2016 Kia Soul

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.

The engine long-block assembly suffered a catastrophic, terminal internal collapse and sudden stall due to abrasive substrate particle ingestion from a previously failed, melted manifold catalytic converter under Safety Recall SC176 (NHTSA Campaign 19V120000). The vehicle has been extracted to preserve evidence and is available for immediate physical inspection. The vehicle suffered a complete, sudden loss of motive power and stalled while traveling at high speeds on a busy public highway. It went into an un-accelerated limp mode, creating an immediate hazard of a high-speed rear-end collision on the highway shoulder. Authorized franchise facility Garden Grove Kia officially confirmed the terminal block failure under Repair Order #6238999. A diagnostic scan confirmed multi-cylinder misfires (P0300–P0304). A physical compression test confirmed a terminal drop to 59.6 psi in Cylinder 2, and an internal camera borescope confirmed a catastrophic internal Cylinder 2 wall crash damage not sealing alongside a fractured spark plug tip inside Cylinder 4. The dealership officially recommended a total engine replacement. The vehicle was inspected by a certified franchise dealer technician representing the manufacturer. A formal enforcement case has been opened regarding this vehicle asset and documentation file with the California Bureau of Automotive Repair (BAR) under Reference Case #669B-C5PDRP

NHTSA ID

11766582

Incident

Jul 7, 2026

Component or system: Catalytic converter (exhaust emissions system). The converter is physically restricted due to substrate damage consistent with the defect identified in NHTSA Campaign 19V120 / Kia Recall SC176. The restriction limits engine RPM to approximately 3,000 under all conditions. The vehicle is available for inspection at any authorized Kia dealership. No DTC is stored because the restriction has not yet degraded catalytic efficiency below the ECU's threshold — the catalyst is still chemically functional but physically blocked. Safety risk: The RPM limitation prevents the vehicle from accelerating past ~3,000 RPM, creating a significant hazard when merging onto highways, passing in traffic, or climbing grades with risk of fire. The recall notice identifies the risk as "abnormal engine combustion and damage to pistons and possible piston connecting rod failure," which can result in sudden engine stall while in motion. The restriction is progressive and will worsen, increasing the likelihood of complete power loss. Reproduced or confirmed by a dealer: The vehicle was inspected at an authorized Kia dealer. The dealer scanned for DTCs, found none, and declined to perform the recall remedy (catalytic converter replacement) on the basis that P0420 had not been stored. The dealer confirmed catilitic converter was clogged.

NHTSA ID

11764798

Incident

Sep 10, 2026

The contact owns a 2016 Kia Soul. The contact stated that the vehicle failed to start immediately and lost motive power while driving. The contact was able to continue driving at reduced power. Additionally, there were abnormal sounds coming from under the hood, excessive engine oil consumption, and a plastic burning odor inside the vehicle. The vehicle was taken to an authorized dealer, where the crankshaft position sensor was replaced; however, the failure persisted. The vehicle was taken to a second dealer, Kia Store Clarksville (826 E Lewis and Clark Pkwy, Clarksville, IN 47129), where Voluntary Service Campaign: SC334 (Service Brakes), Technical Service Bulletin: SA485 (ECM Logic Improvement), and Customer Satisfaction Program: CS2311 (Theft Deterrent Ignition Cylinder Protector & Decal Installation) were performed. The failure recurred, and the vehicle was taken back to the first dealer, who diagnosed that the catalytic converter had melted. The vehicle was then taken back to Kia Store Clarksville, where it was diagnosed that the catalytic converter had melted, the engine cylinders were scored, and the pistons had failed; however, no diagnostic trouble codes (DTCs) were retrieved as required for engine and catalytic converter replacement. The contact associated the failure with NHTSA Campaign Number: 19V120000 (Engine, Engine and Engine Cooling); however, the VIN was not included in the recall. The manufacturer was notified of the failure, and a case was filed. The failure mileage was approximately 139,500.

NHTSA ID

11764721

Incident

Aug 2, 2026

Mileage

139,500 mi

My car is under 130000 miles and about two years ago I already had to replace one catalytic converter. The past six months the oil usage of my car, which has always been high and requires frequent topping off and more frequent oil changes at my mechanic, has gotten even worse. A check engine light came on a few weeks ago due to a catalytic converter fault. While car is still functional my mechanic expects the second converter will have to be replaced soon. These are all signs of an engine and system that is not functioning properly and could cause an issue at any time.

