2001 Kia Rio

ON MARCH 24, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-030) TO INVESTIGATE ALLEGED STEEL WHEEL FRACTURES IN CERTAIN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE SUBJECT VEHICLES ARE EQUIPPED WITH WHEELS MANUFACTURED FROM MAY 12 THROUGH OCTOBER 17, 2000.WHEELS WERE MANUFACTURED DURING THIS PERIOD USING A TOOL (RING DIE) THAT HAD IMPROPER SURFACE TREATMENT.THIS ALLOWED TOOL DAMAGE TO DEVELOP WITH ACCUMULATED USE AND RESULTED IN AN IRREGULAR SHAPED STAMPING ON THE WHEEL DISC AT THE HAT AREA.THE IRREGULAR SHAPED HAT AREA CREATES A STRESS RISER THAT MAY LEAD TO THE FORMATION OF CRACKS.ODI IS AWARE OF 40 NON-DUPLICATIVE CONSUMER REPORTS ALLEGING WHEEL FRACTURE, 6 OF WHICH ALLEGED WHEEL SEPARATION INCIDENTS ON THE SUBJECT VEHICLES.AS OF MARCH 31, 2005, KIA MOTORS AMERICA, INC. (KIA) HAS PAID 535 WARRANTY CLAIMS FOR THE REPLACEMENT OF ONE OR MORE WHEELS ON THE SUBJECT VEHICLES DUE TO FRACTURE.BY LETTER DATED APRIL 18, 2005, KIA HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NTHSA RECALL NO. 05V-159) TO REPLACE DEFECTIVE WHEELS IN APPROXIMATELY 24,119 SUBJECT VEHICLES.KIA WILL REPLACE ALL FOUR STEEL WHEELS FREE OF CHARGE.THE ACTION TAKEN BY KIA IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

ON MARCH 24, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STEEL WHEEL FRACTURES IN CERTAIN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE SUBJECT VEHICLES ARE EQUIPPED WITH WHEELS MANUFACTURED BETWEEN MAY 12 AND OCTOBER 18, 2000.WHEELS WERE MANUFACTURED DURING THIS PERIOD USING A TOOL (RING DIE) THAT HAD IMPROPER SURFACE TREATMENT.THIS ALLOWED TOOL DAMAGE TO DEVELOP WITH ACCUMULATED USE AND RESULTED IN AN IRREGULAR SHAPED STAMPING ON THE WHEEL DISC AT THE HAT AREA.THE IRREGULAR SHAPED HAT AREA CREATES A STRESS RISER THAT MAY LEAD TO THE FORMATION OF CRACKS.ODI IS AWARE OF 30 NON-DUPLICATIVE CONSUMER REPORTS ALLEGING WHEEL FRACTURE AND 3 ALLEGED WHEEL SEPARATION INCIDENTS ON THE SUBJECT VEHICLES.KIA HAS PAID 576 WARRANTY CLAIMS FOR WHEEL REPLACEMENT ON THE SUBJECT VEHICLES.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA04-020) TO FURTHER STUDY THE SCOPE AND SAFETY CONSEQUENCES OF THIS ISSUE.

