2014 Kia Rio

The Office of Defects Investigation (ODI) has received eight Hyundai Motor America (Hyundai) and eight Kia America, Inc. (Kia) Part 573 Recall Reports between 2016 and 2023. The combined 16 safety recalls all involve the antilock braking system (ABS) modules or Hydraulic Electronic Control Units (HECU) manufactured by the equipment supplier Mando. The Part 573 Recall Reports contain varying defect descriptions and differing remedy descriptions for the same or similar equipment supplied by Mando. Safety recalls included in this Audit Query (AQ) review include: Hyundai recalls 20V-520, 20V-543, 21V-161, 21V-160, 21V-303, 22V-056, 22V-810, and 23V-651. Kia recalls 16V-815, 20V-518, 20V-519, 21V-137, 21V-331, 22V-051, 22V-800, and 23V-652 The purpose of this AQ is to evaluate the timeliness and scoping of Hyundai and Kia’s defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.

On March 29, 2019, the Office of Defects Investigation (ODI) opened two Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) to broadly investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model year Hyundai and Kia vehicles.  During the PE investigations, Hyundai and Kia issued several recalls to address vehicle fires, including those due to engine failures involving various engine types.  The remedies for the engine failure recalls typically involve engine inspection (to detect existing damage), and if necessary, engine replacement.  Additionally, both manufacturers have been installing an engine control software modification known as Knock Sensor Detection Software (KSDS) which is intended to detect impending engine failure, alert the driver, and limit engine power (to lessen likelihood of engine failure).KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties (see recall files). On December 22, 2021, ODI upgraded PE19-003 and PE19-004 to this Engineering Analysis (EA21-003, covering both Hyundai and Kia) to evaluate the scope of the prior recalls related to engine failures/fires and the efficacy of the recall remedies for the recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia.  The former issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio.  The latter issue involved approximately 2.5 million recalled vehicles, which have been identified as displaying potential remedy concerns: Hyundai recalls 15V-568, 17V-226, 20V-746, and 21V-727; and Kia recalls 17V-224, 19V-120, 20V-750, and 21V-844. Regarding the recall scope issue, among all of the scope vehicles identified at EA opening, ODI found only the MY 2011 Kia Sorento vehicles equipped with both the Theta II 2.4L 4-cylinder Multi-Point Injection (MPI) and the Lambda II 3.5L 6-cylinder MPI engines experienced relatively high rates of reported fires.  In December 2023, Kia issued recall 23V-877 that will cover about 80,000 MY 2011 Kia Sorento vehicles equipped with the Theta II 2.4L MPI engines.  The remedy will involve an inspection, and if necessary, a replacement of the engine, as well as the installation of KSDS.  It should be noted that in 2021 these vehicles were included in a KSDS product improvement campaign with warranty extension.  For the MY 2011 Sorento vehicles equipped with the Lambda II 3.5L engines, ODI believes that future engine failures/fires involving these vehicles will likely be due to a lax in adhering to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue. Regarding the issue of the efficacy of the recall remedies, ODI found the majority of the recalled Hyundai and Kia vehicles, by model, experienced lower reported fire rates after the remedies were applied.  Furthermore, ODI found that for most vehicles that did not receive the recall remedies, by model, experienced relatively high fire rates.  To address this problem, Hyundai informed ODI in December 2023, that it will renotify all of its owners covered by the Hyundai recalls of engine failures/fires every 8 months for the next 3 years.  In December 2023, Kia stated that it will renotify the majority of its owners every 8 months for the next 3 years.Several previously recalled Kia models are excluded from the renotification due to their lower reported rates of engine fires.  Overall, the renotification actions will help to increase the recall completion rates, thus reduce the frequency of engine fires in the future. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI is closing this Engineering Analysis.  Also, both companies have been released from the 2020-iniated Consent Orders (Kia since November 2022 and Hyundai since November 2023).  The agency reserves the right to take additional action if warranted by future circumstances.  To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

Webwas deiving down the road and flames started shooting from underneath the hood we stopped car jumped out and looked back an whole front of car was on fire it burnt most of car

NHTSA ID

11755573

Incident

Jul 25, 2026

I am filing this complaint regarding Kia America's arbitrary denial of coverage for a suspected connecting-rod-bearing failure in my 2014 Kia Rio (85,000 miles). The vehicle exhibits classic symptoms of the Gamma 1.6L GDI defect: excessive oil consumption (bone-dry after ~1,200 miles post-January 2026 shop oil change), flashing CEL, and loud rod knock after oil starvation. Kia corporate denied all extended warranty/campaign relief on 03/18/2025, stating the powertrain warranty expired in 2019 and "no campaigns" apply. This is inconsistent and deceptive: -U.S. Litigation: Early complaints and law-firm summaries in In re: Hyundai and Kia Engine Litigation II (C.D. Cal., 8:18-cv-02223) and related MDL explicitly referenced 2012–2019 Kia Rios with 1.6L Gamma GDI for the exact defect (oil burn → bearing failure → seizure/fire risk). However, Kia negotiated to exclude Rios from the final E2 Class Vehicles list (see kiaengineclasssettlement.com FAQ #6), limiting relief to Souls and select others despite the identical engine family. -Canadian Precedent: The McKenzie Lake/Strosberg class action explicitly includes 2012–2017 Kia Rios with Gamma 1.6 GDI for the same issues, providing inspections/repairs—proving the defect transcends model badging. -Safety & Consumer Impact: This selective denial violates Magnuson-Moss (unreasonable warranty conditions) and constitutes deceptive trade practices, as Kia advertised these engines as reliable while knowing the failure mode. I request: immediate investigation, compelled goodwill repair (or full engine replacement), and documentation of how Kia limited Rio coverage in settlement negotiations. Attached are all supporting records.

