2020 Kia Telluride

On January 27, 2023, the Office of Defects Investigation (ODI) opened PE23002 to investigate allegations of loss of high beams with no warning and no re-engagement resulting in reduced visibility at night in the 2020 Kia Telluride. The investigation revealed that the halogen bi-function projector beam, used in vehicles built between January 2019 and November of 2019, is composed of one halogen bulb light source that provides light for both low beam and high beam. The heat generated by the halogen bulb will inflict damage to the gear mechanism and as a result the shutter’s electric motor will no longer be able to move the shutter to the open position to reveal the high beams. A loss of high beams, prevents the driver from having proper distance illumination, therefore increasing the risk of a crash. On February 24, 2024, Kia filed recall 24V-148 for certain MY 2020 Kia Tellurides. The recall remedy provides an inspection of the high beam shield gear mechanism and will either apply a clip to secure the shield gear to the shaft or replace the headlamp assembly with one that is resistant to heat damagefrom the halogen bulb. In view of the recall action being taken by Kia, ODI is closing this Preliminary Evaluation. 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.

I bought my vehicle used around 62,000 miles, I was the second owner. Around 90,000 miles my vehicle suddenly stopped driving. There was absolutely no signs of issues prior to this event. I had it towed to the Kia dealership where they recommended an entire engine replacement, but assured me I was outside of warranty. I did not pay for extended warranty so I decided to take it to an independent mechanic who informed me there was a missing internal pin. This mechanic felt certain this was a manufacturing issue. He was able to repair multiple components without replacing the whole engine and the vehicle was drivable again. Now at 122,000 miles the vehicle had the same exact issue occur. I have owned this vehicle for less than three years and have had engine failure twice. After researching online there are many people who have experienced the same exact issues and probably thousands more who were not vocal about it. This is absolutely a manufacturing problem with this vehicle and it deserves to be addressed.

NHTSA ID

11754612

Incident

Jun 30, 2025

**1. What component or system failed or malfunctioned, and is it available for inspection upon request?** The engine failed catastrophically and caught fire while I was driving. The vehicle was towed to the Kia dealership, where it remains available for inspection upon request. **2. How was your safety or the safety of others put at risk?** The engine suddenly caught fire while I was driving, creating an immediate risk of a serious crash, injury, or death to me, my passengers, and other motorists. I had to pull over immediately, and the fire department responded to extinguish the fire and ensure everyone's safety. **3. Has the problem been reproduced or confirmed by a dealer or independent service center?** Yes. The Kia dealership inspected the vehicle and confirmed that the engine has failed and requires replacement. However, they attributed the failure to "engine wear and tear" despite the vehicle having only approximately 111,000 miles and having been regularly maintained according to Kia's recommended maintenance schedule. Two months before the failure, the same dealership repaired an engine oil leak, and they have been unable to explain why the engine failed and caught fire. **4. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives, or others?** The vehicle has been inspected by the Kia dealership. The local fire department responded to the vehicle fire at the scene. At this time, the vehicle has not been inspected by the manufacturer or any other parties. **5. Were there any warning lamps, messages, or other symptoms of the problem prior to the failure, and when did they first appear?** Approximately two months before the engine failure, the engine warning light illuminated due to an oil leak. I immediately took the vehicle to the Kia dealership, where they repaired the oil leak at a cost of approximately $3,000. After the repair, there were no warning lights, messages, unusual noises, or other symptoms before

NHTSA ID

11753450

Incident

Jun 27, 2026

Vehicle experiences intermittent brake failure at normal and low speeds. No indicator lights are present, no warnings are given.

NHTSA ID

11753368

Incident

Jul 20, 2026

instrument cluster began failing intermittently (tachometer first, then other gauges), and the dealer determined the entire cluster had to be replaced at a cost of about $3,000. The vehicle had 78,000 miles, so it was outside Kia's 5-year/60,000-mile basic warranty.

NHTSA ID

11753294

Incident

Jul 14, 2026

Purchased this car used in July of 2025 with 77,000 miles. When we went in for the first complimentary oil change at ~5,000 miles, there was no noticeable oil on the dipstick. The dealership continued with the oil change and advised us to come back every 500miles for an oil consumption test. We did this three separate times and each time we were at least a full quart low each time. It was determined that the engine needed to be replaced. Luckily for us, it was covered under warranty. Our engine was replaced with a remanufactured engine from Kia. When we asked if this problem was going to happen again, we were told yes, but with no timeline. We now have no idea what to expect with this “new, but used” engine and why we were never alerted to the car being low on oil before the first complimentary oil change. Concerns for the purpose of this report are the reliability of these engines and the oil level/pressure sensing system.