ON APRIL 15, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-016) TO INVESTIGATE ENGINE COMPARTMENT FIRES DUE TO ALLEGED FUEL SYSTEM LEAKS IN MODEL YEAR (MY) 2001 KIA RIO VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON AUGUST 28, 2003.ON SEPTEMBER 22, 2003, THE MANUFACTURER NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (03V-352) TO INSPECT THE SUBJECT VEHICLES FOR FUEL LEAKS.AN INFORMATION REQUEST (IR) LETTER WAS SUBMITTED TO THE MANUFACTURER ON NOVEMBER 17, 2003 TO OBTAIN ADDITIONAL INFORMATION SO THAT THE OFFICE COULD EVALUATE THE DEFECT AS REPORTED BY KIA.THE IR LETTER ALSO ADDRESSED OTHER KIA VEHICLES NOT SUBJECT TO THIS INVESTIGATION THAT USE FUEL DELIVERY SYSTEM COMPONENTS IDENTICAL TO THE SUBJECT VEHICLES BUT WERE NOT INCLUDED IN RECALL 03V-352.KIA?S SEPTEMBER 22, 2003 DEFECT NOTIFICATION LETTER IDENTIFIED QUALITY DEVIATIONS IN THE SUBJECT COMPONENTS THAT COULD RESULT IN FUEL LEAKAGE.DURING MY 2001 PRODUCTION, THE SUPPLIER OF THE FUEL RAIL (FUEL DISTRIBUTOR ASSEMBLY) IDENTIFIED QUALITY ISSUES THAT AFFECTED THE INTEGRITY OF PLASTIC WELDS AT THE SERVICE PORT AND/OR FUEL INTAKE NIPPLE.FUEL LEAKAGE COULD ALSO OCCUR IF THE BRASS SERVICE PORT (SCHRADER) VALVE WAS NOT PROPERLY INSTALLED INTO THE VALVE RECEPTACLE.THE SUPPLIER ADOPTED CHANGES TO REMEDY THE PROBLEM AND INSTITUTED A 100% INSPECTION PROCEDURE.SUBSEQUENT TO THIS INVESTIGATION, KIA ALSO CONDUCTED PERFORMANCE TESTING AND ANALYSIS OF WARRANTY AND COMPLAINT DATA.KIA DETERMINED THAT THE FUEL RAIL IS SUBJECT TO FRACTURE AT THE INTAKE NIPPLE DURING THE ASSEMBLY PROCESS OR VEHICLE SERVICING.DAMAGE MAY OCCUR WHEN THE FLEXIBLE FUEL LINE (MAIN FUEL TUBE ASSEMBLY) QUICK CONNECT COUPLING IS IMPROPERLY ATTACHED OR REMOVED FROM THE FUEL RAIL, OR WHEN EXCESSIVE FORCE IS OTHERWISE APPLIED.ODI IS AWARE OF 9 NON-DUPLICATE, NON-CRASH ENGINE COMPARTMENT FIRES CAUSED BY FUEL SYSTEM LEAKS AND AN ADDITIONAL 14 FIRES OF UNKNOWN CAUSE THAT MAY BE RELATED TO THE DEFECT IN THE SUBJECT VEHICLES.ODI IS ALSO AWARE 6 FIRES IN MY 2002 AND 3 FIRES IN MY 2003 RIO/RIO CINCO VEHICLES THAT MAY BE RELATED TO THE DEFECT.TO REDUCE THE POSSIBILITY OF FUEL RAIL DAMAGE, KIA HAS REDESIGNED THE FUEL RAIL TO INCLUDE A STEEL INTAKE NIPPLE, AND THE ATTACHING FUEL LINE QUICK CONNECT COUPLING HAS BEEN CHANGED TO FACILITATE EASIER SERVICING.ON APRIL 7, 2004, KIA NOTIFIED THE AGENCY THAT IT WOULD CONDUCT A SAFETY RECALL (04V-179) TO REPLACE THESE TWO COMPONENTS FREE OF CHARGE FOR OWNERS OF ALL MY 2001-2004 KIA RIO AND RIO CINCO VEHICLES PRODUCED FROM MAY 4, 2000 THROUGH MARCH 31, 2004.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

KIA HAS IDENTIFIED 22 NON-CRASH ENGINE COMPARTMENT FIRES OF ANY OR UNSPECIFIED CAUSE ON THE SUBJECT VEHICLES.NINE FIRES (OF WHICH 4 WERE ALSO REPORTED TO ODI) ARE IDENTIFIED AS BEING DUE TO A FUEL SYSTEM LEAK ORIGINATING BETWEEN THE FIREWALL AND THE FUEL INJECTOR RAIL (P/N 0K30E 13 150) IN THE PASSENGER SIDE AREA OF THE ENGINE COMPARTMENT.THE REMAINING FIRES WERE DUE TO VARIED OR UNKNOWN CAUSES.ALL 9 FIRES CAUSED BY A FUEL SYSTEM LEAK SUSTAINED SEVERE AND TOTAL DAMAGE.ANALYSIS INDICATES THAT 1 FIRE WAS CAUSED BY A FAILED QUICK CONNECT BETWEEN THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE (P/N 0K32A 13 49XB) AND THE RIGID LINE MOUNTED TO THE FIREWALL; 5 FIRES WERE CAUSED BY A FAILURE OF THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE ITSELF OR ITS RELATED CONNECTORS; THE REMAINING 3 FIRES WERE CAUSED BY UNSPECIFIED FUEL LEAKS IN THE VICINITY OF THE FUEL INJECTOR RAIL, FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE, AND THE RIGID LINE MOUNTED TO THE FIREWALL.KIA REPORTS THAT NEITHER THE FUEL INJECTOR RAIL NOR THE FLEXIBLE HIGH-PRESSURE FUEL SUPPLY LINE HAS BEEN SUBSTANTIALLY MODIFIED SINCE THEIR INTRODUCTION IN THE 2001 MODEL YEAR.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA03-015) SO THAT ODI MAY COLLECT ADDITIONAL INFORMATION AND CONDUCT FURTHER STUDY OF THIS ISSUE.

DOOR LOCKS ON BOTH FRONT DOORS STUCK IN THE LOCKED POSITION.

