Investigations by Make
Kia Investigations
16 investigations. 1 open. 15 closed.
Investigation Records
Kia 25V099 Piston Oil Ring Recall Effectiveness
On August 6, 2025, the Office of Defect Investigation (ODI) opened Audit Query (AQ) 25001 to assess the implementation of Kia America, Inc.âs (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 âcoldâ engine to a âwarmâ 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 âcoldâ 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 NHTSAâs IR: Kia reported the change in temperature f
Windshield Wiper Failure
On April 29, 2025, NHTSAâs Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE25004) to investigate inoperative windshield wipers in model year (MY) 2024-2025 Kia EV9 vehicles. The complaints report windshield wipers that malfunction while driving, when snow and/or ice accumulates on or at the bottom of the windshield or in the cowl. ODI further received videos and photographs that depict relatively small amounts of snow and/or ice accumulation that leads to the wipersâ malfunction. Inoperative windshield wipers could reduce driver visibility during inclement weather and increase the risk of a crash. ODI identified 7 Vehicle Owners Questionnaires (VOQs) related to this investigation. Five VOQs describe inoperative windshield wipers due to snow and/or ice accumulation. Two other VOQs describe other malfunctioning windshield wipers including snow build-up on the blades and an odor of overheating. The wipers are equipped with thermal overload protection designed to limit overheating of the wiper motor. Further, consumers describe windshield wipers that temporarily stop working when they are not able to clear the windshield. This may happen when the wipers
3.3L Engine Loss of Motive Power (LOMP)
The Office of Defects Investigation (ODI) received a petition on February 20, 2024, requesting the opening of an investigation into an alleged defect of the "engine" on the following vehicle model stated by the petitioner: 2016 Kia Sedona vehicles equipped with the 3.3L V-Shaped GDI Lambda-II engine. The petitioner raised the issue of a Loss of Motive Power. On November 13, 2023, ODI opened PE23-019 to address allegations of loss of motive power, on the 3.3L V6 Lambda-II engine for 2016-2017 Kia Sorento and included the 2016 Kia Sedona as a peer vehicle. This investigation is ongoing and addresses the potential safety-related defect raised by the petitioner. In view of the open Investigation, PE23-019, ODI considers the petition moot and is closing this action. The closing of the petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to make that determination at the close of PE23-019.
Hyundai and Kia ABS Module Fires
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 Kiaâs defect decision making and adherence with reporting requirements; and understand the varying defect descriptions and remedies between these recalls.
Loss of Motive Power
On November 13, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23-019) to investigate allegations of loss of motive power relating to head gasket and/or head bolt failure in Model Year (MY) 2016-2017 Kia Sorento vehicles equipped with the 3.3 L Lambda II engine. When the investigation was opened, ODI had received 13 Vehicle Owner Questionnaires (VOQs) related to reports of loss of motive power. In an information request letter dated November 30, 2023, ODI requested technical information and failure data relating to the alleged defect in the subject MY 2016-2017 Kia Sorento as well as several peer vehicle populations which share the 3.3 L engine. In its February 26, 2024, response to ODIâs information request, Kia provided 2022 customer complaints (including techline and field reports) and 1738 warranty claims representing 2411 unique vehicles within the subject vehicle population. Of the customer complaints provided by Kia, they identified only 53 unique allegations of a loss of motive power resulting from the alleged defect. Kia determined that the remaining reports were minor vehicle drivability or engine performance issues. ODI reviewed the
Loss of Motive Power
On July 3, 2023, the Office of Defect Investigation (ODI) opened PE23012 to investigate allegations of loss of motor power on model year (MY) 2022 Kia EV6 vehicles. Some consumers reported loss of motor power immediately after warning lamp illumination or reduction of motive power while the vehicle was in motion. This investigation found that the Integrated Charing Unit (ICCU) may become damaged over time from transient high voltage and thermal cycling. A damaged ICCU may not be able to charge the 12-volt battery which can discharge gradually while driving with a reduction of motive power. The vehicle could eventually experience a complete loss of motive power thereby increasing the risk of a crash. On July 13, 2023, Kia conducted a service campaign to inspect the ICCU and install an improved over-current detection software logic in certain 2022-2023 EV6 vehicles. On March 15, 2024, Kia filed recall 24V-200 for 48,232 MY 2022-2024 Kia EV6 vehicles. The recall remedy provides an inspection of the ICCU, and if necessary, a replacement of the ICCU and the associated fuse. The ICCU software reduces the risk of overcurrent and implements voltage peak reduction at the end of EV battery c
Pedestrian alert sounds
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.
