2001 Kia Rio Recalls

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.

THIS INVESTIGATION IDENTIFIED A TOTAL OF 82 REPORTS ALLEGING NON-DEPLOYMENT OF THE DUAL FRONT AIR BAGS.OF THE 82 REPORTS, ONLY ONE INCIDENT, THE FATAL CRASH THAT WAS THE BASIS FOR OPENING THE INVESTIGATION, HAS BEEN IDENTIFIED AS A MODERATE TO SEVERE CRASH IN WHICH THE AUTOMOTIVE RESTRAINT CONTROLLER ISSUED A COMMAND TO DEPLOY BUT THE AIR BAGS DID NOT DEPLOY.A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES. SEE ATTACHED SUMMARY REPORT

IN ADDITION TO THE DECEMBER 2001 FATAL CRASH REPORTED TO ODI THAT PROVIDED THE BASIS FOR OPENING PE02-022, KIA PROVIDED ODI 29 ADDITIONAL REPORTS OF ALLEGATIONS OF NON-DEPLOYMENT OF THE AIR BAG IN A CRASH.NO ADDITIONAL FATAL CRASHES ARE REPORTED.AN ENGINEERING ANALYSIS HAS BEEN OPENED TO CONDUCT FURTHER ANALYSIS OF THE SUBJECT VEHICLE'S AIR BAG SYSTEM.