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February 22, 2019 NHTSA CAMPAIGN NUMBER: 19V120000
Overheated Catalytic Converter May Damage Engine
Piston damage may result in an engine stall, increasing the risk of crash. A broken connecting rod may puncture the engine block allowing engine oil to escape. The leaking oil may contact the exhaust, increasing the risk of a fire.
NHTSA Campaign Number: 19V120
Manufacturer Kia Motors America
Components ENGINE, ENGINE AND ENGINE COOLING
Potential Number of Units Affected 378,967
Summary
Kia Motors America (Kia) is recalling certain 2012-2016 Kia Soul vehicles equipped with 1.6L Gasoline Direct Injection (GDI)
engines. High exhaust gas temperatures may damage the catalytic converter, possibly resulting in abnormal engine combustion and damage to one or more of the engine’s pistons and possible piston connecting rod failure.
Remedy
Kia will notify owners, and dealers will upgrade the Catalytic Overheating Protection Engine Control Unit logic to prevent overheating of the catalytic converter. In addition, the catalytic converter will also be replaced if it has been damaged. Depending on the extent of any damage, the engine may also be replaced, free of charge. The recall began April 17, 2019. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC176.
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.safercar.gov.
Check if your Kia has a Recall
SC176 (Rev 2, 05/31/2019)
April 2019
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
This bulletin provides the procedure to upgrade the Catalyst Overheating Protection (COP) logic in the Engine Control Unit (ECU) and, if necessary, replace the Catalytic Converter on some 2012 ~ 2016 MY Soul (AM/PS) vehicles, produced from July 8, 2011 through August 11, 2016. Depending on the extent of damage, the short block assembly may also need to be replaced. The affected vehicles may exhibit catalyst system efficiency deterioration or a malfunction indicator lamp illumination with an active, history or pending DTC P0420 (Catalyst System Efficiency Below Threshold Bank 1). Under certain conditions, the catalytic converter may become damaged due to overheating caused by an excessive increase of exhaust gas temperatures. If the catalytic converter is damaged, substrate particles can enter the engine combustion chamber and cause abnormal engine combustion. Continuous abnormal engine combustion can result in damage to one or more of the engine’s pistons which can cause piston rod breakage, potentially puncturing the engine block allowing engine oil to escape. Engine oil that contacts a hot exhaust surface may result in a fire. Before conducting the procedure, verify the vehicle is included in the list of affected VINs.
SC176 – 2012-2016 MY KIA SOUL ENGINE CONTROL UNIT (ECU) LOGIC UPGRADE
SAFETY RECALL CAMPAIGN
Q & A
April 8, 2019
Q1. What type of campaign is Kia conducting?
Kia Motors has decided that a defect which relates to motor vehicle safety exists in all 2012-2016 MY Kia Soul vehicles equipped with the 1.6L Gasoline Direct Injection (GDI) engine.
Q2. What vehicles are affected by the recall?
All 2012-2016 MY Kia Soul vehicles equipped with the 1.6L Gasoline Direct Injection (GDI) engine, manufactured from July 8, 2011 through August 11, 2016.
Q3. How many customer vehicles are affected by this recall?
Approximately 378,967 vehicles are included in this campaign.
Q4. What is the concern with the Engine Control Unit (ECU) Logic?
Under certain conditions, the catalytic converter may become damaged due to overheating caused by an excessive increase of exhaust gas temperatures. If the catalytic converter is damaged, substrate particles can enter the engine combustion chamber and cause abnormal engine combustion. Continuous abnormal engine combustion can result in damage to one or more of the engine’s pistons which can cause piston connecting rod breakage, potentially puncturing the engine block allowing engine oil to escape and potentially contact a hot exhaust surface.
Q5. Are there any warnings associated with the condition described above?
If this condition occurs, owners may hear knocking noise from the engine and/or the Malfunction Indicator Lamp (MIL) may illuminate.
A6. Can you describe the recall campaign and fix?
Kia has advised its authorized dealers to upgrade the Catalytic Overheating Protection (COP) logic in the Engine Control Unit (ECU). Also, the catalytic converter will be replaced if it has been damaged. Depending on the extent of any damage, the engine may also be replaced.
Q7. How was the issue discovered?
Through the regular monitoring of field information.
Q8. What should vehicle owners do when they receive the notification?
In the interest of the safety of their passengers, as well as their own safety, customers should immediately contact their Kia dealer to arrange for the recall repair to be conducted.
Q9. Have there been any deaths or injuries as a result of this condition?
There have been no deaths or injuries.
Q10. Has Kia had any litigation regarding this condition?
No.
Q11. Will this cost vehicle owners any money?
