PE20008 · PE
EXTERIOR LIGHTING:HEADLIGHTS Investigation
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) based on seventy-four Vehicle Owner Questionnaires (VOQs) reporting headlight failures on model year (MY) 2011-2013 KIA Sorento vehicles.In its response to ODI's June 25, 2020, information request letter (portions of which were submitted under request for confidentiality), Kia Motor America (Kia) provided design details of the headlight system showing that each headlight circuit is independently powered by the Smart Junction Box (SJB), a power control module. Kia claimed that the design minimizes the chance of both headlights failing simultaneously due to a headlight connector defect, a component located downstream of the SJB. Kia also advised that the SJB contains a safety feature designed to monitor power consumption for each headlight circuit; if excessive current is being demanded by either headlight the SJB will open the circuit (i.e., stop supplying current). Lastly Kia presented testing showing that the maximum headlight connector temperature achieved prior to the SJB opening the circuit was below the autoignition temperature of the plastic material the connector housing is made of, which Kia maintains eliminates the potential for a fire originating from an electrically overheated headlight connector. In its review of all available data, ODI determined that the majority of both VOQ and Kia customer complaints (1,339 reports in total) involved the loss or dimming of a single low beam headlight assembly caused primarily by a poor or overheated connector terminal located at the headlight. In some cases the failures were momentary in nature (i.e., flickering) with the headlights coming back on without driver intervention. A minority of VOQs and Kia complaints (the 196 Other reports) alleged simultaneous (and persistent) loss of both low beam headlights, and in most cases the driver was able to take an action (e.g., toggle the headlight switch, or use the ON rather than the AUTO setting on the headlight switch) to reinstate the low beam headlights. The high beam headlights were not seen to be affected and were available for drivers to use as alternate lighting.ODI did not identify any crashes or injuries, nor any fire incidents caused by a headlight related defect. While some VOQ and Kia reports alleged or indicated a fire occurrence, the incidents were found to involve melting or smells/odors due to thermal overheating of the plastic headlight connector housing, rather than an open flame fire.ODI notes that in April 2019, Kia initiated a 10 years/unlimited mileage warranty extension program to replace the headlight connector for MY 2011-2013 Sorento vehicles.Based on this analysis, a safety-related defect has not been identified at this time, and ODI is closing the investigation. This does not constitute a finding by the Agency that a safety-related defect is not present; the Agency will take further action if warranted by additional information received.The reference (ODI) numbers for the VOQs cited above are included in the downloadable version of this closing resume available at NHTSA.gov.
EA14002 · EA
VISIBILITY:SUN/MOON ROOF ASSEMBLY Investigation
The investigation focused on spontaneous breakage (fracture) of the panoramic sunroof (sunroof) on MY 2011-2013 Kia Sorento vehicles. The sunroof is constructed of tempered glass (often referred to as ?safety glass?), which, when broken, crumbles into granular chunks rather than splintering into jagged shards. The failure summary above shows NHTSA reports identified by the Office of Defects Investigation (ODI), and reports submitted by Kia from start of production of the subject MY 2011-2013 Kia Sorento through October 8, 2019, the date of ODI's last request for Kia data.Reports of sunroof failures typically occurred while the vehicle was in motion and often described a loud noise when the fracture occurred. If the sunshade is closed when the sunroof fractures, the particles are contained, otherwise the particles can drop into the passenger compartment.Reported injuries generally were minor in nature, such as nicks and cuts that often occurred when complainants were cleaning-up glass particles post-incident. No crash incidents have been identified, and complaints display a declining trend since 2014.During EA14-002, ODI requested and obtained failure data for the subject vehicles, the MY 2014 Sorento (which used a similar sunroof from a different supplier), and other peer Kia products (Optima and Sportage).ODI also requested and obtained failure data for peer vehicles produced by Hyundai, Ford, Nissan, and