NHTSA ID

11725736

Incident

Mar 13, 2026

I tried to get the parts fixed from the recall. However, when I tried to get it serviced I was adviced that the parts would take a few weeks to arrive. With an appending move to Helena, Mt from Lambertville, Mi they informed me that they would not be able to fix the recall issues. There is no KIA dealership within a reasonable distance from my current location. I am having issues with the dealership towing the rio without charging me the amount of $1300. The engine had completely stopped. I towed the car from Michigan to Montana with a Uhaul because of the recall issues.

NHTSA ID

11661646

Incident

May 7, 2025

The engine started to lose power, and the check engine light illuminated. The power drop was most noticable when accelerating from a stop. At times, randomly, the engine RPMs would dip down to 200-300 at idle and would almost stall. Upon further investigation, the engine has been excessively consuming oil. I brought the vehicle to a local mechanic shop to get a detailed diagnosis, they informed me the catalytic converter was clogged and constricting exhaust flow. The engine has developed a ticking/knock. The catalytic converter, and an O2 sensor was replaced with that visit. The ticking/knock persists.

NHTSA ID

11651826

Incident

Feb 1, 2025

Driving to work I exited US-26 in Hillsboro, Oregon at the 185th exit. The exit is an uphill ramp with a traffic signal at the top of the hill. The traffic signal at the end of the ramp was green. I was following a Tesla Model Y and I saw the brake lights activate. I applied my brakes causing my car to slow down and then I had to proceed through a yellow light because I did not think I could stop safely without ending in the intersection. At the next traffic signal, I rolled down my window and yelled to the other driver to not apply their brakes when they are proceeding uphill through a green light. The other driver told me it is "regenerative braking." Unnecessary braking causes disruptions in the flow of traffic. It does not make sense that brake lights would activate if the driver is not applying the brakes.

NHTSA ID

11610720

Incident

Aug 25, 2024

The contact owned a 2014 Kia Rio. The contact stated that the vehicle was taken to a dealer where it was serviced under NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic). After the recall remedy was completed, the dealer provided documentation indicating that engine rods #3 and #4 were failing and could soon cause the engine to explode if not immediately repaired. Approximately 2 weeks later while the daughter was driving at approximately 70 MPH, the vehicle began to decelerate and emit smoke from underneath the hood. The driver was able to coast to the side of the road and safely exit the vehicle as it caught on fire. The fire department arrived on the scene and extinguished the fire. A police report was filed and no injuries were reported. The vehicle was towed and deemed totaled since the fire consumed it. A dealer was contacted. The manufacturer was made aware of the failure and opened a case. The failure mileage was 133,223.

NHTSA ID

11592161

Incident

May 28, 2024

Mileage

133,223 mi

The contact owns a 2014 Kia Rio. The contact received notification of NHTSA Campaign Number: 23V652000 (Service Brakes, Hydraulic) however, the part to do the recall repair was not yet available. The check engine warning light was illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the failure. The failure mileage was approximately 95,000. VIN tool confirms parts not available.

NHTSA ID

11578079

Incident

Mar 18, 2020

Mileage

95,000 mi

hydraulic electronic control unit HECU fire risk Kia recall sent a letter they would repair, never called so I have called many times, keep repeating no repair part, an excuse

NHTSA ID

11573284

Incident

Nov 14, 2023

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION: CYLINDER PROTECTOR & DECAL INSTALLATION (CS2311) - 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) are not able to 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 that are not equipped with an immobilizer, 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.

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.

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.

CUSTOMER SATISFACTION CAMPAIGN: POSTCARD OWNER RENOTIFICATION (CS2311) - This document is the owner renotification advising that Kia is conducting Customer Satisfaction Campaign. Kia has developed a new zinc-reinforced ignition cylinder protector hardware upgrade and can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Prior notifications stated that this modification had to be performed by July 1, 2025, but the subject vehicles are now eligible until March 31, 2027, to have the ignition cylinder protector installed—if requested—at no cost through an authorized Kia dealership. (Mailing of these notifications to vehicle owners will be completed from December 19, 2025 through December 31, 2025)

TECHNICAL SERVICE BULLETIN: CUSTOMER SATISFACTION: THEFT DETERRENT IGNITION CYLINDER PROTECTOR AND DECAL INSTALLATION (CS2312) - This bulletin provides information to install a Theft Deterrent Ignition Cylinder Protector on certain 2010-2022MY Kia vehicles outlined on page 19, 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.

CUSTOMER SATISFACTION CAMPAIGN: OWNER NOTIFICATION (CS2312) - This document is the owner notification advising that Kia is conducting Customer Satisfaction Campaign. A software upgrade that addresses the social media theft method has been made available to owners of eligible Kia model vehicles free of charge at authorized Kia dealers since 2023. In addition to the anti-theft software, a new zinc-reinforced ignition cylinder protector hardware upgrade has been developed and can be installed at the ignition cylinder location to provide additional protection against the social media theft method. Because the subject Kia vehicles were not factory-equipped with an engine immobilizer and were previously eligible for the software upgrade, these vehicles are eligible until March 31, 2027, to have the ignition cylinder protector installed—if requested—at no cost through an authorized Kia dealership. (Mailing of these notifications to vehicle owners will be completed from December 17, 2025 through February 27, 2026)