No. Kia will perform the recall repair at no cost to the customer.
Q12. What about customers who may have already paid to have this issue remedied?
If the customer has incurred expense to have this issue remedied prior to the date of this notice, the customer may have the opportunity to obtain reimbursement for that expense. Customers may submit their receipts online to Kia via the Owners section of www.kia.com or mail their receipts with the attached Request for Reimbursement Form directly to Kia for review and consideration:
Consumer Assistance Center
Kia Motors America, Inc.
P.O. Box 52410
Irvine, CA 92619-2410
1-800-333-4542
Q13. How long will the repair take?
The time required to upgrade the COP logic in the ECU is approximately one (1) hour. Note that if the catalytic converter and/or the engine need to be replaced, additional time to complete the repair will be necessary. Kia recommends that customers contact the dealer for an estimate of how long they may need the vehicle and schedule a service appointment to minimize inconvenience. (Most Kia dealers have online appointment scheduling via their dealership web sites to maximize your convenience).
Q14. How will owners of the affected vehicles be notified?
Kia will be notifying owners of the affected vehicles by first-class mail beginning on April 12, 2019.
Q15. Are there any restrictions on an owner’s eligibility?
No.
Q16. If a customer has an immediate question, where can they get further information?A16.The customer can contact their local Kia dealership or call Kia’s Consumer Assistance Center at 1-800-3334KIA (4542), Monday through Friday, 5 AM to 6 PM Pacific Standard Time, or via the internet @ www.kia.com (Owner’s Section).
IMPORTANT SAFETY RECALL
(NHTSA Recall Number: 19V120)
This notice applies to your vehicle: (Insert VIN)
April 16, 2019
Kia has identified a defect in your vehicle which relates to motor vehicle safety.
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Kia Motors has decided that a defect which relates to motor vehicle safety exists in the 2012-2016 MY Kia Soul vehicles equipped with the 1.6L Gasoline Direct Injection (GDI) engine. The defect may cause damage to the catalytic converter due to overheating, resulting in abnormal engine combustion and damage to the engine pistons. Piston damage can result in a stall, increasing the risk of a crash. If a piston rod breaks and punctures the engine block, oil can escape, increasing the risk of a fire.
What Is The Problem?
Under certain conditions, the catalytic converter may become damaged due to overheating caused by an excessive increase of exhaust gas temperatures. If the catalytic converter is damaged, substrate particles can enter the engine combustion chamber and cause abnormal engine combustion. Continuous abnormal engine combustion can result in damage to one or more of the engine’s pistons which can cause piston rod breakage, potentially puncturing the engine block allowing engine oil to escape and potentially contact a hot exhaust surface. These conditions can increase the risk of an engine stall or fire.
If this condition occurs, you may hear knocking noise from the engine and/or the Malfunction Indicator Lamp (MIL) may illuminate.
Kia Will Upgrade the Catalytic Overheating Protection (COP) logic in the Engine Control Unit (ECU) and If Necessary Replace the Catalytic Converter and/or Engine at No Cost to You.
Kia has advised its authorized dealers to upgrade the COP ECU logic to prevent overheating of the catalytic converter. The catalytic converter will also be replaced if it has been damaged. Depending on the extent of any damage, the engine may also be replaced. This work will be performed at Kia’s expense at no cost to you. The time required to upgrade the COP ECU logic is approximately one (1) hour. Note that if the catalytic converter and/or the engine need to be replaced, additional time to complete the repair will be necessary. We recommend that you contact the dealer for an estimate of how long they may need the vehicle and schedule a service appointment to minimize inconvenience.
What Should You Do
- In the interest of the safety of your passengers, as well as your own safety, please immediately contact your Kia dealer to arrange for the recall repair to be conducted.
- To find your nearest dealer, visit kia.com and click the “Find Dealer” button in the upper right corner (“Dealers” on a mobile device). You can also use the QR code below with your mobile device to access this information (see the bottom of this letter for more information about QR code use):
What If You Have Already Paid To Have This Situation Corrected?
If you have incurred expense to remedy this issue prior to the date of this notice, you may have the opportunity to obtain reimbursement for that expense. You may submit your receipts online to Kia via the Owners section of www.kia.com or mail your receipts with the attached Request for Reimbursement Form directly to Kia for review and consideration:
Consumer Assistance Center
Kia Motors America, Inc
P.O. Box 52410
Irvine, CA 92619-2410
1-800-333-4542
The Kia Consumer Assistance Center is available at the number listed above if you have any questions or require assistance in submitting your claim.
Pursuant to the General Reimbursement Plan issued by Kia pursuant to Federal Regulation 49 CFR 573.13, Kia will use its best efforts to respond to your claim within sixty (60) days of receipt and at that time Kia may either accept or reject that claim or it may request more information to evaluate the claim.
