2020 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.

car and Jen was replaced October 2025 for engine failure 10 months later the engine begin stalling and not accelerating on the highway or on any road so we brought it to our dealership to get it looked at a code came up, which said the engine was in failure . no oke will cover the engine and kia wont stand behind the work that they did

NHTSA ID

11775492

Incident

Aug 26, 2026

My vehicle experienced a catastrophic engine failure, losing power on the roadway. The vehicle is currently located at the Kia dealership, and I have been provided a formal Repair Order showing an active Diagnostic Trouble Code (DTC) P1326. Kia Corporate and the dealership are currently denying coverage under the In re: Hyundai and Kia Engine Litigation Class Action Settlement, claiming that the "VIN shows clean with no open issues." This is a fundamental misinterpretation of Kia's internal database. The VIN shows "clean" because the mandatory Product Improvement Campaign PI1806 (Knock Sensor Detection System / KSDS) was successfully completed on my vehicle on November 13, 2019. I hold physical, printed proof of this completed campaign from a certified Kia dealership. Under the terms of the court-approved settlement and Kia's own Technical Service Bulletins (TSBs): 1. Completion of the KSDS update (PI1806) qualifies the vehicle for a Lifetime Short-Block Warranty Extension against connecting rod bearing failure. 2. An active or history P1326 fault code mandates that the dealership perform a digital Bearing Clearance Test (BCT) and submit a Prior Authorization (PA) package to corporate for an engine replacement. By refusing to look at the historical campaign completion data and denying my claim based on a "closed/clean" status, Kia is actively violating the court-mandated terms of the settlement.

NHTSA ID

11775433

Incident

Oct 10, 2026

Factory Defect: paint and clear coat delamination on 2020 Kia Sportage with less than 10,000 miles and has never been in an accident. Car is bright silver color. Paint/clear coat has started to bubble and peel on the rear spoiler and side mirrors. This is a know issue. • Poor Factory Bonding: The issue typically stems from a failure of the topcoat or clear coat to adhere properly to the underlying primer or e-coat layers. • Common Areas: Peeling frequently starts or spreads on plastic or fiberglass components like rear spoilers and side mirrors, as well as metal surfaces like roofs, hoods, and door handles.

NHTSA ID

11775421

Incident

Oct 15, 2026

On Saturday, XXX, while driving on XXX in [XXX], my 2020 Kia Sportage (2,4 L engine, 152,245 miles) suffered a sudden, catastrophic loss of motive power. The vehicle actively entered Limp Home Mode at high speed, dropping velocity rapidly and creating an immediate traffic hazard that my husband and I stranded 6.5 hours away from home. The vehicle was brought back to [XXX] on Sunday XXX, to Stokes Hodges Kia in [XXX], where a diagnostic scan pulled faulted code P0404. No low-oil pressure warning light or dashboard oil alerts were illuminated prior to or during the failure. The engine suffered a sudden internal mechanical failure directly relating to the vehicle's progressive, severe internal oil consumption defect, causing a severe highway safety hazard. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11774277

Incident

Oct 24, 2026

"While driving to work and actively attempting to pass another vehicle, the battery light suddenly illuminated out of nowhere. A short time later, while slowing down at a stoplight coming into town, the engine completely stalled out and died in the middle of a busy, active intersection. I lost all acceleration and power steering capabilities, and narrowly avoided an accident while coasting blindly across traffic to safety. The vehicle has had a chronic, active P0420 Catalytic Converter efficiency code caused by a known Kia manufacturing defect of massive, excessive oil consumption (requiring constant oil additions to maintain operation). The excessive oil burning directly fouled the exhaust and caused this sudden, life-threatening engine failure on a public roadway."

NHTSA ID

11774185

Incident

Oct 28, 2026

My vehicle's check oil light repeatedly lit up on several occassions before my next scheduled maintenance. Contacted my vehicle's manufacturer for assistance and unfortunately got a lukewarm response.

NHTSA ID

11773460

Incident

Sep 11, 2026

I was driving and my vehicle and saw smoke and it caught on fire and burnt..

NHTSA ID

11773080

Incident

Oct 15, 2026

Rod Bearing failure June 29,2026 with prior Kia manufacturer recalls June 19,2023: (1.) SC206, HECU fire Recall, a serious safety recall regarding the Hydraulic Electronic Control unit. The circuit board can short out and cause an engine bay fire even when the vehicle is parked. (2.) SC249B (Tow Hitch Harness Fire Recall): Another active safety recall. Moisture or debris on the Tow Hitch accessory circuit board can short-circuit and spark a fire. March 11, 2024 Recalls (1.) SC340(Engine Emissions ECM Ligic Improvement). This is a voluntary service campaign to upgrade the software logic in your engine control module (ECM(. It is iften tier directly to how your car judges engine diagnostic faults. (2.) CS 2312/Theft Det recall(Theft Deterrent Ignition Cylinder Proctector): This is a customer satisfaction campaign that installs a physical metal protector sleeve around your Ignition cylinder to prevent "Kia Botz" style theft bypasses.

NHTSA ID

11770638

Incident

Jun 29, 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.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: THETA II 2.4L GDI EMISSIONS: ECM LOGIC IMPROVEMENT (SC340 REVISION 5) - 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 upgrade the Electronic Control Module ‘ECM’ system software for certain 2016-2020MY Optima, 2016-2020MY Sorento, 2017-2022MY Sportage vehicles equipped with 2.4L Theta II engines listed in the table below. Kia has become aware that certain 2016-2022MY vehicles equipped with 2.4L Theta II engines may have engine calibrations that were not optimized for emissions standards under certain specific conditions. These calibrations may cause the vehicle to release air pollutants which exceed Federal and California standards. These standards were established to protect your health and welfare from the dangers of air pollution.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER NOTIFICATION (SC340 FLIGHT 105) - This document is the owner notification advising that Kia is conducting a Voluntary Emissions Service Campaign to improve the emissions software logic in the Electronic Control Module (ECM) for certain 2017-2022 MY Sportage vehicles equipped with 2.4L Gas Direct Injection (GDI) engines to ensure compliance with emissions regulations.

TECHNICAL SERVICE BULLETIN: VOLUNTARY EMISSIONS SERVICE CAMPAIGN: THETA II 2.4L GDI EMISSION SECM LOGIC IMPROVEMENT (SC340 REV 4) - 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 upgrade the Electronic Control Module ‘ECM’ system software for certain 2016-2022MY vehicles equipped with 2.4L Theta II engines listed in the table below. Kia has become aware that certain 2016-2022MY vehicles equipped with 2.4L Theta II engines may have engine calibrations that were not optimized for emissions standards under certain specific conditions. These calibrations may cause the vehicle to release air pollutants which exceed Federal and California standards. These standards were established to protect your health and welfare from the dangers of air pollution.

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.

VOLUNTARY EMISSIONS SERVICE CAMPAIGN: OWNER NOTIFICATION (SC340 FLIGHT 103 / QL) - This document is the owner notification advising that Kia is conducting a Voluntary Emissions Service Campaign to improve the emissions software logic in the Electronic Control Module (ECM) for certain 2017-2022 MY Sportage vehicles equipped with 2.4L Gas Direct Injection (GDI) engines to ensure compliance with emissions regulations.