Volkswagen and failure reports through a General Order NHTSA issued to 13 OEMs (including Kia) in April 2016.This produced a significant volume of data upon which ODI bases this closing. NHTSA's Vehicle Research and Test Center (VRTC) also conducted testing on the subject sunroofs in an attempt to better understand potential hazards.In its responses to ODI, Kia states it has continuously monitored sunroof failure allegations throughout this investigation, and that the only consistently identified cause is external impact from foreign objects. Kia notes that the sunroof complies with the applicable Federal Motor Vehicle Safety Standards for glazing, and that it has not identified a manufacturing defect or assembly process error despite significant investigative efforts. Kia maintains that the field data supports its conclusion that an unreasonable risk to motor vehicle safety does not exist, citing a comparatively moderate failure rate, low injury risk posed by tempered glass, and the lack of an identified defect mechanism. Kia further notes it has received no reports of crashes due to driver distraction related to roof failure events, nor is NHTSA aware of any such reports.NHTSA's April 2016 General Order requested data on vehicles with panoramic glass sunroofs greater than 0.5 square meters in area. The response identified 97 distinct models produced over 11 model years totaling some 10 million vehicles. Over 4,000 sunroof fractures were reported (none of which alleged a crash due to driver distraction) forming a high to low frequency continuum by model.While the subject vehicles were at the high end of the spectrum, they were not the highest.Through its analysis of the information obtained to date, ODI has not identified sufficient evidence of a safety-related defect in the subject sunroof. This includes the absence of any suggestive trends by region, seasonality, date of production, or vehicle age, together with the minor nature of the alleged injuries and the lack of crash allegations in the subject or any of the peer vehicles. Accordingly, the investigation is closed. ODI will take further actions if warranted by new evidence. The reference numbers for the ODI failure reports cited above, as well as additi
PE13035 · PE
VISIBILITY:SUN/MOON ROOF ASSEMBLY Investigation
On October 21, 2013 the Office of Defects Investigation (ODI) opened PE13-035 in order to further examine claims that the sunroof would spontaneously break on 2011-2013 Kia Sorento vehicles.The majority of these claims occurred while the vehicle was in motion.Glass shattering while driving may distract the driver, and the resulting glass particles which enter the passenger compartment may injure occupants.To date, ODI has received a total of 26 reports of sunroof breakage on the subject vehicles. Of those, 24 occurred while the vehicle was in motion.There were also four (4) injury incident reports for minor cuts/scratches. Kia submitted a total of 123 field incidents related to sunroof breakage in response to ODI's information request. Of this number, ODI identified 78 unique vehicle identification numbers (VINs), with 9 matching ODI complaint vehicles.Sixty of the submitted reports occurred while the vehicle was in motion.Fourteen (14) of the submitted reports alleged minor cuts/scratches from falling glass.Kia also submitted a total of 101 warranty and goodwill claims for sunroof replacement, of which 86 unique VINs were identified.Kia stated in its response that their field inspections identified only one potential cause for the sunroof breakage - external impacts from rocks or other foreign objects encountered while the vehicle was in motion.In the other instances, no evidence of a defect was found, however, Kia's inspection results were inconclusive as to a cause for the breakage.Kia advises that the Sorento sunroofs also have a greater surface area than many other vehicles, potentially making them more susceptible to road debris strikes.While ODI recognizes that the Sorento may be more at risk due to its larger impact area, the rate of ODI reported incidents is concerning.Thus, the investigation has been upgraded toan Engineering Analysis (EA14-002) to further analyze the scope, frequency, and consequence of these failures.The ODI reports cited above can be reviewed online at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers: 10345933, 10410440, 10432904, 10453957, 10466987, 10478778, 10492886, 10502219, 10508983, 10514388, 10531972, 10534883, 10553341, 10555931, 10556212, 10562460, 10562516, 10563779, 10564555, 10567351, 10568629, 10572959, 10575487, 10583122, 10583626, 10584650