Have You Changed Your Address Or Sold Your Kia?
If you have changed your home address, sold your Kia vehicle, or no longer own your vehicle, please complete the attached prepaid “Change of Address/Ownership” card and mail it to us. You can also contact the Consumer Assistance Center phone number listed above.
What If You Are A Vehicle Lessor?
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
What If You Have Other Questions?
If your dealer does not respond to your service request in a timely manner, we suggest that you call Kia’s Consumer Assistance Center at 1-800-333-4542. This number has TTY capability. If you still are not satisfied that we have remedied this situation without charge and within a reasonable amount of time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, S.E., Washington, DC 20590; or call the toll free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov.
This action has been taken in the interest of your safety, and we regret any inconvenience this situation may cause you.
Sincerely,
Consumer Affairs Department
5 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| KIA | SOUL | 2012-2016 |
14 Associated Documents
Remedy Instructions and TSB
RCRIT-19V120-5381.pdf 1382.59KB
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Chronology
RMISC-19V120-6176.pdf 41.126KB
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Recall Acknowledgement
RCAK-19V120-4114.pdf 245.776KB
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Defect Notice 573 Report
RCLRPT-19V120-1711.PDF 213.761KB
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Manufacturer Notices(to Dealers,etc)- April 8, 2019 Attention: All Kia Parts & Service Managers
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Miscellaneous Document – SC176 – 2012-2016 MY KIA SOUL ENGINE CONTROL UNIT (ECU) LOGIC UPGRADE SAFETY RECALL CAMPAIGN Q & A April 8, 2019
RMISC-19V120-2440.pdf 47.771KB
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ISSUED Owner Notification Letter(Part 577)
RCONL-19V120-7353.pdf 94.747KB
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Manufacturer Notices(to Dealers,etc)- April 8, 2019 Attention: All Dealer Principals
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Remedy Instructions and TSB
RCRIT-19V120-4755.pdf 1465.916KB
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Remedy Instructions and TSB
RCRIT-19V120-9149.pdf 1460.726KB
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Remedy Instructions and TSB
RCRIT-19V120-8764.pdf 1391.898KB
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Recall Quarterly Report #1, 2019-2
RCLQRT-19V120-0841.PDF 211.157KB
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Recall Quarterly Report #2, 2019-3
RCLQRT-19V120-2946.PDF 211.262KB
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Recall Quarterly Report #3, 2019-4
RCLQRT-19V120-1637.PDF 211.361KB
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Latest Recalls Documents
For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V120&docType=RCL
1 Associated Investigation
Non-crash Vehicle Fires
NHTSA ID: DP18003
Dated opened: August 21, 2018
In a letter dated June 11, 2018, the Center for Auto Safety (CAS) petitioned the National Highway Traffic Safety Administration (NHTSA) to initiate a safety defect investigation into non-collision related fires on model year (MY) 2011-2014 Kia Optima and Sorento, and Hyundai Sonata and Santa Fe vehicles. In a letter dated July 24, 2018, CAS requested that MY 2010-2015 Kia Soul vehicles be added to the petition. CAS stated that there is a higher number of complaints to NHTSA regarding non-crash fires on these vehicles compared to other similar vehicles. The Office of Defects Investigation (ODI) had already opened Recall Queries (RQ17-003 and RQ17-004) on all Kia and Hyundai vehicles equipped with Theta II engines for engine failures that may cause stalling and fires. The queries cover most of the petition subject Optima, Sorento, Sonata, and Santa Fe vehicles but not any of the subject Soul vehicles.
On August 21, 2018, ODI opened a Defect Petition (DP18-003) to evaluate whether to grant or deny the CAS petition. ODI sent Information Request letters to Kia and Hyundai (September and October 2018) requesting information on all engine and non-engine related fires in the petition vehicles. ODI performed extensive analysis on the information obtained from Kia and Hyundai. During the DP18-003 analysis, Kia and Hyundai each initiated three additional safety recalls related to engine compartment fires on certain petitioned and non-petitioned vehicles (nearly 740,000 total vehicles: Recalls 18V-907, 18V-934, 19V-101, 19V-063, 19V-120, and 19V-204). Based on ODI’s review of the applicable materials, including responses to Information Requests sent to multiple manufacturers, Vehicle Owner Questionnaires (VOQ), and Early Warning Data, NHTSA decided to grant the petition.
The CAS petition was granted on March 29, 2019. Preliminary Evaluations (PE19-003 on Hyundai and PE19-004 on Kia) have been opened to assess the scope, frequency, and potential safety-related consequences of alleged defects relating to non-collision vehicle fires in the 2011-2014 Kia Optima and Sorento, 2011-2014 Hyundai Sonata and Santa Fe, and 2010-2015 Kia Soul.
