You’re driving your 2022 Kia Seltos, enjoying the commute, when suddenly the engine starts making a sound like a bag of marbles in a blender. It’s a gut-sinking feeling. Honestly, it’s a scenario thousands of Kia owners have faced recently. Kia America has issued a massive recall for approximately 137,256 vehicles due to a specific manufacturing defect that can lead to catastrophic engine failure or, in some terrifying cases, a fire.
This isn't just about a loose screw. We’re talking about piston oil rings that weren't made right.
Which Cars Are Actually Involved?
If you're driving a Kia, you've probably heard the news, but the "which ones" part is vital. This specific recall (NHTSA Campaign Number 25V-099) targets two main models equipped with the 2.0-liter "Nu" MPI engine. If you have the turbocharged 1.6-liter engine found in the higher-trim Seltos models, you can breathe a little easier—you’re likely in the clear for this specific issue.
- 2021-2023 Kia Seltos: Specifically those built between July 2, 2020, and July 1, 2022. That’s roughly 53,635 SUVs.
- 2021-2023 Kia Soul: The boxes-on-wheels built between July 2, 2020, and April 19, 2022. This accounts for about 83,621 hatchbacks.
Basically, if your car was born at the Autoland Hwaseong plant in South Korea during those dates, you're on the list.
Why Piston Rings Are Causing Such a Headache
So, what’s the deal with these rings? Piston oil rings have a simple job: they scrape excess oil off the cylinder walls so it doesn't get burned up in the combustion chamber. In these 137,000 vehicles, the supplier—who remains nameless in most official documents—messed up the heat treatment process.
Because the rings are too hard, they start acting like a lathe, chipping and scoring the engine's cylinder walls. Once those walls are scratched, oil starts leaking past the rings.
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Here’s how the disaster chain works:
- The rings score the cylinder walls.
- The engine starts "eating" oil at an alarming rate.
- The oil level drops so low that the engine's moving parts aren't lubricated.
- The engine seizes up entirely (stalls).
- In the worst-case scenario, oil leaks onto hot exhaust parts, and the car catches fire.
It's a "quality deviation" that has turned into a $2 billion nightmare for the brand, especially since the National Highway Traffic Safety Administration (NHTSA) opened an audit query in late 2025 to see if Kia’s "fix" is actually working. Some owners have reported that even after inspections, their engines still failed later on.
The Red Flags You Shouldn't Ignore
Don't wait for a letter in the mail if your car is acting up now. I've talked to people who didn't even know there was a recall until their car died on the highway. There are four big warning signs you need to watch for.
1. The "Death Rattle"
If you hear a knocking or loud ticking sound that gets faster as you accelerate, pull over. That’s metal hitting metal.
2. The Disappearing Oil
Check your dipstick every single time you get gas. If you're losing a quart of oil every 1,000 miles and there’s no puddle on your driveway, your engine is likely burning it through those faulty rings.
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3. The Oil Pressure Light
If that little red teapot lights up on your dashboard, your engine is already starving. Turn the car off immediately.
4. Burning Smells or Smoke
If you smell something like burning oil or see a "blue" tint to your exhaust smoke, that’s a clear sign oil is getting where it shouldn't be.
What Kia Is Doing (And What They Aren't)
Kia’s official remedy is a bit of a mixed bag. Dealers are instructed to inspect the engines for damage. If the cylinder walls are already scored, they are supposed to replace the entire engine assembly for free.
However, if they don't see immediate damage, they won't just give you a new engine. Instead, they’ll install something called Piston-ring Noise Sensing System (PNSS) software. This is essentially a "early warning system" that listens for the specific vibration of a failing piston ring. If the software hears a problem later, it puts the car into "Limp Home Mode" and triggers a dash light, at which point Kia says they will replace the engine.
Many owners find this frustrating. They feel like they’re driving a "ticking time bomb" waiting for a sensor to tell them their engine is dying. It's kinda like having a doctor tell you, "We won't fix your heart now, but we'll give you a heart rate monitor that screams when you're about to have a heart attack."
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How to Protect Yourself and Your Wallet
If you own one of these vehicles, you have rights. There is a massive class-action settlement (In re: Hyundai and Kia Engine Litigation II) that provides extra protections.
Follow these steps right now:
- Run your VIN: Go to the NHTSA Recall Website and type in your 17-digit VIN. It’ll tell you exactly if your specific car is part of this 137,000-unit batch.
- Keep Every Receipt: If you paid for an engine repair out of pocket before this recall was announced, Kia is legally required to reimburse you. Keep receipts for towing, rental cars, and even the "top-off" oil you’ve been buying.
- Get the Software Update: Even if you think it's a "band-aid," you must get the PNSS software installed to remain eligible for the lifetime warranty extension that often comes with these settlements.
- Documentation is King: If a dealer tells you "the engine is fine" but it’s making noise, record the sound on your phone. Ask for a written "Repair Order" even if they don't do any work.
It’s worth noting that Kia has been under fire for years over engine issues, particularly with the older Theta II engines. This latest 137,000-vehicle recall shows that while they’ve moved to newer engine designs (like the "Nu" MPI), supply chain quality control still seems to be an Achilles' heel for the company.
Don't ignore a knocking sound. A stall in the middle of a 70-mph highway is a lot more than an "inconvenience"—it's a massive safety risk. If your car is part of the 2021-2023 Seltos or Soul group, get it to a dealership and insist on a borescope inspection of the cylinder walls.
Actionable Next Steps:
- Verify your VIN on the NHTSA website immediately to confirm your status.
- Schedule the PNSS software update at your local dealer to lock in your warranty protections.
- Perform a weekly oil level check to catch excessive consumption before the engine seizes.
- Save all service records in a dedicated folder, as these are required for any future reimbursement or "lemon law" claims.