2022 Kia Soul

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.

My 2022 Kia Soul (VIN: [XXX], ~57,000 miles) is subject to Safety Recall 25V-099 (SC336) for defective piston oil rings causing rapid oil loss, engine noise, stalling, seizure, and fire. On XXX, my vehicle suffered severe engine rattling and was towed to Kia of Frisco (TX). Technicians physically inspected it and documented two critical findings: 1. The oil pan was completely dry/empty. 2. The engine exhibited heavy carbon buildup in the combustion chamber. The vehicle was 1,000 miles UNDER its maintenance interval, with the previous service done at this same dealership. A dry oil pan and carbon fouling are direct physical proof of defective piston rings allowing oil to burn rapidly. REMEDY FAILURE & FALSE NEGATIVE: Despite documenting a bone-dry oil pan and carbon fouling, the dealership ran Kia's PNSS sound/vibration test, which yielded a false "pass." Based on this false negative, Kia of Frisco and the regional DPSM formally refused on XXX, to authorize recall engine replacement. Instead, they are forcing me to drive this internally damaged, oil-starved, rattling vehicle on public highways for a 1,000-mile oil consumption test. SAFETY HAZARD & AUDIT AQ25001: Ordering a consumer to drive an oil-starved, rattling engine on public roads creates an immediate hazard of high-speed engine failure or fire. Kia Consumer Affairs refuses to transfer calls, leaving me stranded with out-of-pocket rental costs. This directly demonstrates the flaws investigated under NHTSA Audit AQ25001 regarding unreliable 25V-099 recall protocols. I request the NHTSA investigate Kia for issuing false-pass inspections and forcing consumers to operate severely compromised, fire-risk vehicles. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11774659

Incident

Oct 19, 2026

The contact owns a 2022 Kia Soul. The vehicle was previously repaired under NHTSA Campaign Number: 25V099000 (Engine and Engine Cooling); however, the dealer only inspected the engine and had not installed the piston-ring noise sensing system (PNSS) software, free of charge. The contact stated that the failure had occurred after the recall repair. While driving 45 MPH, the vehicle made an abnormal clicking sound and failed to accelerate, and there was an abnormal smoke odor. Several unknown warning lights were illuminated. The vehicle was towed to the residence and then to an independent mechanic, who determined that the engine had failed. The vehicle was then towed to a second dealer, DeMontrond Kia (14101 N Fwy Service Rd, Houston, TX 77090); however, the contact was informed that manufacturer authorization was required to perform the recall repair again under NHTSA Campaign Number: 25V099000 (Engine and Engine Cooling). The manufacturer was notified of the failure by phone. The failure mileage was approximately 100,000.

NHTSA ID

11774399

Incident

Sep 1, 2025

Mileage

100,000 mi

The contact owns a 2022 Kia Soul. The contact stated that the vehicle was previously repaired under NHTSA Campaign Number: 25V099000 (Engine and Engine Cooling); however, the engine was not replaced under the recall. While the contact's wife was driving 10 MPH, the vehicle started sputtering. The vehicle later lost motive power while the contact was driving. Upon inspection, the contact discovered there was no engine oil inside the engine. The vehicle was taken to O'Reilly's and diagnosed with a cylinder #3 misfire. The vehicle was taken to the dealer, who performed an oil change, but after 3,000 miles there was no oil in the engine. The check engine warning light illuminated. The vehicle was taken back to the dealer several times for oil consumption tests, and the spark plugs were replaced; however, the contact was informed that the engine could not be replaced under recall because the engine oil level was full at inspection. The manufacturer was notified of the failure by phone. The failure mileage was approximately 33,000.

NHTSA ID

11772606

Incident

Feb 1, 2026

Mileage

33,000 mi

My 2022 Kia Soul was previously serviced under Safety Recall SC336 (NHTSA Campaign 25V099000), and the dealership only uploaded the monitoring software. The safety recall remedy has now completely failed. The software's warning triggers are active: the oil light is flashing, the check engine light is flashing, and the engine is vibrating violently and failing to run. The manufacturer's remedy did not fix the physical defect, and the car is now dangerously disabled."

NHTSA ID

11771506

Incident

Oct 7, 2026

The paint above the windshield is peeling.

NHTSA ID

11770368

Incident

Jun 14, 2024

The paint above the windshield is peeling off.

NHTSA ID

11770367

Incident

Jun 14, 2024

Jake Sweeney Kia opened a repair order for Safety Recall SC336 on my 2022 Kia Soul at 8:00 AM on Wednesday. At 3:10 PM the exact same day, they finalized the ticket with a 'PASS' result and issued an invoice. The manufacturer’s official Technical Service Bulletin for Campaign SC336 explicitly mandates a 24-hour overnight cold engine soak before the PNSS acoustic test can be executed. The dealership completely bypassed this federal safety mandate, testing a warm engine in only 7 hours, and uploaded closed-out safety data to the manufacturer network to wipe the open recall from my VIN.

NHTSA ID

11769794

Incident

Oct 7, 2026

Engine oil light came on and went to take in to get an oil change though it had 1000 miles or so to go. Had oil change but light did not go out, and service said to get it diagnosed at mechanic. Made an appointment and car then driven by my daughter stalled when entering the freeway. The car started and I had her drive it home. I tried it the next day and had no problem other than lack of power. At the car appointment, stated that it looked like a National Safety Recall problem and to take it to Kia for the problem. At Kia, they said there were a number of recall's that the fixed on the vehicle, but the safety recall for the engine did not apply as they didn't "hear" anything. They agreed it was losing power and it stalled when coming to a stop, turning and or accelerating. They said for $250 they could run a diagnostic. Having already done that with a trusted mechanic, I seemed at a loss on what to do. I had another mechanic look at it with the same recommendation that it was a recall problem and engine should be replaced.

NHTSA ID

11769676

Incident

Jun 25, 2026

TECHNICAL SERVICE BULLETIN: MISFIRE CONCERN DUE TO OVERRUNNING ALTERNATOR DECOUPLER - This bulletin provides information to address unresolved misfire events on some 2020–2024MY Forte (BDm) produced from January 1, 2019 through September 30, 2024, and 2020–2022MY Soul (SK3) vehicles produced from November 1, 2018 through May 31, 2022 equipped with a Gamma 1.6L T‑GDI engine. In certain cases, misfire symptoms may persist after completing normal diagnostic procedures and replacing ignition‑related components (spark plugs, ignition coils, and fuel injectors). If misfire concerns remain after these repairs are performed, excessive torsional oscillation of the Overrunning Alternator Decoupler (OAD) pulley may be the contributing factor. This bulletin provides the procedure to replace the OAD pulley with the updated Overrunning Alternator Pulley (OAP) kit and associated damper components.

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: KEY AND CYLINDER SET REPLACEMENT - This bulletin provides information to replace the driver’s door lock and trunk lid key cylinders on some 2019-2024MY Kia vehicles listed below. On affected vehicles, the stored key code may not correspond to the mechanical key profile, which can result in incorrect key cutting when the original key is lost or damaged.

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).

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.