Attached is a list of the reference numbers for the 404 VOQs cited above.
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SEOCONTENT-START***************************************************************************************************************
*
*
*
*
*
***************************************************************************************************************File Under: <Safety Recall Campaign>
Circulate To: General Manager Service Manager Parts Manager
Service Advisors Technicians Body Shop Manager Fleet Repair
X
X
X
X
X
X
There is no charge to the vehicle owner for this repair. Under applicable law, you may not sell or otherwise deliver any affected new vehicle until it has been repaired pursuant to the procedures set forth in this bulletin.
NOTICE
To assure complete customer satisfaction, always remember to refer to WebDCS Warranty Coverage (validation) Inquiry Screen (Service → Warranty Coverage → Warranty Coverage Inquiry) for a list of any additional campaigns that may need to be performed on the vehicle before returning it to the customer.
NOTICE
For any other failure not related to MIL ON with DTCs P0420 and P030X, perform diagnostic and repair according to normal service procedures.
IMPORTANT
SUBJECT:
GROUP
MODEL
Safety Recall Campaign
2012-2016MY
Soul (AM, PS)
NUMBER
DATE
SC176 (Rev 3, 07/30/2019)
April 2019
SAFETY RECALL CAMPAIGN
ENGINE CONTROL UNIT (ECU)
LOGIC IMPROVEMENT (SC176)
This bulletin provides the procedure to upgrade the Catalyst Overheating Protection (COP) logic in the Engine Control Unit (ECU) and, if necessary, replace the Catalytic Converter on some 2012 ~ 2016 MY Soul (AM/PS) vehicles, produced from July 8, 2011 through August 11, 2016. Depending on the extent of damage, the short block assembly may also need to be replaced. The affected vehicles may exhibit catalyst system efficiency deterioration or a malfunction indicator lamp illumination with an active, history or pending DTC P0420 (Catalyst System Efficiency Below Threshold Bank 1). Under certain conditions, the catalytic converter may become damaged due to overheating caused by an excessive increase of exhaust gas temperatures. If the catalytic converter is damaged, substrate particles can enter the engine combustion chamber and cause abnormal engine combustion. Continuous abnormal engine combustion can result in damage to one or more of the engine’s pistons which can cause piston rod breakage, potentially puncturing the engine block allowing engine oil to escape. Engine oil that contacts a hot exhaust surface may result in a fire. Before conducting the procedure, verify the vehicle is included in the list of affected VINs.
This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area.
NOTICE
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
Page 2 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
SUBJECT:
Inspection Procedure:
1. Using the KDS (connected to the internet to create and transmit a VDN*), perform a Fault
Code Search and confirm DTC P0420 or both P0420 and P030X is/are stored (Active,
History or Pending). Follow the flow chart below and perform the necessary procedure(s).
*A Vehicle Diagnosis Number (VDN) must be created with DTC P0420 or P0420 and P030X, prior to ordering select
parts and performing necessary procedure(s) according to flow chart. If a VDN is not created, Parts order entry or
Warranty claim submission issues may occur.
Flow Chart:
Is DTC P0420 stored?
Is DTC P0420 stored?
Perform Engine Compression Check Replace catalytic converter & perform ECU logic improvement
Replace short block, catalytic converter, & perform ECU logic improvement Perform ECU logic
improvement
Yes
Fail
(under minimum specification of 149 psi)
Pass
(above minimum specification of 149 psi)
Is DTC P030X stored?
No
Yes
No
Replace catalytic converter & perform ECU logic improvement Is DTC P030X
“Active”
No
Yes
Contents:
ECU Upgrade Procedure: …………………………………………………………………….. Pages 2-8
Engine Compression Check Procedure: ……………………………………………………. Page 9
Catalytic Converter Assembly Replacement Procedure: …………………………….. Page 9
Short Block Replacement Procedure: ……………………………………………………… Pages10
ECU Upgrade Procedure:
To correct this condition, the ECU should be reprogrammed using the KDS download, as described in this bulletin.
Upgrade Event Name
412. PS GAMMA 1.6GDI ECU MIL ON DTC (P0420) LOGIC IMPROVEMENT
413. AM GAMMA 1.6GDI ECU MIL ON DTC (P0420) LOGIC IMPROVEMENT
A fully charged battery is necessary before ECU upgrade can take place. It is recommended that the Midtronics GR8-1299 system be used in ECU mode during charging. DO NOT connect any other battery charger to the vehicle during ECU upgrade.