NHTSA ID

10945096

Incident

Jan 12, 2017

Mileage

125,000 mi

PARKED CAR AT WORK CAME BACK OUT AND THE DOOR LOCK WAS DOWN TRIED TO PULL UP BUT IS STUCK OR CAUGHT ON SOMETHING. THE WAY THE SCREWS ARE IN THE DOOR 2 OF THEM CANNOT BE TAKEN OUT WITHOUT HAVING THE DOOR OPEN. WITH LONG LEGS ITS VERY DIFFICULT TO GET IN AND OUT OF VEHICLE!!! ALSO TROUBLE WITH THE ENGINE MISFIRING OF SPARKPLUG WITH SOME LOSS OF POWER. *TR

NHTSA ID

10554083

Incident

Nov 12, 2013

Mileage

129,500 mi

IT IS DIFFICULT TO ENTER THE CAR WITH THE KEY AND WHEN I PULL THE DOOR HANDLE THE LOCK DROPS DOWN TO THE CLOSE POSITION AND I CAN'T GET OUT THIS HAPPENS ON THE DRIVER'S SIDE AND THE FRONT PASSENGER SIDE,I HAVE TO HOLD THE LOCK ON THE UP POSITION WITH A PIECE OF METAL OR LEAVE THE REAR DOORS UNLOCKED IN CASE I HAVE TO JUMP OUT..THIS CAR IS A LEMON I HAVE REPLACED SENSORS ALTERNATOR, STARTER, AC PARTS AND MANY OTHER PARTS THE ONLY THING GOOD IS THE TRANSMISSION AND THE ENGINE... *JS

NHTSA ID

10545123

Incident

Sep 4, 2013

Mileage

140,000 mi

CONSUMER COMPLAINT: ODI CASE NUMBER: 10136024 COMPONENT: WHEELS GAS IGNITION? YOU TELL ME? WHEN ARE THESE PEOPLE GOING TO BE COMPENSATED FOR THEIR LEMONS KIA-2001 DETAILS: DT: THE CONSUMER WAS INVOLVED IN AN ACCIDENT AND A TIRE BLEW OUT. AFTER THE VEHICLE STOPPED SPINNING, THE CONSUMER GOT OUT OF THE VEHICLE AND IT BURST INTO FLAMES, THE FIRE DEPARTMENT CAME AND THEY SAID FIRE STARTED FROM HEAT OF POWER EQUIPMENT AND THE IGNITION BURNED. THIS HAPPENED ON AUGUST 6, 2005. *AK THE CONSUMER STATED SHE WAS NOT INFORMED ABOUT THE RECALL REGARDING THE WHEELS. THE CONSUMERS DAUGHTER COMPLAINED THAT THE STEERING WHEEL VIBRATED FROM THE TIME THE VEHICLE WAS PURCHASED. THE SAME TIRE THAT THE BLEW OUT WAS THE SAME ONE THAT HAD BEEN REPLACED NUMEROUS TIMES. *JB OCCURRENCES: 1 INJURIES: 0 FAIL DATE: 08/06/2005 DEATHS: 0 DATE ADDED TO DATABASE: 9/9/2005 [FILE] YOUR OWN COMPLAINT ON THIS MODEL CAR. *TR

NHTSA ID

10471283

Incident

Aug 8, 2005

I WAS ON A MAJOR INTERSTATE DOING THE SPEED LIMIT OF 65 MPH WHEN I HEARD A LOUD POP SOUND. THE CAR STARTED TO SHAKE AND I THOUGHT I HAD A FLAT TIRE. I IMMEDIATELY PUT ON MY HAZARD LIGHTS AND SLOWED DOWN TO REACH THE NEAREST EXIT RAMP. I WAS ALONE IN THE CAR AND THANK GOD I HAD NO CHILDREN IN THE CAR AND AS SOON AS I REACHED THE EXIT RAMP I GOT OFF THE EXIT AND CALLED AAA. THEY SENT A TOW TRUCK BUT WHEN THE DRIVER WENT TO PUT THE CAR UP HE NOTICED THE RIGHT BACK WHEEL WAS EXTREMELY LOOSE AND THEN CALLED FOR A FLAT BED. WHILE BEING TOWED TO MY MECHANIC WITH THE CAR ON THE FLAT BED THE WHEEL CAME COMPLETELY OFF. I LOOKED ONLINE FOR RECALLS ON MY CAR AND THERE WAS ONE ISSUED IN 4/20/2005 AND I WAS NEVER NOTIFIED BY KIA OR THE DEALER WHERE I PURCHASED THE CAR ABOUT THIS ISSUE WHEN THE RECALL BEGAN ON 6/22/2005. I AM WORRIED NOW THAT I MAY HAVE TO PAY OUT OF POCKET FOR THIS REPAIR WHICH KIA MOTORS SHOULD HAVE NOTIFIED ME ON. *JS

