2021 Kia Seltos

On August 6, 2025, the Office of Defect Investigation (ODI) opened Audit Query (AQ) 25001 to assess the implementation of Kia America, Inc.’s (Kia) remedy program for Safety Recall 25V099, involving incorrectly manufactured piston oil rings which may damage the engine causing a loss of motive power or fire. This AQ was opened in response to consumer complaints alleging of an ineffective remedy, inconsistent inspection results to determine whether an engine replacement was needed, and the unavailability of recall remedies. On August 11, 2025, an Information Request (IR) was issued to Kia requesting: 1) why the inspection test was revised from requiring a ‘cold’ engine to a ‘warm’ engine; 2) why the recall remedy was suspended from April 30, 2025 to May 7, 2025; 3) how Kia notified customers of the recall remedy suspension and the need to re-test engines that failed the ‘cold’ engine test; 4) the number of post-recall remedy complaints alleging engine or other engine related failures; and 5) the warranty coverage Kia is offering to vehicles that passed either inspection tests. On September 10, 2025, Kia responded to NHTSA’s IR: Kia reported the change in temperature from ‘cold’ to ‘warm’ engine testing was done to increase accuracy. The inspection test uses diagnostic tools that detects abnormal engine vibrations to identify damaged engines. From the initial launch of the Technical Service Bulletin (TSB) on April 4, 2025 through April 28, 2025, ‘cold’ engine testing resulted in a higher-than-expected failure rate when compared to the pre-recall warranty claim rate. This discrepancy led Kia to re-evaluate its inspection test and found that performing the inspection on a ‘cold’ engine can result in imprecise test results due to normal cold-start vibrations. Kia revised the inspection to ‘warm’ engine testing to minimize vibration interference. Kia sampled the field and performed a comparative analysis between ‘cold’ and ‘warm’ engine testing, and validated that ‘warm’ engine testing was more accurate in identifying damaged engines. Kia also reported the suspension of the recall remedy was due to a software error in the diagnostic tool, which was introduced in concert with the April 29, 2025 launch of the TSB that revised the inspection from ‘cold’ to ‘warm’ engine testing. The software error resulted in all inspection tests reporting false positives for a damaged engine. On April 30, 2025, Kia suspended the remedy until May 7, 2025, which was when the software error was corrected with the release of the latest TSB and software update. The recall remedy remains available to eligible customers. Kia reported owners were not mailed letters concerning the suspension to the recall remedy. Kia reasoned since it resolved the issue faster than it would have taken to draft and mail letters, Kia did not want to create unnecessary customer confusion involving an issue that would have already been addressed upon receipt of a letter. Kia also determined that mailing letters about re-testing engines was unnecessary since those vehicles were already at the dealer awaiting engine replacement. In most instances, Kia Customer Care agents would respond to customer inquiries related to the recall, including remedy availability, dealer issues, and questions about differing test results. Kia provided ODI a review of engine related consumer complaints received on post recall-remedied vehicles. Kia did not find any common patterns or trends related to those complaints following completion of the recall, as the complaints included issues that were unrelated to the subject defect. To aid in the diagnosis of whether a complaint is related to the recall, the remedy includes the installation of a software program, the Piston-ring Noise Sensing System (PNSS), that monitors the engine for unusual noise patterns (an indicator of potential damage to the piston oil rings), and alerts the customer by flashing the check engine light and setting Diagnostic Trouble Code (DTC) P1327. Kia confirmed that it is not offering any specific warranty coverage for this recall. Instead, Kia has instructed dealers to replace the engine, at no cost to the customer, with no time or mileage limitation, following the installation of the PNSS software and the presence of DTC P1327. On September 4, 2025, Kia issued Subsequent Repair Action (SRA) # SC336YZ, which provided engine diagnosis and replacement instructions for vehicles with a potentially related complaint following completion of the recall. Under this SRA, customers whose vehicles set DTC P1327 will have their engine replaced. If DTC P1327 is not set and it is unclear whether the issue is related to the recall, dealers are instructed to contact Kia's Technical Assistance Center to ensure the issue is appropriately handled. Kia notes that any issues determined to be unrelated to the recall are subject to the 10-year / 100,000-mile Powertrain warranty for original purchasers and a 5-year / 60,000-mile Limited Basic Warranty for subsequent purchasers. In summary, Kia identified the insufficiencies of its initial inspection test that led to a pause to its recall campaign, explained why it did not mail letters to affected customers about the paused campaign or revised inspection test, reviewed existing consumer complaints that did not identify any potential trends related to the recall, and identified its warranty coverage for any vehicles exhibiting qualifying engine symptoms. After review of Kia’s response to the IR, ODI has determined that no further action from Kia is necessary at this time, and ODI will close this AQ investigation accordingly. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The contact owns a 2021 Kia Seltos. The contact stated that while driving at 45 mph the engine experienced a complete loss of automotive power, and no warning lights were illuminated. The vehicle was towed to a local dealer where it was diagnosed and the contact was advised that the engine was faulty and needed to be replaced. The contact associated the failure with NHTSA Campaign Number : 25V099000 (ENGINE AND ENGINE COOLING). The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 120,000.

