Summary
The Kia Optima has 30 recalls spanning the 2001–2019 production run, with the most serious recent issue being premature connecting rod bearing wear in 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 two related concerns: a software error in the automatic emergency braking system on turbocharged engine variants can prevent the system from engaging when a stationary vehicle is detected ahead, and a separate engine control module update applies to 2019 Hybrid and Plug-In Hybrid models where engine failure can cut power and create a fire risk. The 2017 model year adds a connecting rod bearing issue specific to the 2.0L Nu GDI engine, where knocking noises or an oil pressure warning light signal damage that can progress to engine failure or fire. On 2017–2018 hybrid models, a voltage protection device can activate inadvertently and cut power to the electric motor while driving in electric-only mode. The 2016–2018 model years share a trunk latch that can crack and trap a person inside the trunk. Two 2016 airbag concerns are also worth noting: some vehicles built from November 2015 through February 2016 were missing a chemical charge needed for second-stage driver airbag deployment, and a separate small batch had an improperly installed inflator end seal that can reduce bag inflation in a crash. The 2016 model year also has a right front axle driveshaft that can crack and separate, leaving the vehicle unable to move and at risk of rolling if the parking brake is not set.
For 2013–2015 models, brake fluid can leak inside the anti-lock brake hydraulic control unit, causing an electrical short that raises the risk of fire while driving or parked. The 2013–2014 model years have a low-pressure fuel hose that can crack from heat and leak fuel, and a follow-up concern affecting vehicles that received repairs under a prior campaign where the high-pressure fuel pipe may not have been correctly reinstalled. The 2012–2013 headliner plates can detach during a side curtain airbag deployment and strike an occupant.
Going back further, the 2011 model year has multiple engine-related concerns, including an engine control module update to detect impending failure, a fire prevention campaign for vehicles with 2.0L or 2.4L engines covering potential fuel, oil, and engine damage issues, and a follow-up fuel pipe concern for vehicles that received engine replacements. The 2006–2008 model years have a clock spring that can develop high resistance and disable the driver airbag in a crash, and a shift cable that can detach from the shifter assembly and prevent gear selection, allowing the vehicle to roll. The 2002 model has a fuel tank valve that may not close fully and can leak fuel in a rollover. The 2001 model year has three separate issues: front subframe corrosion in salt-belt states that can cause the subframe to separate from the vehicle, a crankshaft position sensor that can cause engine stalling, and a side airbag wiring harness that can be cut by the seat mechanism and prevent deployment in a crash.