All ECU upgrades must be done with the ignition key in the ‘ON’ position.
Be careful not to disconnect the VCI-II connected to the vehicle during the ECU upgrade
procedure.
DO NOT start the engine during ECU upgrade.
DO NOT turn the ignition key ‘OFF’ or interrupt the power supply during ECU upgrade.
When the ECU upgrade is completed, turn the ignition ‘OFF’ and wait 10 seconds before starting the engine.
ONLY use approved ECU upgrade software designated for the correct model, year.
NOTICE
Before attempting an ECU upgrade on any Kia model, make sure to first determine whether the particular model is equipped with an immobilizer security system. Failure to follow proper procedures may cause the PCM to become inoperative after the upgrade and any claims associated with this repair may be subject to chargeback.
NOTICE
A “stored” DTC
refers to either;
an Active, History
or Pending DTC.
Page 3 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
SUBJECT:
ROM ID INFORMATION TABLE:
Upgrade Event #412 (PS) & 413 (AM) Model EM TM IMMO ECU P/No. ECU ROM ID Previous New
12-13MY
Soul (AM)
1.6
ULEV
MT
No
39110-2BCG0 39110-2BCJ0
GGAM-BNU6ES00600 GGAM-BNU6ES01600 GGAM-BNU6ES02600 GGAM-BNU6ES03600 GGAM-BNU6ES04600 GGAM-BNU6ES05600 GGAM-BNU6ES06600 GGAM-BNU6ES07600 GGAM-BNU6ES08600 GGAM-DNU6ES00600 GGAM-DNU6ES01600 GGAM-DNU6ES02600 GGAM-DNU6ES03600 GGAM-DNU6ES04600 GGAM-DNU6ES05600 GGAM-DNU6EF05600 GGAM-DNU6EF06600 GGAM-DNU6EF07600
GGAM-DNU6EF08600
AT
No
39110-2BCG5 39110-2BCG2 39110-2BCC1
GGAM-BNU6PS00C00 GGAM-BNU6PS01C00 GGAM-BNU6PS02C00 GGAM-BNU6PS03C00 GGAM-BNU6PS04C00 GGAM-BNU6PS05C00 GGAM-BNU6PS06C00 GGAM-BNU6PS07C00 GGAM-BNU6PS08C00 GGAM-DNU6PS00C00 GGAM-DNU6PS01C00 GGAM-DNU6PS02C00 GGAM-DNU6PS03C00 GGAM-DNU6PS04C00 GGAM-DNU6PS05C00 GGAM-DNU6PS06C00 GGAM-DNU6PS07C00 GGAM-DNU6PF07C00 GGAM-DNU6PF08C00 GGAM-DNU6PF09C00
GGAM-DNU6PF0AC00
39110-2BCG8 39110-2BCG3 39110-2BCE1
GIAM-BNU6PS00C00 GIAM-BNU6PS01C00 GIAM-BNU6PS02C00 GIAM-BNU6PS03C00 GIAM-BNU6PS04C00 GIMA-BNU6PS05C00 GIAM-BNU6PS06C00 GIAM-BNU6PS07C00 GIAM-BNU6PS08C00 GIAM-DNU6PS00C00 GIAM-DNU6PS01C00 GIAM-DNU6PS02C00 GIAM-DNU6PS03C00 GIAM-DNU6PF03C00 GIAM-DNU6PF04C00
GIAM-DNU6PF05C00
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176) Page 4 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
SUBJECT: Model EM TM IMMO ECU P/No. ECU ROM ID Previous New
14MY
Soul (PS)
1.6
ULEV
MT
No
39110-2BSH0
GGPS-DNU6ES00600 GGPS-DNU6ES01600 GGPS-DNU6EF01600 GGPS-DNU6EF02600 GGPS-DNU6EF03600
GGPS-DNU6EF04600
AT
No
39110-2BSH5
GGPS-DNU6PS00C00 GGPS-DNU6PS01C00 GGPS-DNU6PF01C00 GGPS-DNU6PF02C00 GGPS-DNU6PF03C00
GGPS-DNU6PF04C00
15MY
Soul (PS)
1.6
ULEV
MT
No
39110-2BSH1
GGPS-FNU6ES00600 GGPS-FNU6ES01600 GGPS-FNU6ES02600 GGPS-FNU6EF02600 GGPS-FNU6EF03600
GGPS-FNU6EF04600
AT
No
39110-2BSH6
39110-2BSH7
GGPS-FNU6PS00C00 GGPS-FNU6PS01C00 GGPS-FNU6PS02C00 GGPS-FNU6PF02C00 GGPS-FNU6PF03C00
GGPS-FNU6PF04C00
16MY
Soul (PS)
1.6
ULEV
MT
No
39110-2BSG3
GGPS-GNU6ES00600 GGPS-GNU6ES01600 GGPS-GNU6EF01600
GGPS-GNU6EF02600
AT
No
39110-2BSE8
GGPS-GNU6PS00C00 GGPS-GNU6PS01C00 GGPS-GNU6PF01C00
GGPS-GNU6PF02C00
To verify the vehicle is affected, be sure to check the Calibration Identification of the vehicle’s ECM ROM ID and reference the Information Table as necessary.