NHTSA ID

11755100

Incident

Jul 4, 2026

Mileage

120,000 mi

While driving normally at approximately 55 mph on the highway, the vehicle suffered a sudden, catastrophic, and spontaneous structural failure of the rear driver-side suspension and drivetrain. Without striking any road debris, potholes, or other vehicles, the entire driver-side rear wheel, wheel assembly, and structural axle components completely fractured and ejected from the moving vehicle. An eyewitness at the scene explicitly confirmed the nature of the failure, stating on video that they observed the 'entire rear axle just come right out' while the vehicle was in motion. The vehicle sustained extreme structural damage, completely disabling it on a high-speed highway and creating an immediate, life-threatening situation. The vehicle is a low-mileage Certified Pre-Owned (CPO) unit with under 24,000 total miles on the odometer, indicating a severe manufacturing, material, or component fatigue defect rather than wear-and-tear. There were no warning lights or symptoms prior to the failure. The vehicle is currently being held at a recovery yard and is fully available for inspection upon request. A formal defect investigation has been initiated with the manufacturer, and the insurance provider is inspecting the sheared axle and metal components for structural forensic analysis

NHTSA ID

11754636

Incident

Jul 30, 2026

The contact owns a 2021 Kia Seltos. The contact stated that on March 13, 2026, the vehicle was serviced under NHTSA Campaign Number: 21V259000 (Engine); however; the spark plugs were not replaced when the vehicle was repaired. The vehicle was taken to the dealer, where it was diagnosed with a misfire in the engine associated with the spark plug. The dealer stated that the failure was not associated with the recall. The contact stated that the failure was caused by the dealer not installing new spark plugs during the recall repair. The manufacturer was made aware of the failure and stated that the recall repair was performed and was out of warranty. The failure mileage was approximately 92,000.

NHTSA ID

11753845

Incident

Jul 5, 2026

Mileage

92,000 mi

The contact owns a 2021 Kia Seltos. The contact stated that while driving at an undisclosed speed, there was an abnormal sound coming from the vehicle with the check engine warning light illuminated. The contact received notification of NHTSA Campaign Number: 25V099000 (Engine and Engine Cooling). The vehicle was taken to the dealer, where it was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The contact was informed that while the technician was attempting to start the vehicle, the engine seized, and the contact was informed that the failure was not associated with the recall. The manufacturer was made aware of the failure, and a case was filed. The vehicle was scheduled for a diagnostic test at the dealer. The failure mileage was approximately 77,500.

NHTSA ID

11753695

Incident

Jul 23, 2026

Mileage

77,500 mi

Purchased new, Feb, 2020. Received piston ring defect recall notice (SC209). Serviced by dealer July, 2021. In 2025, noticed engine knocking noise. Car stalling out. No warning lights. Car 3 quarts low on oil. Consumption tests proved excessive oil used. Piston ring soak (Kia's "solution") did nothing to reduce oil use. After ring soak, oil still low at 1000 mile test. I stressed my belief the engine needs replacement and a ring soak is a band aid, NOT a permanent fix. Was asked to drive 3000 miles, check the oil, and top off if necessary. The engine was noisy during this test. At the 3000 mile mark, I pulled the dipstick. Bone dry. Drove to the dealer and told them it was very low. They sent me to the lounge and said they would pull the car in and come get me. When they didn't come, I went to check, to find a service rep putting oil in my car out in the parking lot. He claimed it was only about one quart low. Then, another consumption test at 1000 miles. Low again. They wanted to do another 1000 mile check after this. They changed the oil and told me to come back at 1000 miles. When I came back, I asked to be present to witness the oil level. They took me to the lounge, said they were pulling the car into the shop, and would come get me. Again, they pulled the stick without my presence, and told me it was full. Now, they want me to do another 4000 mile test. I took the vehicle to two independent mechanics. Their borescope inspection proved engine damage. I have filed a complaint with Kia Corporate and it seems to be falling on deaf ears. I demand a full refund at this point! Kia has lost my trust, both in quality and customer service. I have all the maintenance records and a written statement regarding engine damage, along with photos from the borescope.

