2012 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.

I was driving eastbound in my 2012 Kia Sportage on I-82 just past Benton City MP97 at about 11AM on Monday June 22, 2026, when my engine knocked twice, the red check engine light came on, and I lost power. I pulled over off the road next to a concrete barrier that was beside a rock roadcut. My flashers would not operate, I put it into park, turned off the ignition and immediately noticed the smell of burning oil or rubber. I had 2 half gallon containers of water on my front seat, so I popped the switch, lifted the hood, used the prop rod to hold the hood up as I started dowsing the flames that were popping up on the passenger side of my engine compartment near the firewall. After using both half gallons, I ran to the rear of the vehicle, opened the hatchback, and grabbed a gallon spray bottle of water and brought that back around to the front of the vehicle. By this point the prop rod holding the hood was bending and the flames were popping back up, I pumped the sprayer and directed a stream of water with my left hand and used my right to hold up the hood as the prop rod was not working. After the fire was completely out, I returned to the rear of the vehicle, donned my reflective vest, put a portable flasher on my vehicle, and at this point a Benton County fireman in a pickup arrived - he was called by a motorist that saw me pulling over with smoke trailing my vehicle. The fireman was followed by a large firetruck and crew. They propped up the hood with a bar and inspected the motor to verify the fire was completely extinguished. They took my information and left. A Washington State Patrol arrived, assessed the scene and offered assistance, but I already had called my wife so he left me to wait for her. He told me I had 24 hours to get the car off the interstate. I had the car towed to my driveway by A&E towing at about 2:30PM. I just realized this morning that I ought to report it to you. I haven't tried to start it, but I'm sure it won't.

NHTSA ID

11746708

Incident

Jun 22, 2026

On XXX, my 2012 Kia Sportage experienced a catastrophic engine failure while traveling on the interstate. The connecting rod failed, breaking through the engine block, causing sudden and sever oil leak and heavy smoke. The safety of the occupants was put at risk due to the sudden powefr loss in high-speed traffic. This vehicle has two active federal safety recalls, SC200 snd SC 284, which are unrepaired. After the vehicle was towed to Auffenberg Kia in Cape Girardeau, MO I experienced an unreasonable delay of atr a mininum of 2 weeks or more before they could assess the damage, and they refused to provide a loaner vehicle while I was left without transport. Futhermore, they have stated they will not assist with anything until the inspection is complete and the exact cause of failure is determined.

NHTSA ID

11744253

Incident

Jun 9, 2026

The contact owns a 2012 Kia Sportage. The contact stated while attempting to open to the front driver's side door from the inside of the vehicle, the contact heard an unknown part inside the door fall, and the door required to be opened manually by pulling on the exterior door handle. A dealer was contacted. The vehicle was taken to the dealer, where it was inspected, and the contact was informed that the vehicle would not be repaired unless the manufacturer contacted the dealer. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 103,841.

NHTSA ID

11701684

Incident

Nov 26, 2025

Mileage

103,841 mi

The car experienced sudden engine failure, flashing check engine light. The car was towed to the nearest mechanic and knock sensor code P1326, consistent with recall 20V750, was present. Kia Corporate refuses to authorize inspection and repair under the recall because the code was cleared after the event in order to get it towed to the dealer. The defect clearly matches the recall condition, but Kia is declining inspection in violation of recall obligations. Car has been maintained with regular oil changes at the scheduled intervals for the duration of it's life.

NHTSA ID

11695866

Incident

Oct 23, 2025

VIN# [XXX] My recall has not been repaired because Kia claims the repair parts have not been made available to them yet. This recall is from Sept. 2023. Why hasn't this been taken care of yet? Ridiculous & DANGEROUS!! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11680046

Incident

Aug 12, 2025

I was sold this car in April 2025. June 29 2025 my engine stopped working. Confirmed it is entirely blown. I was unaware of open unaddressed recalls when I purchased the car. Because of the recalls not being addressed by previous owners, kia and the warranty company refused to fix the engine.

NHTSA ID

11670845

Incident

Jun 29, 2025

there were no warning lamps/lights/messages prior to the failure. I have been begging Kia Car pros Glendale to repair my engine since May 27 2025 as it qualifies under the settlement. I have requested in writing a response but they continue to use stalling tactics only calling me to convey they need the first 13,000mile oil change now. I have pictures and video timestamped I have documents to prove no negligence on my part for repairs and oil changes. I am a disabled veteran who lives on a mountain in a fire prone area. I have a service dog. I am not trying to endange my life, my service dogs or my neighbors. Email dated 21 June 2025: , I want to reiterate the full scope of documentation and context we have already provided in support of this case. To date, we have submitted: Over a decade of detailed maintenance and service records, covering 2012 through April 2023, demonstrating consistent oil changes and routine and meticulous upkeep; Confirmation that the KSDS upgrade was installed by Kia Glendale on June 6, 2022, and was fully operational at the time of failure; Proof of an oil change on March 7, 2025, at 98,798 miles; Photographic and video documentation dated March 27, 2025, showing the vehicle at exactly 100,000 miles with no check engine lights, warning indicators, or abnormal engine noise; A clear timeline showing that, just five weeks later on May 6, 2025, the vehicle experienced a sudden catastrophic engine failure at approximately 101,000 miles—despite having had an oil change only weeks earlier. For your convenience, we have re-sent all supporting documentation in case any records were misplaced during what has now become a significantly drawn-out process. Importantly, the vehicle owner did not continue driving after any warning light appeared. They immediately pulled over and had the vehicle professionally towed, demonstrating responsible action at every turn.

NHTSA ID

11668822

Incident

May 26, 2025

The car has been giving off a burning smell each time that I begin to drive especially if the heat is being utilized. The smell worsens as I drive a further distance.

NHTSA ID

11655352

Incident

Apr 18, 2025

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.