2017 Kia Niro

I am submitting this complaint regarding a repeat failure of the Active Air Flap System on my 2017 Kia Niro, which I believe raises a broader safety and reliability concern. On XXX, my vehicle displayed a check engine light and “Check Active Air Flap System” warning. An authorized Kia dealer, Huffines Kia Corinth in Texas, diagnosed the issue and replaced the active air flap assembly (listed on the repair order as “FLAP ASSY–ACTIVE AIR”) at approximately 87,638 miles. At around 105,000 miles, the same warning and check engine light have returned, indicating that the Active Air Flap System is again malfunctioning despite the prior repair and part replacement. This suggests either repeated component failure or an underlying design or control issue that was not resolved. Owners of Kia Niro and related Hyundai/Kia models frequently report similar Active Air Flap System warnings and related diagnostic codes, and Kia has issued technical guidance addressing inspection, cleaning, and software behavior for this system. Although these issues may not yet be the subject of a formal recall, the pattern of repeated failures across multiple vehicles points to a systemic problem in a component tied to engine cooling and efficiency, which can reasonably affect safety, emissions, and vehicle reliability. I am asking NHTSA to review Kia’s handling of Active Air Flap System failures on the Niro and related models, including repeat failures after dealer repair, and to consider whether this issue warrants further investigation or recall/extended coverage action. Vehicle: 2017 Kia Niro Approximate mileage at initial repair: 87,638 Approximate mileage at repeat failure: 105,000 Location of repair: Huffines Kia Corinth[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Cooling system broke down at 140k miles. Water pump, EHRS failure EGR Cooler. Engine head gasket blown needs engine replacement 144k miles $9000 repair. Problems confirmed by dealership. Engine light never came on for cooling system, water pump coupling repair. Engine light did come on for head gasket and vehicle stopped working.

My Kia Niro 2017 began losing antifreeze back in January of 2024. Upon inspection by Folsom Lake KIA they determined that the EGR needed to be replaced. The dealership made the repair under my third-party warranty that I purchased when I bought the car preowned in 2020 (22,000 miles). In August 2024 the engine began to overheat triggering and engine light. The car had approximately 90,000 miles on it at the time. The antifreeze was gone, and I filled it up and took it to the dealership a few weeks later when they had an available appointment. They were not able to diagnose the issue during that visit. They said that I had to schedule a multiday appointment to get a diagnostic done. In the meantime, I was adding antifreeze every few days to keep the reservoir full. I took the car back to Folsom Lake KIA on October 14th and received a diagnostic on the 17th that the vehicle's heat exchange recover system was leaking the antifreeze into the exhaust which burns off as a white smoke. The recommendation was to replace the entire heat exchanger. I decided to do some research and found find out what exactly this part does. I discovered that it simply warms up the antifreeze faster using the engine exhaust and shuts off when the coolant temperature reaches a setpoint. After further research on the internet, it became clear to me that this is a systemic issue with these vehicles, but no recall has been made. My warranty claim was denied due to the part not being covered. When I took it to an independent shop, they said that the part was not available from anyone, but KIA and they said that there was no price listed, and you had to contact KIA for the part. KIA quoted 3,000.00 for the part and labor to replace the heat exchanger. All of this just seems very suspect. I believe KIA knows this is a systemic problem but refuse to recall the part. Instead, they are making a bundle replacing this part. Any help would be appreciated. Thank you.

I am unsure of what to say about my car. I saw a check oil light flicker and it went away. The car had oil when I checked on it so it didn't seem to be a problem. There was no sign of leakage and no sign of burning oil or fuel. Several days later, the check oil light came on permanently. Before I could get the car anywhere, the car started making a strange sound. I took it to my usual shop. They said it had sprung a spontaneous leak. They said it was a large oil pressure switch leak. They replaced the sensor and added oil. They said there was some damage but that the car was still drivable. I drove the car for a week and then when I was on the highway, the car starting roaring and shaking like I was in an earthquake. The check engine light started blinking. I could not accelerate properly and had to coast to safety on the electric. I was able to use my friends scanner and found 4 misfire codes: PO300-303. My neighbor (a mechanic) looked at the vehicle and said that was damage was internal and was going to need extensive work or a new engine. He didn't have the time to take the vehicle apart so we did not find the true cause and I am now wondering if this is a new safety issues or related to the recall. I did not receive the recall information until recently (I tend to have issues receiving my mail sometimes) and haven't even had time to get to the dealership to check on it. Everyone I have spoken to has said this is how Kia's are and they are not worth purchasing.

