towing process and at dealership drop-off. The vehicle was transported to a Kia dealership, where a bearing clearance test was performed and passed. The dealership also identified an external oil leak. However, the cause of the sudden loss of power and P1326 activation has not been conclusively established. I am reporting this incident because the unexpected and substantial loss of engine power while driving on a mountainous highway created a potentially dangerous situation. I am concerned that the condition could recur and pose a safety risk to other drivers and passengers.

NHTSA ID

11774145

Incident

Oct 25, 2026

My vehicle keeps consuming/burning oil. In between oil changes I still need to add oil

NHTSA ID

11770053

Incident

Oct 8, 2026

On August 20, 2026, while my minor son and I were inside my 2020 Kia Optima LX, strong burning odors and fumes entered the passenger compartment through the HVAC vents. No dashboard warning lights or messages appeared before or during the incident. Although no visible flames were observed, I suspected an electrical component was overheating or melting, creating a potential fire and respiratory hazard. My son has asthma and experienced coughing and shortness of breath throughout that day, requiring use of his prescribed rescue inhaler. Neither of us received immediate medical treatment. Due to safety concerns, I had the vehicle towed to R&E Auto Repair on August 21, 2026, rather than risk driving it. The independent repair facility documented suspected melting of the HVAC temperature control unit and identified the blower motor resistor as a possible contributing component. Video evidence of the suspected damage was obtained. I formally reported the incident to Kia Customer Care on September 1, 2026. The vehicle was delivered to authorized dealer DeMontrond Kia on September 23, 2026, for further inspection. Despite the independent findings, Kia's dealership reported that it could not identify melted components. The suspected defect remains unresolved. The vehicle remains at DeMontrond Kia and may be available for inspection. I have not been advised whether any affected components have been removed or replaced. No police or insurance inspection has been reported. I am concerned about potential electrical fire hazards, fumes entering the passenger compartment, and respiratory injuries to occupants. I request that NHTSA investigate this suspected HVAC electrical defect and potential safety risk to other Kia owners.

NHTSA ID

11769959

Incident

Aug 20, 2026

At around 103K miles, I took to the dealership for a multipoint inspection for knocking when braking and my forward collision/lane assist systems going offline mid drive. I learn I have to replace my axle, despite replacing my axle in sept 2025. I return a week after due to the red oil light blinking on randomly, and when I checked the oil myself it was dry. The braking and assumed wiring issues remained. I find out that my oil is low despite an oil change July 16th 2026. It is October 8th 2026 as I type this. I am doing an engine flush in hopes to improve oil consumption, but i have since learned that my engine may fail from these other Kia stories. I have not stalled or had engine failure yet but now I am worried about having to sell my car to avoid having to keep replacing the same flawed parts over and over, or worse injuring myself while driving it. I was hoping to take a trip but now I have to rent a car and play another 1,600 dollars for the engine flush which I have no guarantee will actually work. I am disgusted, and there should be consequences for KIA (and many other companies) for taking advantage of their customers. I need a new car now!

NHTSA ID

11769918

Incident

Oct 8, 2026

purchased this vehicle on June 18, 2024, as a second owner with 125,019 miles on the odometer. Within months of purchase, the engine began exhibiting symptoms consistent with connecting rod bearing failure: engine knock, excessive oil burning (requiring oil top-ups every 2-3 weeks), and rough running. The check engine light illuminated with diagnostic code P1326 (Knock Sensor Detection System warning). I took the vehicle to Kia Stonecrest dealership for diagnosis. Kia informed me that the engine failure is not covered under warranty because I am not the original owner. A independent mechanic at Lions Auto evaluated the engine and quoted $4,800 for full engine replacement. THE DEFECT: This vehicle is equipped with a Theta II 2.4L GDI engine identical to engines in 2011-2019 Kia Optimas and Kia Sorento models that were subject to multiple recalls (including NHTSA Recall 17V-224) and a $1.3 billion class action settlement. The defect is manufacturing debris left in the crankshaft oil passages during production, which restricts oil flow to connecting rod bearings, causing premature bearing wear, engine seizure, and potential engine fire. KIAS KNOWLEDGE AND RESPONSIBILITY: Kia had clear notice of this defect years before the 2020 model year was introduced. Despite this knowledge, Kia continued manufacturing 2020 and later Optimas with the identical Theta II 2.4L GDI engine without remedying the manufacturing process. The class action settlement litigation was filed in 2017 and covered model years through 2019; however, Kia’s decision to exclude 2020 models from coverage despite using the same defective engine creates an unjust gap in consumer protection. SAFETY CONCERN: Connecting rod bearing failure can cause sudden engine seizure while driving, resulting in loss of power steering and brake assist, creating an immediate crash hazard. The symptoms I experienced — engine knock and P1326 code — are documented precursors to catastrophic failure.

NHTSA ID

11768350

Incident

Jun 18, 2026

The contact owns a 2020 Kia Optima. The contact stated that while driving 32 MPH, there was smoke coming from under the hood and underneath the driver's side of the vehicle, and a bystander informed the contact to exit the vehicle. The vehicle was coasted to a stop, and the contact quickly exited the vehicle. The smoke coming from the vehicle went from gray to black. The vehicle then completely became engulfed by flames. The Fire Department was contacted and arrived on scene to extinguish the fire. The vehicle was deemed a total loss by the insurance company. A Police report was filed; however, the information was not available. The vehicle was towed to a temporary impound lot. The failure mileage was approximately 185,700.

NHTSA ID

11768078

Incident

Sep 29, 2026

Mileage

185,700 mi

While driving to work, my 2020 Kia Optima suddenly lost engine power and went into limp mode in the middle of the highway, leaving me stranded and creating a severe safety hazard in traffic. The check engine light immediately started flashing and displaying diagnostic code P1326 which indicates an abnormal engine and/or a catastrophic rod bearing failure. This problem has been confirmed by the Kia dealership along with a 3rd party auto repair shop. However, Kia is refusing to cover the inspection, diagnostic, or any repairs due to the vehicle not having any open recalls, having more than 100k miles and the model of my vehicle despite this being a well known and documented manufacturing defect issue to these engines. The vehicle is currently available for inspection.

NHTSA ID

11766255

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.