NHTSA Office of Defects Investigation
Preliminary Evaluation PE20-008: Headlight Failure
- Closed
NHTSA's Office of Defects Investigation opened Preliminary Evaluation PE20-008 on June 1, 2020 and closed it on January 25, 2022. NHTSA's investigations file lists the 2011–2013 Kia Sorento for it.
Updated daily from NHTSA's investigations file
Key facts
- NHTSA number
- PE20-008 (also written PE20008)
- Investigation type
- Preliminary Evaluation The first stage of most defect investigations: NHTSA's Office of Defects Investigation gathers basic information about a possible safety defect, including from the manufacturer.
- Status
- Closed January 25, 2022
- Opened
- Closed
- Vehicle or equipment manufacturer
- Kia America, Inc.
- Components
- Exterior Lighting; Exterior Lighting — Headlights; Exterior Lighting — Headlights — Bulbs
- Vehicles and equipment
- 2011–2013 Kia Sorento
A recall appears here only when NHTSA's investigations file links one to the investigation; NHTSA's summary or record can name others.
NHTSA's summary
As NHTSA's Office of Defects Investigation wrote it for Preliminary Evaluation PE20-008.
try.vin does not copy NHTSA's investigation documents; NHTSA's investigation record lists the ones NHTSA has published.
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.
Vehicles and equipment listed for this investigation
NHTSA's investigations file lists these vehicles and equipment for Preliminary Evaluation PE20-008. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. Model years with a try.vin recall page link to that page's NHTSA investigations section.
Kia
All Kia recallsWhat an NHTSA investigation is
NHTSA's Office of Defects Investigation (ODI) looks into possible safety defects in vehicles and equipment, often after owner complaints. An investigation usually starts as a Preliminary Evaluation, or as a Recall Query when it concerns whether an existing recall covers the right vehicles or fixes the problem, and ODI can upgrade it to a more detailed Engineering Analysis. A Defect Petition asks NHTSA to open an investigation, and Audit and Equipment Queries are administrative investigations into whether companies complied with federal vehicle safety requirements, such as reporting, recall and certification rules.
An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.
To see whether a specific vehicle has an open recall, enter its VIN at nhtsa.gov/recalls.
Kia VIN check: decode a VIN to see its year, make and model.
Sources
NHTSA's investigation record for PE20-008
Investigation details come from NHTSA's investigations file, which try.vin imports once a day. The investigation types are described from the U.S. Department of Transportation Inspector General's May 2023 report on NHTSA's Office of Defects Investigation, NHTSA's petition rules (49 CFR Parts 552 and 557) and NHTSA's Office of Defects Investigation procedures. How try.vin reads NHTSA investigations.