NHTSA ID

11753530

Incident

Aug 29, 2025

Car cutoff. Started back up to get off interstate. Saw smoke under hood and got it. Within 5 min sparks under the frame and then 10-15 min later flames

NHTSA ID

11753443

Incident

Jun 30, 2026

After getting recall work done last year regarding SC336 my sensor went off and now my car needs a new engine due to defective heat-treated Piston oil rings causing Catastrophic failure. Kia is declining responsibly because of lack of enough oil changes. They have not proved this failure was from neglect.

NHTSA ID

11753056

Incident

Jul 18, 2026

Just purchased a used 2021 KIA seltos with about 45k miles. I did my research and checked prior if there were any major issues. Since it showed zero recalls and received relatively good reviews I thought it would be a safe and reliable vehicle. I was wrong.I had the vehicle for only about three months when I noticed the check engine light come on while driving on the freeway. It was solid, however, I thought it was better to be safe than sorry and started to look for an exit. While driving up a freeway interchange the car suddenly started to lose speed. I pressed the accelerator but couldn’t get any power to the engine. As the car started to slow rapidly I pulled over to a narrow strip of the road. This was a dangerous stretch of the freeway because there was virtually no shoulder and cars were accelerating to merge up the rising ramp on the stack. After I came to a stop I put the car in park and turn it off. I then tried to restart the engine but had no luck. The engine would crank but would not start. I was now stuck and getting anxious as traffic began to steadily increase. Cars were flying by at high speeds less than a foot away. I had no choice but to call for a tow truck and patiently wait. I sat there praying that nobody would hit my car. I was fortunate to be safely towed to a service center.The technician performed a borescope and found severe scoring on the cylinder walls directly relating to defective piston rings. The improperly heat-treated piston rings chipped and literally carved deep grooves into the block dropping the compression causing the car to sputter and die.The engine has internal damage and will not start. Needs a new long block (Engine replacement). There is a recall on these piston rings.The dealership sent in their inspection including compression test and borescope images showing the groves and scoring on the cylinder walls. KIA is refusing to cover cost because the car is out of warranty. Safety recalls never expire with warranty!!!!!!

NHTSA ID

11752762

Incident

Jun 22, 2026

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: INFOTAINMENT SYSTEM SOFTWARE UPDATE USING UPDATE.KIA.COM - This bulletin provides information and service procedures for updating the infotainment systems on applicable Kia vehicles using the Kia Navigation Updater available at update.kia.com. The software update may improve system performance, enhance existing features, and apply the latest operating software for supported vehicles (2021-2026MY All Models).

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER RENOTIFICATION (SC199 FL301) - This document is the owner renotification advising that Kia is conducting Voluntary Service Campaign to update the software programming on the Transmission Control Module (TCM) and, if necessary, replace the Intelligent Variable Transmission (IVT) on certain 2021 MY Seltos vehicles.

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)

PITSTOP: TECHNICAL OPERATIONS: EXTERNAL DAMAGE TO ULTRASONIC SENSOR: This Pitstop provides information related to Parking Distance Warning (PDW) alerts and repairs involving ultrasonic sensors. The PDW system alerts the driver while parking, by calculating distance based on the difference in signal transmission and reception times between the vehicle (ultrasonic sensor) and an object. The membrane film of the ultrasonic sensor is used for object detention and can be damaged by stone chips or foreign substances while driving. Damage to the cover of the ultrasonic sensor can also lead to damage to the internal circuit. As a result of this external damage, the PDW system may not receive the proper signal from the ultrasonic sensor. In some cases, the system may cause a false alarm, no alert, or phantom warnings by a “Warning Lamp’ to be displayed on the cluster. The ultrasonic sensor membrane film should be always inspected for external damage and if any part replacement should be treated as a general repair, not as a warranty claim repair for this concern. (Please note that this Pitstop only applies to models/trims that are equipped with the ultrasonic sensors.)