NHTSA Complaint #11672345 — 2016 KIA OPTIMA

Several safety-critical systems failed on this vehicle. The engine (Theta II 2.4L GDI) failed due to rod bearing wear, causing sudden power loss on the highway. The vehicle entered limp mode, once at 50 mph in 2018 and again at 70 mph in 2025, and had to be pulled over quickly to avoid collision. Additional issues: all four windows failed at different times, leaving them stuck open and creating safety risks in weather or emergencies. The trunk latch failed, causing unsecured cargo risk. ABS, TPMS, and traction control warning lights illuminated repeatedly, indicating possible loss of critical safety systems. A loose wiring harness caused the turn signal bulb to burn out repeatedly, reducing visibility and signaling. The dealership performed the KSDS software update after I reported engine trouble but did not resolve the issue. The engine soon failed completely while driving. Other issues, such as the fuse box blowing fuses from a standard USB charger have also been documented by a Kia dealership but not always fully repaired. The most recent engine failure and electrical defects are being inspected by a Kia dealership, and Kia Consumer Affairs is reviewing the warranty claim. Prior to the engine failure, I smelled burning oil and topped it off monthly due to excessive consumption. The oil level light and check engine light only appeared during limp mode right before the failure. These repeated safety-critical defects, particularly sudden engine failure at highway speed, created a significant safety hazard for myself and others on the road. At the time of this report, I am in the process of seeking warranty coverage for the catastrophic engine failure through Kia. The failure behavior (limp mode, flashing check engine light, and rod knock) is consistent with the safety defect described in the Theta II engine settlement. I am concerned that despite this being a known issue, there may be delays or denials in honoring the safety-related warranty repair.