1.
Connect the VCI-II to the OBD-II connector, located under the driver’s side of the instrument panel.
Prior to performing the ECU upgrade, be sure to check that the KDS is fully charged.
NOTICE
The ECU upgrade function on KDS operates wirelessly. It is not necessary to perform the upgrade via USB cable.
NOTICE
Page 5 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
SUBJECT:
2.
With the ignition ON, turn ON the KDS tablet. Select KDS from the home screen.
3.
Confirm communication with VCI (A) and then configure the vehicle (B) using the AUTO VIN (C) feature.
4.
Select ECU Upgrade.
5.
The KDS will check the server for recently uploaded Events and then automatically download Upgrade Event #412(PS) or #413(AM).
A
B
C
The vehicle must be identified in Vehicle Selection to download an Event for that vehicle.
NOTICE
KDS screenshot shown above is for demonstration purposes only. Events shown in screenshot are not applicable to this bulletin.
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176) Page 6 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
SUBJECT:
6.
Select Auto Mode.
7.
Select the Engine system under the System selection menu.
Touch ID Check (D) and confirm that the latest update is available.
Select Upgrade Event #412(PS) or #413(AM) and select Upgrade to continue.
8.
The ECU upgrade will begin and the progress of the upgrade will appear on the bar graph. Upgrade part (1/2) (E) will download the upgrade event to the VCI-II. Upgrade part (2/2) (F) will upgrade the ECU.
9.
If a “Communication Fail” screen appears, verify that the VCI-II and KDS are communicating properly. Touch OK and restart the procedure from step 4.
Do NOT attempt to perform a Manual Mode upgrade UNLESS Auto Mode fails. Always follow the instructions given on the KDS in either Auto or Manual mode. CAUTION
D
Do not touch the system buttons (like ‘Back’, ‘Home’, ‘etc.’) while performing ECU Upgrade. CAUTION
E
F
If an error notice continues to appear or if the upgrade cannot be performed, DO NOT disconnect the KDS/VCI-II. Contact GIT America Help Desk at (888) 542-4371 or Techline.
NOTICE
Page 7 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
SUBJECT:
10.
When instructed on the KDS, turn the ignition OFF for ten (10) seconds then back on. Touch OK to continue.
11.
Once the upgrade is complete, touch OK to finalize the procedure.
12.
When prompted, select YES to check for Diagnostic Trouble Codes (DTC) and erase any DTCs stored such as EPS, ESC, and TPMS that may have been set during the upgrade.
13.
Start the engine to confirm proper operation of the vehicle.
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176) Page 8 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
SUBJECT:
Manual Upgrade Procedure:
Manual Mode ECU Upgrade Passwords Model Menu Password
Soul (AM)
AM GAMMA 1.6GDI ULEV 12~13MY MT -IMMO NON ISG : 39110-2BCG0/J0
1020
AM GAMMA 1.6GDI ULEV 12~13MY AT -IMMO NON ISG : 39110-2BCG5/G2/C1
1022
AM GAMMA 1.6GDI ULEV 12~13MY AT -IMMO ISG : 39110-2BCG8/G3/E1
1024
Soul (PS)
PS GAMMA 1.6GDI ULEV 14MY MT -IMMO NON ISG : 39110-2BSH0
1020
PS GAMMA 1.6GDI ULEV 14MY AT -IMMO NON ISG : 39110-2BSH5
1025
PS GAMMA 1.6GDI ULEV 15MY MT -IMMO NON ISG : 39110-2BSH1
1022
PS GAMMA 1.6GDI ULEV 15MY AT -IMMO NON ISG : 39110-2BSH7/H6
1027
PS GAMMA 1.6GDI ULEV 16MY MT -IMMO NON ISG : 39110-2BSG3
1023
PS GAMMA 1.6GDI ULEV 16MY AT -IMMO NON ISG : 39110-2BSE8
1030
1.
Within the ECU Upgrade screen displayed, select Manual Mode.
2.
Select the Engine system under the System selection menu. Select Upgrade Event #412(PS) or #413(AM) and select Upgrade to continue.
3.
Select the appropriate control unit part number with reference to the ROM ID Information Table on pages 3-4 and select OK.