NHTSA ID

10468136

Incident

Jul 28, 2012

Mileage

103,000 mi

BOTH DOOR LOCKS GET STUCK ON BOTH THE PASSENGER SIDE AND DRIVERS SIDE. WE HAVE HAD TO CLIMB IN THE BACK SEAT TO EXIT THE CAR. THIS IS VERY DANGEROUS AND COULD CAUSE DEATH OR INJURY IF A FIRE AND COULD NOT EXIT THE CAR. *TR

NHTSA ID

10419394

Incident

May 2, 2011

Mileage

100,000 mi

I BOUGHT A 2001 KIA RIO IN 2007 AND WITHIN 8 MONTHS MY FUEL PUMP HAD TO BE REPLACED. A YEAR LATER MY CAR STARTED SPUTTERING AND SHUTTING OFF RANDOMLY WHILE I DROVE IT. I ENDED UP HAVING TO REPLACE THE FUEL PUMP TWO MORE TIMES. I RECENTLY TOOK IT TO THE DEALERSHIP WERE THEY INFORMED ME I NEEDED ANOTHER FUEL PUMP. IM SORRY BUT THERE IS SOMETHING WRONG IF I HAVE TO REPLACE THE FUEL PUMP AND FILTER 4 TIMES IN A 2 YEAR TIME SPAN. NOW MY CAR DOES NOT EVEN RUN, AND I REFUSE TO REPLACE THE FUEL PUMP AGAIN WHEN I KNOW IT WONT DO ANYTHING. *TR

NHTSA ID

10406167

Incident

Sep 16, 2008

REF 2001 KIA RIO. PERPETUAL INTERMITTENT FAILURE OF FUEL PUMP TO OPERATE. FUEL PUMP REPLACED, RELAY REPLACED, AND ECM REPLACED. PUMP WON'T TURN ON AT START UP AND PERIODICALLY, THE PUMP STOPS OPERATING AFTER IT DOES COME ON WHILE DRIVING. NO WARNING. CAUSES SAFETY PROBLEM ON ROAD BY NOT HAVING ANY POWER TO MOVE CAR OFF ROAD. *TR

NHTSA ID

10392541

Incident

Mar 20, 2011

Mileage

26,483 mi

TECHNICAL SERVICE BULLETIN: INFORMATION FOR HEADLAMP CONDENSATION AND MOISTURE - 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 some Kia models that may exhibit fogging, condensation, and/or moisture inside a headlamp assembly. Generally, a fogging condition is considered normal and can be eliminated by turning on the headlamps with the engine running for up to 30 minutes or during normal driving conditions. Headlamp assembly replacement WILL NOT be necessary in most cases.

PITSTOP - ENGINE COMPONENT RE-USE GUIDELINES - In general, parts and components removed during engine repairs should be considered serviceable, and should be thoroughly cleaned and transferred to the new engine.

TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners, which are designed to lock into place once fully attached, are utilized in various Kia models and are strictly intended for ?one time use.? Some examples are: axle shaft nuts with stake collar, cotter pins, washers with locking tabs and other similar hardware, including threaded fasteners with pre-applied ?thread-locking adhesives.? It is critical for technicians to be aware that ALL such locking fasteners, regardless of type, are for ?one time use? only.

TSB: MANDATORY REPLACEMENT OF LOCKING/SECURITY HARDWARE - By design, certain fasteners utilized in various Kia models are strictly intended for ?one time use?. Though not limited to the following, some examples are: axle shaft nuts with stake collar, cotter pins, washers with locking tabs and other similar hardware, including threaded fasteners with pre-applied ?thread-locking adhesives.?

TSB - USE OF AFTERMARKET USB CHARGING CABLES IN USB/12V PORTS - This article provides information regarding the use of USB ports and 12V power outlets to connect/charge mobile phones. Customers may experience issues with their head units that may be related to the use of aftermarket USB charging cables, including; * Electrical interference and limited or no functionality when attempting to play music, or when charging a device through the USB port * Excessive static or noise when listening to the audio source * Malfunctions and screen freeze of the head unit screen * Slow down of the system response while device is plugged in * Music will not play from iPhone 5 or 6 with Kia iPod cable and aftermarket adapter * No or limited functionality when trying to play music from an Apple device

TSB: AUTOMATIC TRANSMISSION FLUID APPLICATION GUIDE - THIS BULLETIN PROVIDES INFORMATION RELATING TO THE CORRECT AUTOMATIC TRANSMISSION FLUIDS THAT ARE REQUIRED FOR EACH KIA MODEL. REFER TO THE SHOP MANUAL ON KGIS FOR THE SPECIFIC KIA MODEL, THEN REFERENCE THE AUTOMATIC TRANSAXLE SYSTEM/ REPAIR PROCEDURES/ INSPECTION AND ADJUSTMENT SECTION FOR THE CORRECT ATF CHECK/FILL PROCEDURES.