Kia Optima Recalls

The Kia Optima has 34 recalls spanning the 2001–2019 production run, with the most serious recent issue being premature connecting rod bearing wear on 2017–2018 Hybrid and Plug-In Hybrid models, where engine damage can cause a stall or an engine compartment fire.

The 2019 model year has a software error in the forward collision-avoidance system on turbocharged models that prevents automatic braking from engaging when a stationary vehicle is detected ahead. The 2017–2018 Hybrid and Plug-In Hybrid models also have a Voltage Protection Device that can cut power to the electric motor unexpectedly, causing a loss of drive while in electric mode. On 2017–2018 models, a prior engine replacement campaign may have left a high-pressure fuel pipe improperly seated, creating a fuel leak risk near ignition sources. The 2016–2018 model years have a trunk latch base that can crack and trap a person inside the trunk. Some 2016 models built in a narrow window lack the chemical charge needed for the driver's airbag second stage to deploy in a crash, and the front axle driveshaft on 2016 models with the 2.4L engine can crack and separate, leaving the vehicle unable to move and potentially rolling if the parking brake is not set.

The 2013–2015 model years have a recurring brake control module issue where brake fluid leaks internally into the hydraulic electronic control unit, shorts the electronics, and can start an engine compartment fire while parked or driving. Prior repair attempts under an earlier recall did not fully resolve this issue, leading to a follow-up campaign covering the same years. The 2013–2014 models with 2.4L or 2.0L turbo engines have a low-pressure fuel hose that can crack from heat and leak fuel, with a follow-up recall addressing cases where the original repair left the hose damaged or missing its heat-protective tape. The 2013 Optima Hybrid has a safety plug fuse that can blow and cut hybrid power at low speeds, and an incorrect aftermarket replacement fuse can overheat. On 2012–2013 models, headliner plates above the side curtain airbags can detach during deployment and strike occupants. The 2011–2015 model years share the brake control module fire risk described above, and 2011–2014 models have an engine bearing wear defect that can cause the engine to seize. The 2011–2013 Optima Hybrid has a separate engine compartment fire risk while driving. On 2011–2012 models, the airbag control unit can short-circuit in a crash and prevent frontal airbags and seatbelt pretensioners from firing.

Going further back, the 2006–2008 model years have two issues: a shift cable that can detach from the shifter assembly and prevent gear changes, leaving the vehicle unable to engage park and at risk of rolling, and a clock spring that can develop high resistance and disable the driver's airbag in a crash. The 2002 model has a fuel tank valve that may not close fully, spilling fuel in a rollover. On 2001 models, front subframe corrosion in salt-belt states can cause the subframe to separate from the vehicle, and a misrouted side airbag wiring harness can be cut by the seat mechanism and prevent side airbag deployment. The 2001 model also has a crankshaft position sensor with an internal circuit board def