Products Liability Law Daily Wrap Up, NHTSA NEWS—ODI INVESTIGATION—ODI closes engineering analysis of Kia, Hyundai engine fire recalls, (Feb 13, 2024)

By Susan Engstrom

Renotification actions taken by the automakers will help increase the recall completion rates and reduce the frequency of engine fires, the agency determined.

The National Highway Traffic Safety Administration’s Office of Defects Investigation (ODI) has closed an engineering analysis that evaluated the scope and efficacy of recalls and remedies relating to engine failures/fires in various model year vehicles manufactured by Kia America, Inc. and Hyundai Motor America. Kia recently issued a new recall covering about 80,000 model year (MY) 2011 Sorento vehicles, and both automakers informed ODI that they will periodically send renotifications of previous recalls to affected owners in order to increase the rates of completion. The agency found that most vehicles that received the remedies experienced lower fire rates (NHTSA ODI Investigation, No. EA21003, February 5, 2024).

Background. In 2019, ODI opened two preliminary evaluations (PEs) to broadly investigate incidents of non-crash fires in 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 the likelihood of engine failure). KSDS is being installed under recalls and non-safety field actions, and both companies have extended limited engine warranties.

In 2021, ODI upgraded the PEs to this engineering analysis (EA) to evaluate: (1) the scope of the prior recalls related to engine failures/fires; and (2) the efficacy of the recalls’ remedies, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia. The first issue involved approximately 550,000 MY 2013 Hyundai Elantra, MY 2011 Kia Sorento, and MY 2012-2015 Kia Rio vehicles. The second issue involved approximately 2.5 million recalled vehicles that have been identified as displaying potential remedy concerns (Hyundai recalls 15V568, 17V226, 20V746, and 21V727; and Kia recalls 17V224, 19V120, 20V750, and 21V844).

Scope of recalls. Among all of the scope vehicles identified at EA opening, ODI found that 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 23V877, which 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. ODI noted that in 2021, those 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 will likely be due to a failure to adhere to the proper or scheduled engine maintenance (regular engine oil changes), rather than a design or manufacturing engine issue.

Efficacy of recall remedies. Regarding the efficacy of the recall remedies, ODI found that the majority of the recalled Hyundai and Kia vehicles experienced lower reported fire rates after the remedies were applied. Furthermore, ODI found that most vehicles that did not receive the recall remedies experienced relatively high fire rates. To address this problem, Hyundai informed ODI that it will renotify all of its owners covered by the recalls every 8 months for the next 3 years. Kia also 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 and reduce the frequency of engine fires in the future, ODI said.

Decision. In view of the recall action being taken by Kia and renotification actions being taken by both Kia and Hyundai, ODI closed 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.

Companies: Kia America, Inc.; Hyundai Motor America

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