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February 7, 2024 NHTSA CAMPAIGN NUMBER: 24V077000
Engine Valve Springs May Break
A loss of drive power increases the risk of a crash. A hole in the engine block increases the risk of a fire.
NHTSA Campaign Number: 24V077
Manufacturer Kia America, Inc.
Components ENGINE AND ENGINE COOLING
Potential Number of Units Affected 2,872
Summary
Kia America, Inc. (Kia) is recalling certain 2024 Telluride vehicles. The engine valve springs may break while driving, which can result in a loss of drive power and possibly create a hole in the engine block.
Remedy
Dealers will replace the engine sub-assembly, free of charge. Owner notification letters are expected to be mailed April 5, 2024. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC296.
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
2024 MY TELLURIDE VEHICLES – ENGINE VALVE SPRING
SAFETY RECALL CAMPAIGN (SC296)
Q & A
February 12, 2024
Q1. What type of campaign is Kia conducting?
A1. Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign to address a condition involving the engine valve spring.
Q2. What vehicles are affected by the recall?
A2. Certain 2024 MY Telluride vehicles manufactured from October 1, 2023 through December 6, 2023.
Q3. How many customer vehicles are affected by this recall?
A3. Approximately 2,872 vehicles.
Q4. What is the concern with the Engine Valve Spring?
A4. The engine valve springs may break while driving due to fatigue cracking as a result of damage to the springs during manufacture by the supplier. A broken valve spring may result in a loss of motive power, increasing the risk of a crash. Customers may experience abnormal engine noise, check engine light illumination, and engine running rough. In rare cases, a hole in the engine block may occur due to a broken valve entering the combustion chamber, increasing the risk of a fire.
Q5. Can you describe the recall campaign and fix?
A5. Kia dealers will replace the engine sub-assembly.
Q6. How will owners of the affected vehicles be notified?
A6. All owners of the subject vehicles will be notified by first class mail with instructions to contact their authorized Kia dealer to have the recall campaign performed beginning on April 5, 2024.
Q7. What should vehicle owners do when they receive the notification?
A7. Upon receipt of the letter, owners are to contact their authorized Kia dealer to arrange to have the recall campaign performed on their vehicle free of charge at no cost to them.
Q8. Where were these vehicles produced?
A8. The affected vehicles were produced at a Kia assembly plant in the U.S.
Q9. Will this cost vehicle owners any money?
A9. No. Kia will perform the recall repair free of charge at no cost to the customer.
Q10. Are there any restrictions on an owner’s eligibility?
A10. No.
Q11. If a customer has an immediate question, where can they get further information?
A11. The customer can contact their local authorized Kia dealership or call Kia’s Customer Care Center at 1-800-333-4KIA (4542), Monday through Friday, 5 AM to 6 PM Pacific Time, or via the internet at www.kia.com (Owner’s Section).
2024MY Telluride
Engine Valve Spring
Basis of Safety Defect Determination 573.6(c)(6)
November 15, 2023
Kia North America (Kia NA) receives techline case from dealer identifying customer complaint of hearing a “pop” noise while driving followed by smoke emitting from the engine compartment of a 2024MY Telluride (incident vehicle). Dealer inspects vehicle and identifies a hole in the engine block.
November 20, 2023—November 21, 2023
Kia NA Safety Office inspects incident vehicle at dealer and identifies damaged internal engine components, a hole in the front side of the engine block, and localized melting on the engine underbody shield. Kia NA Safety Office works with dealer to obtain engine for further evaluation.
December 5, 2023—December 15, 2023
Kia NA Product Quality identifies increasing number of engine replacements for 2024MY Telluride vehicles with low mileage and begins collecting engines for further analysis.
Kia NA Safety Office performs preliminary field data analysis and identifies 47 techline cases involving 2024MY Telluride engine replacements with low mileage. Kia NA Safety Office escalates matter to SEL for further investigation.
December 18, 2023—January 10, 2024
Kia NA collects engines, identifies damaged valves and broken springs and ships parts to Kia HQ for further analysis.
