In 2017, the NHTSA Office of Defects Investigation (ODI) opened two Recall Queries (RQ) affecting certain Hyundai and Kia vehicles equipped with “Theta II” engines. The investigation looked at both the timeliness and scope of the recalls as well as the compliance of each company to meet their reporting requirements under the Motor Vehicle Safety Act. Numerous violations of the requirements were found for both companies, and in November 2020, both companies entered into Consent Orders with NHTSA to resolve NHTSA’s assertions of violations of law.

In 2018, the Center for Automotive Safety (CAS) petitioned the Agency to investigate non-crash fires on various Hyundai and Kia models, alleging vehicle fires at varying points of origin and occurring under various non-crash related circumstances (including key-off fires). The ODI found that many of the fire incidents appeared to start in the engine compartment area and made reference to the two open RQ investigations as likely pertinent. After reviewing responses two Preliminary Evaluations were started to investigate incidents of non-crash fires (regardless of origin or operational status of the vehicle) on various model-year Hyundai (Sonata and Santa Fe) and Kia (Optima, Sorento, and Soul) models.

To date, Hyundai and Kia have issued several recalls addressing vehicle fires, including those due to engine failure involving various engine types (Theta II GDI, Theta II MPI, Theta II MPI HEV, Nu GDI, and Gamma GDI). The repair for the engine failure recalls typically involves engine inspection (to detect existing damage), and if necessary, engine replacement. Additionally, both manufacturers are 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. They have even replaced engines if the KSDS software detects an impending engine failure.

The Office of Defects Investigation (ODI) is opening this Engineering Analysis for two primary purposes. First, the investigation will continue to evaluate the scope of recalls initially begun under prior ODI actions, and will also include other recalls for fires due to engine failure. Second, the investigation will monitor and evaluate the efficacy of the recall remedies for engine fire-related recalls, as well as the long-term viability of related programs and non-safety field actions being conducted by Hyundai and Kia.