4.
Enter the appropriate password from the Manual Mode password table above and select OK.
5.
The upgrade will begin and the progress of the upgrade will appear on the bar graph.
6.
When instructed on the KDS, turn the ignition OFF for ten (10) seconds then back on. Touch OK to continue.
7.
Once the upgrade is complete, touch OK to finalize the procedure.
8.
When prompted, select YES to check for Diagnostic Trouble Codes (DTC) and erase any DTCs stored such as EPS, ESC, and TPMS that may have been set during the upgrade.
9.
Start the engine to confirm proper operation of the vehicle.
The manual upgrade should ONLY be performed if the automatic upgrade fails.
If the automatic upgrade fails, turn the ignition OFF for about 10 seconds then place it back in the ON position to reset the control unit BEFORE performing manual upgrade.
See table below for Manual Mode passwords.
NOTICE
Page 9 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
SUBJECT:
Engine Compression Check Procedure: P0420 “stored” & P030X “Active”
1.
Ensure all conditions are met and then perform an engine compression check by referring to the “Engine Mechanical System → Compression Test” chapter in the applicable Shop Manual on KGIS.
Conditions:
Coolant at operating temp (176°F)
Battery fully charged
If all cylinder compression results* are above the minimum specification, proceed to the Catalytic Converter Assembly Replacement Procedure below.
If any cylinder compression result* is below the minimum specification, proceed to the Short Block Assembly Replacement Procedure on page 10.
*Perform all cylinder compression checks twice (2x) and record both peak cranking values clearly and legibly on the repair order.
Tightening torque for spark plugs:
10.8 – 17.0 lb.ft (14.7 – 24.5 N.m,
1.5 – 2.5 kgf.m)
Compression Specifications
Standard
178 PSI, 1225.83 KPa, 12.5 kg.cm2
Minimum
149 PSI, 1029.69 KPa, 10.5 kg.cm2
Catalytic Converter Assembly Replacement Procedure:
1.
Record or retain the customer’s radio presets using the Memory Saver and then disconnect the negative (-) battery terminal.
2.
Replace the catalytic converter assembly by referring to the “Engine Mechanical System → Intake and Exhaust System → Exhaust Manifold → Repair procedures” chapter in the applicable Shop Manual on KGIS.
3.
Reconnect the negative (-) battery terminal. Verify customer’s radio presets were retained and restore, if necessary, using recorded information in step 1 of the Inspection Procedure.
4.
Perform the ECU Logic Improvement Procedure on page 2.
Be sure to transfer the O2 sensor and replace the exhaust manifold and front pipe gaskets.
NOTICE
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176) Page 10 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
SUBJECT:
Short Block Replacement Procedure: P0420 “stored” & P030X “Active”
1.
Record or retain the customer’s radio presets using a Memory Saver.
2.
Remove the engine by referring to the “Engine Mechanical System → Engine And Transaxle Assembly → Engine And Transaxle Assembly → Repair procedures” chapter in the applicable Shop Manual on KGIS.
Refer to TSB ENG190 for information regarding engine replacement practices.
3.
Remove the cylinder head by referring to the “Engine Mechanical System → Cylinder Head Assembly → Cylinder Head → Repair procedures” chapter in the applicable Shop Manual on KGIS.
4.
Place the new engine short block on an engine stand.
5.
Install all removed components from the old engine block onto the new engine block utilizing all parts from the Short Block Service Kit. Be advised of notes below.
Notes:
Cylinder Head
Use a new cylinder head gasket.
Be sure to replace the cylinder head bolts and washers and torque them in the sequence shown.
Tightening torque of head bolts:
21.7 lb.ft (29.4 N.m, 3.0 kgf.m) + 90° + 90° (180° degrees total)
Some Shop Manual instructions regarding the removal of certain components during the removal of the engine may be repeated in the removal of the cylinder head.
NOTICE
Page 11 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
SUBJECT:
Valve Cover
Use a new valve cover gasket.
Be sure to torque the valve cover bolts in the sequence shown.
Tightening torque of valve cover:
Step 1: 2.9 – 4.3 lb.ft (3.9 – 5.9 N.m,
0.4 – 0.6 kgf.m)
Step 2: 5.8 – 7.2 lb.ft (7.8 – 9.8 N.m,
0.8 – 1.0 kgf.m)
High Pressure Pump & Roller Tappet:
Refer to TSB ENG083 for special attention and handling procedures of GDI-specific components.
When installing the high pressure pump and roller tappet onto the new engine, apply engine oil to the roller tappet and O-rings of the high pressure pump.
