Engine failure, knocking or rod bearing

On August 6, 2025, the Office of Defect Investigation (ODI) opened Audit Query (AQ) 25001 to assess the implementation of Kia America, Inc.’s (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 ‘cold’ engine to a ‘warm’ 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 ‘cold’ 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 NHTSA’s IR: Kia reported the change in temperature from ‘cold’ to ‘warm’ engine testing was done to increase accuracy. The inspection test uses diagnostic tools that detects abnormal engine vibrations to identify damaged engines. From the initial launch of the Technical Service Bulletin (TSB) on April 4, 2025 through April 28, 2025, ‘coldâ€

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 as

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