NHTSA ID

11753165

Incident

Nov 12, 2025

I attempted to open the moonroof on our 2020 Kia Telluride. When it opened, it was cockeyed and off track. I pushed the button to close it, and I heard a plastic piece break and the moonroof remained stuck open. I took this car to Kia of Olympia, Kia of St. Cloud and Horne Kia, all confirmed that the plastic parts that broke are related to to their issued TCB#BOD319. This is well known and frequent issue on 2020-2022 Kia Tellurides, where the plastic for the wind guard snaps off and gets lodged in the sunroof track. Even though this is a known issue with the Kia Telluride, they have declined to cover the repair cost, and we now must pay over $7,000 for an entirely new sunroof assembly.

NHTSA ID

11753133

Incident

Jun 24, 2026

The contact owns a 2020 Kia Telluride. The contact received notification of NHTSA Campaign Number: 26V430000 (Seats); 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 contact stated that the vehicle was consuming an excessive amount of engine oil. The contact needed to add a quart of oil per week. The vehicle was taken to a certified mechanic who diagnosed that the piston in the engine was damaged from oil consumption, ultimately causing the engine failure. The engine was replaced. The dealer was not contacted. The manufacturer was made aware of the issue and denied covering the cost of the repair. The manufacturer was not contacted about the recall. The failure mileage was 60,000.

NHTSA ID

11753074

Incident

Jul 2, 2026

Mileage

60,000 mi

The sun roof came completely off the tracks and won’t close. The car is no longer weather proof and is at risk of the glass flying off at high speeds. Problem has not been reproduced or confirmed. Has not been inspected by the manufacturer or others. No warnings prior to the failure.

NHTSA ID

11751921

Incident

Jul 21, 2026

TECHNICAL SERVICE BULLETIN: WARRANTY EXTENSION CAMPAIGN: OIL FILTER HOUSING GASKET REPLACEMENT (WTY045) - This bulletin provides information regarding the ‘Warranty Extension Program (WTY045)’ for the inspection and, if necessary, replacement of the oil filter housing gasket on certain 2020–2025 MY Telluride (ON) vehicles produced from January 9, 2019, through June 12, 2025. Under this program, the New Vehicle Warranty coverage for this condition is extended from 5 years / 60,000 miles to 15 years / 180,000 miles, whichever occurs first, starting from the date the vehicle was first put into service. Affected vehicles may develop an engine oil leak from the oil filter housing gasket. During the extended warranty period, inspect and, if necessary, replace the oil filter housing gasket at no cost to the customer.

TECHNICAL SERVICE BULLETIN: 4WD COUPLING NOISE/VIBRATION LOGIC IMPROVEMENT) - CLOSED & SUPERSEDED BY CHA129 - This bulletin is now closed and superseded by CHA129. This bulletin provides information to upgrade the 4-Wheel Drive ‘4WD’ system software on certain 2020-2022MY Telluride (ON) vehicles produced from January 09, 2019 through September 01, 2022. The affected vehicles may exhibit a noise and/or a vibration, shudder, jerking, binding, or chattering while turning at low speeds (10MPH – 15MPH) located from the 4WD coupling caused by a decrease in the oil friction of the 4WD coupling due to continuous vehicle operation in harsh conditions (high/low ambient temperatures, long time/distance traveling).

TECHNICAL SERVICE BULLETIN: AWD COUPLER NOISE/VIBRATION LOGIC IMPROVEMENT - This bulletin provides information to upgrade the 4-Wheel Drive ‘4WD’ system software on some 2020-2025MY Telluride (ON) vehicles produced from January 08, 2019 through December 17, 2025. The affected vehicles may exhibit a noise and/or a vibration, shudder, jerking, binding, or chattering sensation while turning at low speeds (10MPH – 15MPH). This concern may be caused by decreased oil friction within AWD coupling due to continuous vehicle operation in harsh conditions (high/low ambient temperatures, extended duration / distance driving).

WARRANTY EXTENSION CAMPAIGN: OWNER NOTIFICATION (WTY045) - This document is the owner notification advising that Kia is extending the New Vehicle Limited Warranty coverage, to all owners, for certain repairs related to an engine oil leak from the oil filter housing gasket in certain 2020-2025 MY Telluride vehicles from 5 years / 60,000 miles to 15 years / 180,000 miles, whichever comes first, starting from the date the vehicle was first put into service. This warranty extension is to address the oil filter housing gasket leaking condition at no cost to you during this extended warranty period.

WARRANTY EXTENSION CAMPAIGN: REIMBURSEMENT FORM (WTY045) - This document is a Reimbursement Request form that was mailed with the customer letter advising them to submit the form if they had paid for repairs for this same matter prior to the warranty extension campaign program launch.

WARRANTY EXTENSION CAMPAIGN: DEALER PRINCIPAL MEMO (WTY045) - This document is the announcement to the dealer principals advising that Kia is extending the New Vehicle Limited Warranty coverage to all owners for certain repairs related to an engine oil leak from the oil filter housing gasket in certain 2020-2025 MY Telluride vehicles manufactured from January 9, 2019 through June 12, 2025, from 5 years / 60,000 miles to 15 years / 180,000 miles, whichever comes first, starting from the date the vehicle was first put into service. This warranty extension is to address the oil filter housing gasket leaking condition.