I was driving and the car was stuttering. Then after I stopped for a bit it resumed normal operations. Then the warning light came on, then it went off again. This happened for a couple of weeks until finally, while on a road trip at the end of July 2023, the car seemed to just lose power in 4th gear and I would have to really rev the engine just to keep it moving, that happened while on a road trip. I called the dealership several times during the trip and they said I’d already had the computer recall reset so they didn’t think it made any sense. I took it to my neighborhood repair shop when I got back and they said two spark plugs are shot, they replaced them and it ran fine. But now it’s stuttering again, just a few months later. I called the dealership again and they said I could bring it it for a diagnostic (not free) and then I got a letter about a recall. Not sure if it’s related to my issue because the dealer said probably not and said they’d call me when they knew more and my car had the computer issue not this one. No one has called and the car is still stuttering. I took it to the mechanic again and he said spark plugs look fine, but again, it is losing power in 4th gear, just around 45 mph only when I’ve been driving for more than two hours. I would just like the dealership to take a look and fix it.

I own a 2017 Kia Niro with 48,000 miles on it. In early February 2022, I received a "system overheating" warning on my dashboard. When I pulled over and checked the engine, I noticed that the coolant overflow reservoir was nearly empty. I had the vehicle towed to a dealership (Destination Kia in Albany, NY), who pressure tested the engine but couldn't find any leaks. They returned the vehicle to me, but a day later I got another overheating warning and this time noticed excessive smoke, along with the coolant reservoir once again being drained. I thus brought it to a different dealer (Matthews Kia in Schenectady, NY), who also could not find a leak, but offered to replace the engine. Several months went by without the repair being completed, so I finally went to Matthews last week for a status update. They informed me that they had several Niro's experiencing similar issues, and that Kia Corporate had sent out a "technical service bulletin" to the dealers informing them that this recurring issue in the Niros is due to faulty EGR coolers. I brought the vehicle back to Destination, hoping that as a larger dealer they could complete the repair more quickly. They have since confirmed that the EGR cooler needs replacing, but quoted me $2500 for the repair, stating that it is not covered under warranty. Considering that this problem has recurred in enough Niros to warrant a technical service bulletin from the corporate office, and the obvious safety issues that an overheating vehicle can cause, I argue that Kia should have to send out a recall for this part. It's absurd that I'm being asked to pay $2500 to repair a vehicle with less than 50,000 miles on it, especially considering that this is clearly a recurring issue with this model. I have attached the initial repair records that I received, and will add the $2500 repair order for the EGR cooler once it is completed.

On January 30, 2022 I was driving my 2017 Kia Niro (133,500 miles) when my car broke down. I was driving along at 45 MPH when I had three or so warning lights flash on my dash. I don't clearly remember what they said, but it was something about the hybrid system and then the check engine light came on along with the warning label for the hybrid system again and the car died. I managed to get off the highway and come to a safe stop into a parking lot of a hotel. I tried turning my car off and back on but nothing happened except for the dash panel lights going on saying check hybrid. The last time I did it I waited a couple of minutes before attempting to turn it back on and again, no change. At this point I ended up having to call AAA and had my car towed to my dealership. (40 miles away) Besides being scary to have this happen, I learned that this problem is common in Kia Niro’s. The part I am talking about is the “high voltage fuse”. Evidently manufacturer installs a 125amp fuse and the fuse needed is 175amps. I feel this is a huge problem and will eventually if not already end up causing a serious accident. I look forward to a response and hopefully a solution to get this $434.72 service charge recovered plus tow fees.