2011 Kia Sportage

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.

The National Highway Traffic Safety Administration (NHTSA) received a letter dated July 13, 2022, petitioning the Agency to initiate a safety defect investigation into loss of motive power allegations attributed to oil drain pan assembly failures on certain Hyundai Motor America, Inc. and Kia America, Inc. vehicles spanning Model Years (MY) 2005-2021. The Petitioners cited examples of complaints indicating that the subject vehicles were experiencing rapid loss of engine oil due to oil drain plug back outs, resulting in loss of motive power and/or catastrophic engine damage. Additional complaints were provided which alleged that the oil drain pans lack sufficient structural integrity and are susceptible to cracking. The petition itself can be reviewed at NHTSA.gov under ODI number 11481745. On September 12, 2022, the Office of Defects Investigation (ODI) opened Defect Petition (DP22-003) to evaluate the Petitioners’ request. The Petitioners have provided additional complaints within four supplemental letters dated January 31, 2023, March 21, 2023, May 23, 2023, and August 4, 2023. ODI’s evaluation included the review and analysis of the complaints and supporting information submitted by the Petitioners, as well as additional complaints submitted directly to NHTSA which referenced either the oil drain plug or a crack in the oil pan. After reviewing the available data, ODI has not identified evidence that would support opening a defect investigation into the oil drain pan assemblies of the subject vehicles. Based on a review of the available information, a loss of motive power resulting from an oil drain plug back out has not occurred between the initial sale of a vehicle and the completion of its first oil change. If during an oil change service, a technician fails to remove the existing drain plug gasket before installing a new gasket, it is likely that a proper seal between the drain plug and the oil pan will not be made. An improper seal between the drain plug and oil pan could lead to the backing out on the drain plug, resulting in the sudden loss of oil while driving. Additionally, the provided examples of oil pan cracks were localized to the immediate vicinity of the oil drain plug and/or appeared to be the result of direct-contact with a tool during servicing.  There is no information to support that a vehicle-based defect exists relating to the oil pan assembly, and instead the documented incidents are related to the failure to follow the proper maintenance procedures during oil change service. In October 2023, Hyundai published a Technical Service Bulletin (TSB) that provided detailed instructions for oil change service on its gasoline powered vehicles, specifically highlighting the need to remove and replace the existing drain plug gasket prior to reinstalling the drain plug. After a thorough review of the material submitted by the petitioner, the information already in NHTSA's possession, and the potential risks to motor vehicle safety implicated by the petitioners' allegations, NHTSA does not believe that a formal investigation is warranted. Therefore, the petition is denied. A Federal Register Notice (FRN) further detailing NHTSA’s reasons for denial of the petition will be published. The reference numbers for the complaints to NHTSA cited by the petitioner can be found in the petition submission documents in the public file for DP22-003. To review those complaints and the additional complaints ODI added to its evaluation which are cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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.

NHTSA opened Recall Query (RQ) 17-003 to investigate the timeliness and scope of Kia?s Theta II GDI engine recall (Recall No. 17V-224), and Kia?s compliance with reporting requirements. On November 23, 2020, the Agency entered into a Consent Order with Kia to administratively resolve NHTSA?s assertions of violations of law in connection with RQ17-003. NHTSA?s assertions included that Kia may be liable for civil penalties on multiple grounds, including that Recall No. 17V-224 was untimely and Kia?s recall report contained certain inaccuracies.Under the Consent Order, Kia agreed to a total civil penalty of $70,000,000. The total civil penalty included a payment of $27,000,000 as a Non-Deferred Amount.Kia also agreed to a sum of $27,000,000 as an Abeyance Amount to be deferred and held in abeyance pending its satisfactory completion, as reasonably determined by NHTSA, of the requirements of the Consent Order.Kia also agreed to a $16,000,000 Performance Obligation Amount to be expended by Kia to fulfill specified Safety Data Analytics Infrastructure obligations. The Consent Order also includes other terms designed to enhance Kia?s safety practices, and requires Kia to retain a Third-Party Auditor who directly reports to NHTSA.Other than RQ17-003, the Consent Order is not intended to affect any other current or future investigation of NHTSA which may involve vehicles equipped with Theta II GDI engines. In particular, Engineering Analysis (EA) 21-003 (which is upgraded from Preliminary Evaluation (PE) 19-004) continues NHTSA?s evaluation of certain performance and design issues relating to the Theta II and other engines.Nothing in the Consent Order discharges Kia from any obligation to comply with the Safety Act or regulations thereunder, including the obligation to carry out recalls in accordance with the law, and to initiate a recall upon any future determination by Kia, or upon any finally adjudicated order from NHTSA, that vehicles equipped with Theta II GDI engines contain a defect related to motor vehicle safety or do not comply with an applicable FMVSS.This RQ is closed. Closure of this RQ has no bearing on the terms of the Consent Order, including Kia's ongoing performance obligations, and does not represent a determination by the agency as to Kia's performance under the Consent Order to date.