Complete Loss of High Beams
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 shutterâs 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 clos
Loss of Motive Power
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 Petitionersâ 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. ODIâs evaluation included the review and analysis of the complaints and supporting information subm
Power Sliding Door Auto Reverse Failure
On April 10, 2022, the Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) after receiving 5 consumer complaints alleging the Power Sliding Doors (PSD) auto-reverse function failed to work properly in the model year (MY) 2022 Kia Carnival minivan vehicles.At that time, ODI was aware of 3 complaints alleging injuries to consumer?s arm, hand or shoulder caused by the closing PSD.Additionally, consumers alleged being trapped against the closing door while it was traversing in the closing direction.The initial complaints also alleged excessive force is needed to reverse the direction of the closing door.At this time, ODI is aware of 26 complaints and 11 injuries on the MY 2022 Carnival vehicles.In its August 2022 responses to ODI's Information Request on the PE, Kia provided 36 customer complaints, 21 field reports, and 5 related warranty claims.Kia also provided ODI with 21 reports of alleged injuries, however, Kia stated that it was able to confirm only 9 injuries.Typically, these injuries are attributed to fingers and arms.The Kia Carnival automatic stop and reversal system is designed to automatically reverse the direction of the closing PSD if it meets re
Engine Fires
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 p
Throttle control system vulnerabilities
The Office of Defects Investigation (ODI) of the National Highway Traffic Safety Administration (NHTSA) received a petition letter dated October 10, 2021, requesting an investigation of possible defects in the electronic throttle control (ETC) system on certain Kia vehicles resulting in the opening of DP21-003. Accordingly, Model Year (MY) 2005-2016 Kia Optima/K5, MY 2006-2015 Kia Sorento, MY 2007-2016 Hyundai Elantra, MY 2007-2016 Hyundai Santa Fe, MY 2006-2015 Hyundai Sonatas are all part of the subject population. The petition was originally filed as a Vehicle Owner Questionnaire that can be reviewed at NHTSA.gov under reference (ODI) number 11439675.On November 12, 2021, ODI opened Defect Petition DP21-003 to evaluate the petitioner?s request. ODI performed trend analyses of the VOQs related to vehicle speed control issues for all the subject vehicles and found that none of the 52 Model/Model Year Hyundai/Kia vehicles demonstrated any actionable trend that warranted an investigation.Petitioners submitted 1119 VOQs and non-VOQ cases in which sudden uncommanded acceleration (SUA) or loss of motive power (LOMP) incidents were alleged.For the 1119 reports, 220 were incidents involv
Engine Oil Pressure Switch Leak
In a letter dated September 30, 2021, Mr. Gerald James (the petitioner) requested that NHTSA conduct an investigation of the Model Year (MY) 2015-2017 Kia Sorento equipped with 3.3L V6 ?Lambda? engines for ?severe oil leaks? from the oil pressure switch (OPS) that could ?lead to engine failure? with little warning to the driver. Mr. James based this request on his own experience and data found in NHTSA?s Vehicle Owner Questionnaire (VOQ) database. NHTSA reviewed the material cited by the petitioner, information submitted by Kia, NHTSA?s testing, and other pertinent information in NHTSA databases.On November 12, 2021, ODI opened Defect Petition DP21-002 to evaluate the petitioner?s request. ODI performed an analysis that included evaluation of the petitioner?s vehicle, searches of ODI complaints from vehicle owners, non-dealer field reports, manufacturers? supplemental information relating to design of the component, and component testing performed by ODI.On December 16, 2021, ODI and Kia North America performed a joint inspection on the petitioner?s vehicle. ODI and Kia agreed the OPS was leaking oil and observed oil in the crevices atop the engine block. The vehicle received a new
Electrical overstress
The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect. During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In
Non-crash Vehicle Fires
During this Preliminary Evaluation (PE), the Office of Defects Investigation (ODI) assessed the scope, frequency and potential safety-related consequences of non-crash vehicle fires caused by both engine failures and failures of other vehicle systems/components in model year (MY) 2011-2014 Kia Optima, MY 2011-2014 Kia Sorento and MY 2010-2015 Kia Soul vehicles equipped with Theta II, Gamma, Nu and Lambda II engines (approximately 1.7 million vehicles). ODI also reviewed field and other data on other Kia vehicles (approximately 3.6 million additional vehicles) equipped with the same engines used in the above-mentioned vehicles.As a result of this PE, Kia has issued NHTSA Recalls 20V-750 and 21V-844 to address potential engine failures and fires in certain Kia vehicles equipped with various engine types.Additional information on these and other related recall actions is available in the downloadable version of this resume available at NHTSA.gov.In addition, ODI has upgraded this PE to an Engineering Analysis (EA) 21-003 which will focus on potential recall scope concerns and recall remedy concerns related to the engine failure-related recalls mentioned above and conducted previously.
Non-crash Vehicle Fires
In a letter dated June 11, 2018, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a safety defect investigation into non-collision related fires on model year (MY) 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles. In a letter dated July 24, 2018, CAS requested that MY 2010-2015 Kia Soul vehicles be added to the petition. CAS stated that there is a higher number of complaints to NHTSA regarding non-crash fires on these vehicles compared to other similar vehicles. The Office of Defects Investigation (ODI) had already opened Recall Queries (RQ17-003 and RQ17-004) on all Kia and Hyundai vehicles equipped with Theta II engines for engine failures that may cause stalling and fires.The queries cover most of the petition subject Optima, Sorento, Sonata, and Santa Fe vehicles but not any of the subject Soul vehicles.On August 21, 2018, ODI opened a Defect Petition (DP18-003) to evaluate whether to grant or deny the CAS petition. ODI sent Information Request letters to Kia and Hyundai (September and October 2018) requesting information on all engine and non-engine related fires in the petition vehicle