January 23, 2024—January 29, 2024
Kia HQ conducts Scanning electron microscope (SEM) analysis of broken engine valve springs. All show signs of fatigue cracking.
January 31, 2024
Kia HQ informs Kia NA Safety Office that valve spring may become damaged during manufacturing at the supplier and that such damage can increase valve spring(s) susceptibility to fatigue cracking. Kia HQ investigation with supplier identifies all evaluated valve springs manufactured on same day. Kia HQ identifies potential scope based on traceability to suspected engine production date.
Kia NA Safety Office updates data analysis and identifies 83 unique VINs potentially related to the subject condition from warranty, techline and customer complaints (dates of receipt 10/25/2023—1/26/2024).
January 31, 2024
Kia NA decides to recall certain 2024MY Telluride vehicles. One (1) fire (localized melting). No crashes, injuries, or fatalities.
1 Affected Product
Vehicle
| MAKE | MODEL | YEAR |
| KIA MOTOR | TELLURIDE | 2024 |
6 Associated Documents
Recall 573 Report
RCLRPT-24V077-1532.PDF 213.965KB
Recall Acknowledgement
RCAK-24V077-7313.pdf 645.411KB
Chronology
RMISC-24V077-0922.pdf 81.278KB
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Manufacturer Notices(to Dealers,etc)
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Manufacturer Notices(to Dealers,etc)
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Manufacturer Notices(to Dealers,etc)
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Latest Recalls Documents
For the Latest and Most recent Recall Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V077&docType=RCL
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SEOCONTENT-START
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-077
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Kia America, Inc. FEB 07, 2024 NHTSA Recall No. : 24V-077 Manufacturer Recall No. : SC296 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 : 2,872 Estimated percentage with defect : 3 %
Vehicle Information : Vehicle 1 : 2024-2024 Kia Telluride Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : GAS
Descriptive Information : Certain 2024 model year Telluride vehicles manufactured from October 1, 2023 through December 6, 2023. 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 : OCT 01, 2023 – DEC 06, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The engine valve springs may break while driving due to fatigue cracking as a result of damage to the springs during manufacture by the supplier. A broken valve spring may result in a loss of motive power. In rare cases, a hole in the engine block may occur due to a broken valve entering the combustion chamber.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : A loss of motive power increases the risk of a crash. A hole in the engine
block increases the risk of a fire.
Description of the Cause : Fatigue cracking due to damage to the valve spring during manufacture by the
supplier. Part 573 Safety Recall Report 24V-077 Page 2 Identification of Any Warning
that can Occur : Abnormal engine noise, check engine light illumination, and engine running rough. Involved Components : Component Name 1 : SPRING-VALVE Component Description : Valve Spring Component Part Number : 22221-3L310 Supplier Identification : Component Manufacturer
Name : Daewonkangup
Address : 63 Hamansandan 5-gil, Gunbuk-myeon, Gyeongsangnam-do Haman-gun Foreign States 52601
Country : Korea, Republic of Chronology :
See attached document titled “2024MY Telluride Engine Valve Spring 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 vehicles to a Kia dealer. Kia dealers will replace the engine sub-assembly. Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 10, 2022. How Remedy Component Differs from Recalled Component : The remedy engine sub-assembly contains valve springs that are not damaged and thus not susceptible to fatigue cracking. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-077
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
Engines installed in vehicles produced beginning on 12/11/2023 contain valves springs that were not damaged during manufacture and thus not susceptible to fatigue cracking. Vehicles produced from 12/7/2023 through 12/10/2023 that may be equipped with the recall component will be repaired at the plant before distribution to dealers. As a result, vehicles produced after 12/6/2023 are not included in the recall scope. Recall Schedule :
Description of Recall Schedule : The dealer notification begin and end date is February 12, 2024. The
owner notification begin and end date is April 5, 2024.
Planned Dealer Notification Date : FEB 12, 2024 – FEB 12, 2024
Planned Owner Notification Date : APR 05, 2024 – APR 05, 2024
* NR – Not Reported
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SC296
February 12, 2024
ATTENTION: ALL DEALER PRINCIPALS
Kia America, Inc. has decided that a defect which relates to motor vehicle safety exists in certain 2024 MY Telluride vehicles manufactured from October 1, 2023 through December 6, 2023.
