2016 Kia Optima

Component: Power Window / Door Description: All four power window regulators failed on my 2016 Kia Optima SXL within 16 months - from June 2025-Oct 2026. The failure mode is identical on all four doors: the plastic drum gear in the regulator separates or breaks, causing the window glass to drop into the door and become completely inoperable. The vehicle had 113,867 miles on it at the time of the first failure. This is a known design defect, not wear-and-tear. Kia issued Technical Service Bulletin BOD300 (March 2021) specifically addressing "Window Regulator Drum Gear Replacement" for 2016-2017MY Optima (JFa) vehicles produced September 1, 2015 through July 31, 2016. The bulletin confirms the drum gear separates or breaks. Despite this, Kia has not issued a safety recall. Safety risk: In a collision, intact side windows are an occupant ejection restraint. A window that has fallen into the door removes that protection and increases the risk of occupant ejection. Side curtain airbags deploy through the window frame (FMVSS 208). A window that is detached or lowered can interfere with proper airbag deployment, negating a Federal Motor Vehicle Safety Standard protection. In an emergency (fire, submersion), the driver and passengers cannot lower a window to create an escape path. Evidence of systemic defect: All four regulators failed (not one or two), within a short timeframe, demonstrating a design-level failure rather than isolated component wear. Kia's own TSB BOD300 confirms the root cause (drum gear separation/breakage). This complaint is filed in connection with existing NHTSA investigations PE21004 and EA22002 regarding this exact defect. I paid $3,734.64 out of pocket to have all four regulators replaced. I opted out of the Le Beau v. Kia America class action settlement and retain my individual claims. I am requesting that NHTSA evaluate this as a safety defect warranting a recall.

Concerning my Optima KIA's OEM front windshield. At certain times of the day when the sunlight is shining on a certain angle it is difficult to see through the windshield due to the glare which creates a visual impairment. There were a quite a few instance's where I almost got into serious accidents. With my observation the glass looks like there are thousands of microscopic pits like a light sandblasting embedded within the lamination and not the surface of the glass. It seems prominent at night also. This seems like a manufacture defect. This puts a safety risk for me and others. The dealer and manufacture will not do anything about it do to out of warranty. This appeared about a year ago and has gotten worse.

Severe engine defect (Theta II 2.4L GDI). Sudden total loss of power, metallic knocking, severe oil consumption, and imminent catastrophic failure while driving, creating a high safety risk. Vehicle is currently out of service in [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I am reporting a serious safety concern involving my 2016 Kia Optima, purchased from CarMax in 2024 and financed through CarMax Auto Finance. On or about October 5, 2026, I returned to my parked vehicle and discovered extensive black soot/smoke residue throughout the interior. Wiring and interior components appeared melted or burned. The vehicle had not been involved in a collision. Based on the damage, I believe an electrical or wiring failure may have caused the fire, although the exact cause has not yet been confirmed. The vehicle was inspected by police and the tow operator, and it was determined to be a total loss. An insurance claim has been filed, and the vehicle should be available for inspection if requested. This vehicle also had a significant history of mechanical problems. Since shortly after I purchased it, it experienced severe oil consumption/oil loss, requiring multiple visits to CarMax and multiple 1,000-mile oil-consumption tests. I also experienced repeated spark plug and coil pack problems requiring repairs/replacements. The exact component that failed is currently UNKNOWN. I have not yet had Kia inspect the vehicle or confirm the cause of the fire. This incident created a serious safety risk because the vehicle appears to have caught fire while parked. If this had occurred while I was driving or while my children were inside the vehicle, the fire could have caused serious injury or death. I do not recall receiving a specific warning message immediately before discovering the damage. The vehicle did, however, have its history of ongoing mechanical problems described above. I am requesting that NHTSA investigate whether an electrical, wiring, or other safety defect could have caused this vehicle fire and whether other Kia Optima owners may be at risk.

3 times windows different ones has stopped rolling up/down. 3 motors purchased and installed.

The contact owns a 2016 Kia Optima. The contact stated that while driving 25 MPH, the vehicle shut off without warning. Soon after the failure, the engine caught fire; however, the fire dissipated independently. The insurance agent was contacted and arrived at the scene to inspect the vehicle. The contact was initially informed that the vehicle was safe to drive; however, the engine failed to start after several attempts. Due to the failure, the vehicle was towed to a dealer where a mechanic discovered that the knock sensor was inoperable and had caused the fire. The contact was informed that the vehicle was included in NHTSA Campaign Number: 18V907000 (Fuel System, Gasoline, Engine) and the vehicle was repaired under the recall. Nearly a month after the repair, the vehicle started consuming oil with the master warning light displayed. The vehicle was taken back to the dealer for an inspection; however, no fault was found with the vehicle. The manufacturer was notified of the failure, and the contact was referred to the dealer. After another inspection, the dealer agreed to replace the engine; however, the failure recurred after the repair.

