Model year record

2004 Kia Optima recalls & problems

The 2004 Kia Optima has 1 safety recall and 225 owner complaints on file with NHTSA. The most-reported problem area is latches/locks/linkages (81 complaints).

Recalls1safety recalls

Complaints225filed by owners

Crashes · fires8 · 3reported in complaints

Injuries · deaths8 · 0reported in complaints

2004 Kia Optima in an NHTSA crash test — NHTSA crash test

Safety recalls

SuspensionMay 27, 2009

Front

Recall 09V18300036,538 vehicles

Problem: KIA MOTORS CORPORATION (KMC) IS RECALLING 36,538 MODEL YEAR 2001-2004 OPTIMA VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. ROAD SALT APPLIED IN THESE STATES DURING THE WINTER MONTHS MAY RESULT IN PROGRESSIVE, INTERNAL CORROSION OF THE FRONT SUBFRAME. OVER TIME, SUCH SUBFRAME CORROSION NEAR THE CONNECTION TO THE LOWER CONTROL ARM CAN LEAD TO WHEEL MISALIGNMENT AND/OR OTHER NOTICEABLE STRESS IN STEERING, OR ACCELERATED ABNORMAL TIRE WEAR.
Risk: CORROSION OF THE FRONT SUBFRAME COULD LEAD TO SEPARATION, POSSIBLY RESULTING IN A VEHICLE CRASH.
Fix: KMC WILL NOTIFY OWNERS AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 15, 2009. OWNERS MAY CONTACT KIA'S CONSUMER ASSISTANCE CENTER AT 1-800-333-4542.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2004 Kia Optima 4-DR w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Optima

23mpg combined

City / highway	20 / 27 mpg
Fuel	Regular Gasoline

2.4 L · 4 cyl · Manual 5-spd · Front-Wheel Drive · about $2,900/year to fuel

Optima

22mpg combined

City / highway	19 / 27 mpg
Fuel	Regular Gasoline

2.4 L · 4 cyl · Automatic 4-spd · Front-Wheel Drive · about $3,050/year to fuel

Optima

21mpg combined

City / highway	18 / 25 mpg
Fuel	Regular Gasoline

2.7 L · 6 cyl · Automatic 4-spd · Front-Wheel Drive · about $3,200/year to fuel

Optima

21mpg combined

City / highway	18 / 26 mpg
Fuel	Regular Gasoline

2.7 L · 6 cyl · Manual 5-spd · Front-Wheel Drive · about $3,200/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Latches/locks/linkagesDoors › Latch	81	0	0	1	92,000 mi
Electrical systemHorn; Alternator/generator/regulator	45	2	3	0	85,000 mi
StructureBody; Body › Door	42	1	0	0	103,900 mi
Air bagsFrontal; Frontal › Sensor/control module	26	3	0	5	57,500 mi
SuspensionFront; Front › Control arm › Lower ball joint	19	1	0	2	68,954 mi
Unknown or other	12	0	0	0	88,500 mi
Engine and engine coolingExhaust system › Emission control › Gas recirculation valve (egr valve); Engine › Gasoline › Belts and associated pulleys	11	0	0	0	19,195 mi
Fuel system, gasolineDelivery › Fuel pump; Delivery	9	0	0	0	87,800 mi
Power trainAutomatic transmission; Clutch assembly	8	1	0	0	22,100 mi
SteeringRack and pinion › Rack; Rack and pinion	7	1	0	1	35,000 mi
Service brakes, hydraulicFoundation components › Disc › Rotor; Antilock/traction control/electronic limited slip	6	0	0	0	5,864 mi
Seat belts	6	0	0	0	98,500 mi

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Suspension
Had some noise coming from the front of the car, had my mechanic look at it, he said we needed a control arm. When he took off the cover to replace the control arm, he found the sub frame had rotten and was cracking. As I looked online, I saw that KIA had a recall for this issue. When I contacted KIA, their response was "as my car is not under warranty, they are not required to repair the car" The car in question has 70, 558 miles on it. We are the 2nd owner.
Dec 10, 2024
Structure › Body
Door lock/unlock mechanism has failed. Unable to unlock and open door from outside or inside. This defect causes the door to stay locked and unable to open. This can trap people inside of the car if they are unable to crawl out a window or exit from another door. There are many reports of this on Kia forums and general Google search. There was no warning that this part was wearing out until it became impossible to open the door.
Aug 8, 2022
Fuel system, gasoline
The contact owns a 2004 Kia Optima. The contact stated that after refueling, the vehicle would not start. The vehicle was not taken to a local dealer. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 04V180000 (Fuel System, Gasoline) however, the VIN was not included. The manufacturer was informed of the failure and confirmed that the vehicle was not included in a recall. The failure mileage was approximately 145,000.
Nov 1, 2021 · 145,000 miles
Air bags
I WAS REPAIRING BRAKELINES, WHILE OBSERVING UNDER CARRIAGE I NOTICED SUSPENSION RUST, FRAME. LOOKED UP RECALLS AND THIS IS ONE. I INCLUDED SCREENSHOT OF PROOG
Mar 29, 2021
Vehicle speed control
WHILE DRIVING ON A HIGHWAY WITH CRUISE CONTROL ACTIVE, I WAS UNABLE TO TURN OFF THE CRUISE CONTROL WITH THE STEERING WHEEL CONTROL BUTTONS. THE CANCEL AND SET BUTTONS HAD NO EFFECT WHEN PRESSED. THE CAR REMAINED TRAVELING AT THE SET SPEED. TAPPING ON THE BRAKE PEDAL DID CANCEL THE CRUISE CONTROL.
Oct 25, 2018 · 102,500 miles
Structure › Body
WHILE STATIONARY - DRIVER'S SIDE DOOR WILL NOT OPEN FROM INSIDE OR OUTSIDE WITH KEY, MANUAL LOCK OR ELECTRONIC LOCK CONTROLS (STUCK CLOSED). UNABLE TO EVACUATE CAR FROM DRIVER'S SIDE. SAFETY CONCERN - LACK OF EGRESS
Mar 23, 2018 · 121,000 miles
Air bagsCrash1 injury
TL* THE CONTACT OWNED A 2004 KIA OPTIMA. WHILE DRIVING 25 MPH, ANOTHER VEHICLE CRASHED INTO THE CONTACT'S VEHICLE FROM THE FRONT. THE PASSENGER SIDE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED STOMACH AND CHEST INJURIES THAT REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS DESTROYED. THE MANUFACTURER WAS NOT CONTACTED. THE VIN WAS UNKNOWN. THE APPROXIMATE FAILURE MILEAGE WAS 57,000.
Nov 2, 2017 · 57,000 miles
Electrical system
UNABLE TO OPEN PASSENGER DOOR DUE TO DOOR LOCK ACTUATOR STOPPED WORKING. UNSAFE TO DRIVE.
Dec 12, 2017 · 114,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.