The engine valve springs may break while driving due to fatigue cracking as a result of damage to the springs during manufacture by the supplier. A broken valve spring may result in a loss of motive power, increasing the risk of a crash. Customers may experience abnormal engine noise, check engine light illumination, and engine running rough. In rare cases, a hole in the engine block may occur due to a broken valve entering the combustion chamber, increasing the risk of a fire.
All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Kia dealers will replace the engine sub-assembly.
Your Service Manager was sent a copy of the owner notification letter and a Q&A guide for recall questions both of which describe the issue and information on how to access the list of affected vehicles. Kia will start mailing notices to the affected vehicle owners beginning on April 5, 2024.
What Should You Do?
Please make certain the appropriate personnel in your dealership are familiar with the details of this recall to ensure proper responses to customer inquiries and requests to have the recall performed on their vehicles.
NHTSA ADVISORY: It is a violation of Federal law for a dealer to deliver a new motor vehicle covered by this notification under a sale or lease until the defect is remedied.
LEGAL PRIVACY LIABILITY NOTICE: Pursuant to the terms of the Dealer Sales and Service Agreement and the Gramm-Leach-Bliley federal consumer privacy act, you are required to keep confidential any and all information and documents provided to you by Kia America, Inc. or generated by you in the conduct of carrying out work under that Agreement regarding Kia vehicle purchasers and owners, including but not limited to warranty claim information. Kia dealers may use such owner information for the sole purpose of conducting and performing this safety recall campaign, and for no other purpose.
If you have any questions, please contact your Kia District Parts & Service Manager.
Sincerely, Kia Service Department
Enclosures
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SC296
February 12, 2024
ATTENTION: ALL DEALER PARTS & SERVICE MANAGERS
Kia America, Inc. has decided that a defect which relates to motor vehicle safety exists in certain 2024 MY Telluride vehicles manufactured from October 1, 2023 through December 6, 2023.
The engine valve springs may break while driving due to fatigue cracking as a result of damage to the springs during manufacture by the supplier. A broken valve spring may result in a loss of motive power, increasing the risk of a crash. Customers may experience abnormal engine noise, check engine light illumination, and engine running rough. In rare cases, a hole in the engine block may occur due to a broken valve entering the combustion chamber, increasing the risk of a fire.
All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Kia dealers will replace the engine sub-assembly.
The Technical Service Bulletin that provides vehicle inspection and repair procedures, affected VIN production range, and warranty claim information will be posted on the Kia Global Information System (KGIS) at www.kiatechinfo.com on or soon after February 12, 2024.
Enclosed you will find a copy of the owner notification letter and a Q&A Guide for recall questions, both of which describe the issue. Note that any vehicle owner who has already paid for related repairs can submit a request for reimbursement online via the Owner’s Section of www.kia.com. Kia will mail notices to the affected vehicle owners beginning on April 5, 2024.
Also, please make certain the appropriate personnel in your dealership are familiar with the details of this recall to ensure proper responses to customer inquiries and requests to have the recall performed on their vehicles. This Safety Recall Campaign represents an opportunity for your service department to deliver an exceptional service experience (e.g., flexible service appointment process, car wash and vacuum and timely service).
NHTSA ADVISORY: It is a violation of Federal law for a dealer to deliver a new motor vehicle covered by this notification under a sale or lease until the defect is remedied.
LEGAL PRIVACY LIABILITY NOTICE: Pursuant to the terms of the Dealer Sales and Service Agreement and the Gramm-Leach-Bliley federal consumer privacy act, you are required to keep confidential any and all information and documents provided to you by Kia America, Inc. or generated by you in the conduct of carrying out work under that Agreement regarding Kia vehicle purchasers and owners, including but not limited to warranty claim information. Kia dealers may use such owner information for the sole purpose of conducting and performing this safety recall campaign, and for no other purpose.
If you have any questions, please contact your Kia District Parts and Service Manager.
Sincerely, Kia Service Department Enclosures
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SEOCONTENT-END