Vehicle was purchased in 2023. AC blower failure occurred for the first time in June 2024 and was repaired by PepBoys. On 4/2/2025 the ve3hicle had an active recall event when the engine seized on the highway because of a faulty oil pump/filter, Engine was replaced 4/17/2025 under that recall. Kia advised at the time that the wiring harness should be replaced due to electrical issues at the time but said that there was no recall for that work. At the time, there were no electrical failures of steering, brakes, all power etc. Nor did we know that those were a possibility. The wiring harness quote was $7,000, over the cost of the vehicle. It was decided to continue repairing the electrical issues as they came up, it was assumed that the fuses would blow before there because a safety or total vehicle failure, as automobiles are designed that way. 8/4/2026 the vehicle experienced a complete and total loss of power resulting in a traffic crash into another vehicle as the brakes felt like you were trying to push a wall rather than a pedal. There was minimal physical damage to the other car and the kia, the other driver got my husband's insurance information and then drove off. The car did startup after ~30 minutes or so and was driven home, but taken to the Kia dealership the next day. It was said that the blower motor overheated and melted a portion of the electrical junction box under the hood and that it was unsafe and dangerous to drive. Kia said that there were no active recalls for this work. NHTSA SC351 seems very similar to this issue that has plagued this car since the beginning. We would ask that Kia incorporate this vehicle and others outside of the year/model ranges in SC351 that have similar failure mechanisms as this seems common.

While driving at highway speeds on the freeway in San Diego, the engine of my 2016 Kia Optima catastrophically seized without warning. I instantly lost all power steering, brake assist, and electrical power, creating an immediate life-threatening emergency. The vehicle was towed to a Kia dealer. Corporate Techline and the dealership are refusing to perform the mandated settlement rod bearing test and are falsifying paperwork to deny the safety remedy.

Blower motor is drawing excessive electricity, which in turn burns the fuse and junction pin, which in turn can start a fire in the car. Kia of Irvine suggested redoing all electrical wiring in the car, but that will not solve the issue. As soon as you turn on the AC, the blower motor will use so much electricity and amperage, so the blower motor fuse and junction pins on the fuse box starting to burn. Wanting to charge almost $7000 to fix this issue, which is double the price value of the car, and risking to end up in this situation again, as soon as you turn on the AC, does not make sense. KIA should do recall on this model and fix the root cause, which is excessive electricity and amperage usage by the blower motor.

Window falls into the door. The rear two windows have been repaired 3 times. They are currently both broken again along with the front drivers side. I currently have three windows being help up by tape. They are taped to the frame of the door to stop the window from falling into the door. I don't know why this wasn't a recall. I see there is a TSB BOD300. The dealership repaired once but never informed me about the known defect.

The engine assembly completely seized and the vehicle is currently stored at an independent repair shop . While traveling at high speed on Interstate 4 on July 24, 2026, the vehicle suffered a sudden, catastrophic loss of power and stalled in live traffic, creating an immediate threat of a high speed rear end collision. An independent service center officially confirmed the engine seizure after a dealership failed to perform an inspection during an eight hour wait, and no law enforcement or insurance inspections have occurred. Prior symptoms included severe, recurring oil loss requiring constant manual additions of oil between regular service intervals (most recently serviced in June 2026 at a kia dealership), and eventually the car completely shutoff on July24.

engine failure, i was driving home from work and i went to accelerate from 0 to 20 miles and the car hesitated and didn't want to move. I took the car to the dealer three days later and it was confirmed that i needed a new engine. I was told by the dealership i was outside of my warranty but i just found out that i was covered up to 120k miles. No lights came on at the time and there wasn't any prior warnings to this happening. I had just put oil into the car two days earlier as i know in between oil changes that i have to put oil into the car and or check the oil to see if it is low.

NHTSA Bulletin TSB BOD300 My KIA 2016 Optima Turbo has all four windows impacted by the defective gear. I've opened a case with KIA and it's case number 25563361. None of my windows roll up or down. This presents several very serious safety issues. The dealer has had my vehicle for over 2 weeks. Why has KIA not been forced to issue a recall on these defective gears?