NHTSA ID

11764698

Incident

Sep 3, 2026

On December 4, 2025, I presented my vehicle to Kia Carriage of Woodstock with the following symptoms: • Continuous check‑engine warning • Rattling engine noise • Oil leakage • Strong burning‑oil smell while driving These symptoms are consistent with rod bearing failure, a known Kia safety defect covered under the extended warranty and KSDS settlement. Kia’s own records confirm: • KSDS update completed on 4/10/2021 • Vehicle qualifies for the 15‑year / 150,000‑mile extended warranty • Rod bearing failure requires full engine replacement under warranty Despite this, the dealership refused warranty coverage and attempted to charge me $6,000 for an engine replacement, while also charging $300 for a diagnostic that did not resolve or address the safety issue. --- Dealer Misconduct and Warranty Avoidance Kia Carriage of Woodstock engaged in the following misconduct: • Refused to honor the extended warranty • Returned the vehicle in unsafe condition • Attempted to upsell me into purchasing another vehicle • Sales manager admitted the car “was not pumping oil” and that this was “a Kia problem” • Still refused warranty repair This behavior is predatory, unsafe, and violates Kia’s warranty obligations. --- Consumer Affairs Contradictions and Failure to Escalate On August 11, 2026, I opened Case No. 263276699. On the phone, a Consumer Affairs representative initially confirmed my vehicle is under warranty. After I referenced the denial letter I received, the representative changed her position and stated the rod bearing failure “is not covered,” citing a “multi‑point inspection” from December 2025. A multi‑point inspection does not diagnose rod bearing failure and cannot be used to deny warranty coverage. Consumer Affairs has: • Provided contradictory information • Refused to escalate the case • Relied solely on the dealership’s statements • Failed to address a clear safety hazard This is unacceptable and requires executive intervention. --- Current Statu

NHTSA ID

11764497

Incident

Dec 4, 2025

Was driving car lost power of steering and brakes black smoke filled vehicle I jumped out of the car and it went up in flames . The vehicle behind me said the flames were coming out of my front engine

NHTSA ID

11763887

Incident

Sep 4, 2026

Whistling noise and problem with acceleration over 35mph and drifting uphill. Although VIN number did not appear on the listed recall, the repair work recommended and partially completed by Kia repair dealer points directly to the description of an oil consumption problem that includes the 2016 Kia Soul. Some repairs done at Kia XXX and some done at Scott Kia in [XXX] (where I reside). INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11763808

Incident

Jul 31, 2026

I have a white 2016 Kia Soul Exclaim with 55,150 miles on it. About 3 months ago the paint started bubbling around the panoramic sunroof and has peeled off showing the gray undercoating. Ive read that this is an ongoing issue. I am the original owner and would like to have this issue fixed.

NHTSA ID

11762841

Incident

May 15, 2026

VOLUNTARY SERVICE CAMPAIGN: OWNER RENOTIFICATION (SC334 Flight 201) - This document is the owner renotification advising that Kia is conducting a Voluntary Service Campaign to inspect and, if necessary, replace the brake line(s) in certain 2014-2019 MY Soul vehicles that were originally sold in or are currently registered in states where heavy amounts of road salt are used. In addition, an anti-corrosion material will be applied to the underbody components for added protection.

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: SUBSEQUENT REPAIR ACTION: CATALYTIC CONVERTER REPLACEMENT AND ENGINE INSPECTION/REPLACEMENT (SC176Y) - 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 catalytic converter and engine sub-assembly diagnosis and repair information on certain 2012-2016MY Soul (AM, PS) vehicles produced from July 8, 2011 through August 11, 2016, that previously had the recall campaign SC176 completed. The affected vehicles may exhibit catalyst system efficiency deterioration or a malfunction indicator lamp illumination with an active, history or pending P0420 with or without a P030X misfire DTC.

PRODUCT IMPROVEMENT CAMPAIGN: OWNER RENOTIFICATION (PI2002B FL701) - This document is the owner renotification advising that Kia is conducting a Product Improvement Campaign to perform a software update on 2014-2016 MY Soul vehicles equipped with 2.0L Gasoline Direct Injection (“GDI”) engines to protect the engine from excessive connecting rod bearing damage. The update will be done free of charge and will only involve the addition of this computer software for the Engine Control Unit (“ECU”).

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)

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.)