Front headlights went out also rear brake lights now I have a problem with brake light and tailgate lamp staying on when car and lights are off. The suspension has had a issue ever since I bought it it makes awful loud noises when driving and especially hitting bumps in road. Passenger front and rear windows won't roll down. Had to replace battery as well. Inside door handles fell off as well as outside rear handles.tire pressure indicator light stays on as well as the park assist and drive train lights stay on.problem with car going in drive sometimes it locks up and have to restart and slam on brakes several times to unlock

NHTSA ID

11745422

Incident

May 8, 2025

The contact owns a 2011 Kia Sportage. The contact stated that while driving 40 MPH, the vehicle went into LIMP Mode. While accelerating to overtake a vehicle driving under the speed limit, the vehicle started to stall. The check engine light was flashing, and the vehicle went into ECO mode. The contact associated the failure with NHTSA Campaign Number: 17V224000 (Engine and Engine Cooling); however, the VIN was not included. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The vehicle was taken to an independent mechanic, where it was diagnosed with a misfire and engine failure due to an oil leak. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 180,000.

NHTSA ID

11744681

Incident

Jun 11, 2026

Mileage

180,000 mi

Update to NHTSA (ODI #11679186) Subject: Update to ODI Complaint #11679186 – Kia America Written Response Body: Dear NHTSA Office of Defects Investigation, I am writing to provide an update to my ODI Complaint #11679186 regarding my 2011 Kia Sportage SX (VIN: [XXX] ), which caught fire while I was driving on [XXX]. On August 27, 2025, Kia America issued me a written response (attached). In this letter, Kia explicitly acknowledged: “Preliminary evaluation results show… the fire originated within the engine compartment area.” “The cause was unknown engine oil leaks allowing motor oil to contact hot exhaust surfaces of the engine that led to ignition.” Despite admitting the fire’s cause, Kia refused restitution, stating that the vehicle was “9 years and 163,000 miles outside of warranty.” I request that this letter be added to ODI Complaint #11679186 and considered in your analysis of Kia vehicle fire trends. I believe this documentation is significant in establishing that Kia recognizes the fire hazard but denies responsibility due to warranty expiration, which does not address the broader safety risk. Thank you for your review and for your ongoing work to protect vehicle safety. Respectfully, Daniel McAdams INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11683570

Incident

May 11, 2025

On [XXX], my 2011 Kia Sportage SX (VIN: [XXX] ) caught fire while I was driving. The vehicle rapidly filled with smoke, causing throat and eye irritation from smoke inhalation. My insurance company declared the vehicle a total loss. Kia America (Case #[XXX]) acknowledged the incident and confirmed that a fire inspection would be conducted. The inspection was completed, but Kia has refused to release the findings or determine the cause. On [insert date], Kia denied my claim without explanation, despite the vehicle being a complete loss due to fire. This is a critical safety issue that could have caused severe injury or death. I am requesting NHTSA investigate the cause of the fire and Kia’s handling of post-incident safety reporting. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11679186

Incident

May 11, 2025

The contact owns a 2011 Kia Sportage. 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 contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue and confirmed that parts were not yet available. The manufacturer was made aware of the issue and confirmed that parts were not yet available. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11647865

Incident

Mar 12, 2025

The contact owns a 2011 Kia Sportage. The contact stated that upon taking the vehicle for the State Inspection, the vehicle failed the Emissions test. The State Inspector diagnosed a failure with the Evaporative Emissions Control System (EVAP). The contact was informed that the system was leaking. The check engine warning light was illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 243,000.

NHTSA ID

11647495

Incident

Mar 8, 2025

Mileage

243,000 mi

I'm [XXX] from Brooks Alberta Canada. I purchased this car from a private seller here in Brooks last [XXX] named “Hein Teresa Lorraine” lives in [XXX], Brooks AB T1R 0R7" and she did not include all the details in her car that it has a recall issue with the engine which is the Knock Sensor Problem. After a couple of days of using it I experience engine malfunction, the oil pressure light is keeps on flickering and as I drove from Brooks going to Calgary the engine suddenly stalled and activates the “Lymp Mode”. I cannot able to move forward and almost hit by a huge truck because of that incident. I coordinated with Straightline Kia Medicine Hat that incident, they check the vehicle and test it, after several testings they proved that the vehicle has a engine recall backjob. The check engine code shows P01326 which is responsible for engine stalling while accelerating. Kia Manager "Kent" talk to me and promise me that he will do all the reports to replace the engine. He submitted the report to the engineering department of Kia for the engine replacement but they declined it due to lack of documentation proof for regular maintenance of the vehicle from the previous owner. I told them that i recently purchased the car and I cannot able to provide the previous oil change done with the vehicle. Unfortunately after 2 weeks of waiting for nothing, Kent refuse to do a follow up report on the said incident and telling me that I need to take my car and need to pay a certain amount for their job done to my vehicle. Even the car rental that they provided I am also shouldering the expense because Kent is insisting that my car is not covered by the warranty anymore. As I do my research it has a lifetime warranty for the Knock Sensor failure for the same Car model. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11631322

Incident

Nov 21, 2024

Mileage

102,063 mi

KIA issue a recall for my vehicle. Visited the dealership as instructed and the replacement part was not available. After a month and a half, they still don't know when they will receive the part. Driving a car with a safety recall (fire possible) is not ideal.

NHTSA ID

11619604

Incident

Aug 28, 2024

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.

PRODUCT IMPROVEMENT CAMPAIGN: OWNER RENOTIFICATION (PI2103 FLIGHT #501) - This document is the owner renotification advising that Kia is conducting an important Product Improvement Campaign to perform a software update on 2011-2013 MY Kia Sportage vehicles equipped with 2.4-liter MPI 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 newly developed computer software for the Engine Control Unit (“ECU”).

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.