Code was on and off for a cylinder 2 misfire was off at this point (intermittent misfire) ecl was off car stalled out at 3rpms while driving, tiny puff of smoke once came from between the air intake and the engine, and also no crank no start but car has power. I’ve kept up with the oil changes every 3000 miles car had fluids in it and nothing looked bad all 4 spark plugs were burnt and i replaced them and still no success.

I had just stopped at stop sign and I turned right. My speed was approximately 40 mph and there was a LOUD POP. I immediately hit the brakes and had NO BRAKES. I got car off road and smoke was already coming from under hood. It caught fire immediately and burned up. Total loss . About 6 months prior to it burning I had a good bit of front end work done on it with bearing issues. Also put a new set of tires at same time . The coils and plugs were changed often because it would misfire. I purchased car July 2025. All my documents were burnt also .

The contact owns a 2016 Kia Optima. The contact stated that while driving 10 MPH, the front driver’s and passenger’s side windows lowered unintendedly. Neither the dealer nor an independent was contacted. The vehicle was not taken to the dealer or an independent mechanic to be diagnosed. The rear driver’s and passenger’s side windows were replaced, and the vehicle was repaired. The manufacturer was notified of the failure but offered no assistance since the VIN was not under recall. The failure mileage was 107,000.

My 2016 Kia Optima equipped with the 2.4L DOHC I4 GDI engine began to experience progressive and severe oil consumption during the latter part of my ownership. The oil warning light began activating repeatedly, even after shortly getting the oil changed. Several certified mechanics and oil change service stations told me this was an ongoing issue with this car and engine and that there was nothing I could do but monitor it and keep it filled. At their instruction, I monitored and had it changed more frequently, often topping it off at the oil change station and at home when needed. Approximately 2 weeks after an oil change upon putting the car in reverse it started to shake uncontrollably. The car was towed to a mechanic who stated I needed an engine. I then towed it to an authorized Kia franchise dealership where the technician documented the oil consumption complaint, confirmed a Cylinder 2 misfire code, performed a borescope inspection, and found the Cylinder 2 exhaust valve burnt with a chunk missing. Engine replacement was recommended by the Kia dealership technician. Prior to my purchase, the engine had already been replaced at approximately 80,000 miles under recall-related circumstances. The replacement engine installed by a Kia dealership subsequently failed, exhibiting symptoms consistent with the documented widespread defect affecting the 2.4L DOHC I4 GDI engine in 2016 Kia Optima vehicles, including severe oil consumption, cylinder misfire, and catastrophic internal engine damage confirmed via borescope at a Kia franchise dealership. Kia America denied the claim based solely on mileage despite the damage being confirmed by their franchise technician. My vehicle became unsafe to drive due to this engine instability shortly after starting before becoming fully inoperable. My vehicle has been non-operational for approximately 5 months. Kia has not provided a substantive written determination despite a formal written demand submitted in March 2026.

the engine. I was at a stop sign when the car stop responding to me pressing the accelerator and would not go. Upon further inspection it was noted that my car had no oil in it. I am diligent in getting my oil changed every 3 months or 3,000 miles. My engine had "seized" and i am being advised to purchase a new engine or purchase a new car. While trying to get my car to acclerate i was almost hit 4 times in a matter of 10 mins.

The car returned P1326 and had multiple misfires and audible knocking, the dealers will indeed fight the already existing class action warranties. Was sent home and told to “drive the fuck out of it”, to which the car did not make it home and blew gasoline into my cabin while driving on the highway. Almost passed out, and am still fighting Kia to actually address the defective rod bearings. I personally would fight tooth and nail over a 5 dollar problem, but this is something they do nationwide and can cause serious injury or death. If it weren’t a 200 LB man driving the gasoline shooting into the cabin would absolutely cause a knockout. To the time of this report they are still trying to disregard the rod bearing issue and send me home with fixes to problems caused consequentially.

The contact owned a 2016 KIA OPTIMA. The contact stated that while driving at 30 MPH occupied with her husband the contact heard a noise coming from the rear of the vehicle and smoke coming from the rear of the vehicle as you looked in the drive side rear view mirror and while depressing the brake pedal attempting to come to a complete at the traffic light, the brakes failed to work a intended. No warning light illuminated. The contact mention she kept trying to depress the brake pedal, however the vehicle kept accelerating causing the vehicle to crash into a ditch, go around a telephone poll, crashing into a rock garden which allowing the vehicle to come to a complete stop. The vehicle was towed to a towing lot call interstate towing then the vehicle was then towed by insurance company to a collision center. No injuries were sustained. No medical attention. The fire department extinguished the fire. The contact stated a police report was filed. The vehicle was destroyed. The manufacturer was not made aware of the failure. The approximate failure mileage was 166,834.