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May 22, 2024 NHTSA CAMPAIGN NUMBER: 24V358000
High Voltage Battery Safety Plug May Overheat
A loss of drive power increases the risk of a crash, and a fire increases the risk of injury.
NHTSA Campaign Number: 24V358
Manufacturer Kia America, Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 2,209
Summary
Kia America, Inc. (Kia) is recalling certain 2022 Niro EV vehicles. The high voltage battery safety plug may overheat and melt, which can cause a loss of drive power or fire.
Remedy
Owners are advised not to charge their vehicle in a garage or any other covered structure until the recall repair is completed. Dealers will replace the safety plug, free of charge. Owner notification letters are expected to be mailed July 19, 2024. Kia’s number for this recall is SC314.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check if your Kia has a Recall
2022MY Niro EV
High Voltage Battery Safety Plug
Basis of Safety Defect Determination 573.6(c)(6)
July 31, 2023
Kia NA receives dealer Techline case involving a 2022MY Niro EV (Vehicle #1) with complaint of vehicle shutting off while driving; does not go into ready mode. Dealer identifies isolated melting of safety plug. Kia NA Safety Office begins monitoring issue.
August 9, 2023
Kia NA Safety Office conducts field data analysis and finds no incidents other than Vehicle #1.
September 20, 2023—September 21, 2023
Kia NA Safety Office inspects Vehicle #1 and confirms isolated melting of safety plug assembly. No issues with the high voltage battery cells or temperature sensors. Kia NA Safety Office collects parts and ships to Kia Corporation (Kia HQ) for further analysis.
October 3, 2023—November 14, 2023
Kia HQ shares findings regarding potentially similar incident in Portugal involving a 2022 Niro EV.
Kia HQ conducts testing in an effort to duplicate melting of safety
plug and is unable to duplicate condition. Kia HQ informs Kia NA
Safety Office of results.
November 17, 2023
Kia NA Safety Office escalates matter to SEL. Kia NA Safety Office continues to monitor issue.
February 22, 2024 Kia NA receives dealer Techline case involving a 2022MY Niro EV with complaint of no start condition (Vehicle #2) [TL #16201505; KNDCC3LG7N5 ]. Dealer inspection identifies isolated melting of safety plug.
March 20, 2024—March 21, 2024
Kia NA Safety Office engineer inspects Vehicle #2 at dealer and confirms isolated melting of safety plug.
While at dealer, Kia NA Safety Office engineer incidentally conducts inspection of a 2022MY Niro EV (Vehicle #3) with complaint of 12V battery drain and finds safety plug partially melted. Potential high electrical resistance at the safety plug’s female to female (F-F) terminal identified. Kia NA Safety Office informs Kia HQ.
March 25, 2024
Kia NA Safety Office proactively collaborates with dealers and fleet customers to expand the collection of safety plugs on Niro EV vehicles regardless of vehicle complaint.
April 1, 2024
Kia NA Safety Office and Kia HQ conduct driving and charging evaluation of two exemplar vehicles and Vehicle #3 in an attempt to duplicate melting condition. No issues found with exemplar vehicles. Vehicle #3 exhibits higher than expected temperatures at the safety plug but not reaching melting point.
April 18, 2024
In response to Kia NA Safety Office’s proactive collection of safety plugs, dealer informs Kia NA Safety Office of two 2022MY Niro EV vehicles with isolated partial melting of safety plugs. Parts are collected.
April 23, 2024—May 8, 2024
Kia NA Safety Office sends safety plug parts to Kia HQ and Safety Test & Investigation Lab (STIL) for further analysis. No root cause identified.
May 14, 2024 Kia HQ works with supplier and informs Kia NA Safety Office that potential cause of issue due to supplier deviation in the manufacturing of the safety plug’s Female-Female terminal. Kia HQ identifies scope of suspected safety plug lots to specific vehicle production.
Kia NA Safety Office identifies 3 unique VINs with isolated melting of safety plugs from field data. [(1 warranty claim and 3 Techline cases (dates of receipt 7/31/2023—3/20/2024)] and 2 additional unique VINs with isolated partial melting of safety plug during investigation (date of receipt 4/15/2024). No reports or evidence of vehicle fire.
May 15, 2024
Kia NA decides to recall certain 2022MY Niro EV vehicles.
No injuries, crashes, fatalities.
1 Affected Product
Vehicle
| MAKE | MODEL | YEAR |
| KIA | NIRO EV | 2022 |
3 Associated Documents
Chronology Report
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Recall Acknowledgement
RCAK-24V358-9045.pdf 645.376KB
Recall 573 Report
RCLRPT-24V358-2557.PDF 214.003KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V358&docType=RCL
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-358
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Kia America, Inc. MAY 21, 2024 NHTSA Recall No. : 24V-358 Manufacturer Recall No. : SC314 Manufacturer Information :
Manufacturer Name : Kia America, Inc.
Address : 111 Peters Canyon Road
Irvine CA 92606 Company phone : 800-333-4542
Population :
Number of potentially involved : 2,209 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2022-2022 Kia Niro EV Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : Certain 2022 model year Niro EV vehicles manufactured from July 21, 2021 through December 2, 2021. The recall population was determined by a review of vehicle and supplier production records. The vehicles subject to this recall were not produced in VIN order.
Customers seeking information about their specific vehicle will be referred to Kia’s Customer Care Center or their Kia dealer. Production Dates : JUL 21, 2021 – DEC 02, 2021
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : Over time, the contact surfaces of the high voltage battery safety plug may develop high electrical resistance. Although the exact cause of this high resistance in the safety plug has not been confirmed, Kia suspects it is due to a supplier deviation in the manufacturing of the Female-Female (F-F) terminal. If high electrical resistance occurs while driving or during battery charging, the safety plug may melt, thereby increasing the risk of loss of motive power and/ or fire.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : A loss of motive power increases the risk of a crash. A fire increases the risk
of injury. Part 573 Safety Recall Report 24V-358 Page 2 Description of the Cause : Root cause is not confirmed; however, supplier deviation in the manufacturing of the safety plug’s Female-Female terminal is suspected. Identification of Any Warning
that can Occur : Illumination of the EV Service Warning light, smell of melting plastics and/or smoke. Involved Components : Component Name 1 : SAFETY PLUG ASSY-FEMALE Component Description : Safety Plug Assembly (Female) Component Part Number : 37518-K4000 Supplier Identification : Component Manufacturer
Name : KET
Address : 123, Eunbong-ro, Namdong-gu Incheon Foreign States 21639
Country : Korea, Republic of Chronology :
See attached document titled “2022MY Niro EV High Voltage Battery Safety Plug Chronology”. Description of Remedy :
Description of Remedy Program : All owners of the subject vehicles will be notified by first class mail with
instructions to bring their vehicle to a Kia dealer. Kia dealers will be instructed to replace the safety plug with a new one. Kia will instruct owners not to charge their vehicle in a garage or any other covered structure until the recall repair is completed. Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 1, 2024. How Remedy Component Differs from Recalled Component : The remedy component has a solid bus bar connection with no Female- Female terminal. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-358
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
2022MY Niro vehicles manufactured beginning on 12/3/2021 are equipped with safety plugs without any supplier manufacturing deviations in the Female-Female terminal. Recall Schedule :
Description of Recall Schedule : The planned dealer notification begin and end date is July 16, 2024. The
planned owner notification begin and end date is July 19, 2024.
Planned Dealer Notification Date : JUL 16, 2024 – JUL 16, 2024
Planned Owner Notification Date : JUL 19, 2024 – JUL 19, 2024
* NR – Not Reported
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