Tightening torques of pump bolts:
9.4 – 10.9 lb.ft (12.8 – 14.7 N.m,
1.3 – 1.5 kgf.m)
Tightening torques of pipe flare nuts:
19.5 – 23.9 lb.ft (26.5 – 32.4 N.m,
2.7 – 3.3 kgf.m)
High Pressure Fuel Pipe:
1. Properly position the new fuel pipe (A) and then hand-tighten both flare nuts (B).
Refer to TSB ENG083 for gasoline direct injection (GDI) specific information, including related warnings and cautions for handling high fuel pressure system components.
NOTICE
A
B
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176) Page 12 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
SUBJECT:
2. Install the pipe retaining bracket and bolts (C) and torque to specifications.
Tightening torque (bracket bolts):
5.8 – 8.7 lb.ft (7.8 –11.8 N.m,
0.8 – 1.2 kgf.m)
3. Using a click-type/electronic torque wrench and SST 09314-3Q100, torque both flare nuts (B) to specifications.
Tightening torque (flare nuts):
19.5 – 23.9 lb.ft (26.5 – 32.4 N.m,
2.7 – 3.3 kgf.m)
*Click here to see a video tutorial of high pressure fuel pipe install (includes high pressure pump install).
*The engine used in the video tutorial is a 2.0L Theta engine and is used for demonstration purposes only.
Intake Manifold:
Prior to installation, replace the intake manifold gasket.
Torque bolts in the sequence shown.
Tightening torque of bolts:
13.7 – 17.4 lb.ft (18.6 – 23.5 N.m,
1.9 – 2.4 kgf.m)
C
The high pressure fuel pipe bracket and bolts must be installed and properly torqued prior to torqueing the high pressure fuel pipe flare nuts.
IMPORTANT
B
B
2
4
2
2
2
1
2
5
2
3
C
Page 13 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
SUBJECT:
Exhaust Manifold:
Prior to installation, replace the exhaust manifold and front pipe gaskets.
Torque nuts in the sequence shown.
Replace the exhaust front pipe nuts.
Tightening torque of nuts:
36.2 – 39.7 lb.ft (49.0 – 53.9 N.m,
5.0 – 5.5 kgf.m)
6.
Verify proper operation of the vehicle with road test and erase any stored DTCs (e.g. EPS, ESC, and TPMS) that may have been set by this procedure. Verify no leaks exist and ensure engine oil and coolant are at their proper level.
If any DTCs are still active, follow any related diagnosis and repair as needed.
7.
Verify customer’s radio presets were retained and restore, if necessary, using recorded information in step 1 of the Inspection Procedure.
2
2
2
2
2
2
2
2
2
1
5
4
2
6
3
7
8
9
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176) Page 14 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
SUBJECT:
AFFECTED VEHICLE RANGE: Model Production Date Range
Soul (AM, PS)
July 8, 2011 through August 11, 2016
REQUIRED PART:
Part Name Part Number Figure Comment
Catalytic Converter
Assembly
28510 2BEF1QQK
–
Exhaust Manifold
Gasket
28521 2B400
DTC P0420 must Be stored prior to replacement of the catalytic converter.
For replacement of catalytic converter only (Do not order if replacing short block)
Exhaust Front Pipe Gasket
28751 3S000
Exhaust Front Pipe Nuts (2) (AM) only
28679 21000
Exhaust Front Pipe Nuts (2) (PS) only
13183 12000
Short Block Assembly
204X2 2BH00QQK
(Non-ISG)
DTCs P0420 (Active, Pending or History) and P030X (Active)
must be stored prior to replacement of
Short Block
205X2 2BH00QQK
(ISG)
Short Block Assembly
Service Kit
21110 2BH00QQK
–
Includes:
1 Valve Cover Gasket
1 OCV Adapter Gasket
1 Exhaust Manifold Gasket
1 Intake Manifold Gasket
1 Cylinder Head Gasket
10 Cylinder Head Bolts
10 Cylinder Head Washers
1 High Press. Pump O-Ring
1 High Press. Fuel Pipe
2 High Press. Pump Bolts
1 Exhaust Pipe Gasket
2 Exhaust Pipe Nuts
1 Oil Strainer Gasket
1 Heater Pipe O-Ring
1 Oil Pump O-Ring
1 Water Pump Gasket
Page 15 of 15
TSB: SC176 (Rev 3) Soul (AM, PS) April 2019
ENGINE CONTROL UNIT (ECU) LOGIC IMPROVEMENT (SC176)
SUBJECT:
WARRANTY INFORMATION:
N Code: N99 C Code: C99
Notes: Use sublet code ‘X1’ with a maximum allowed amount of $2.00 for liquid sealant. Use sublet code ‘X3’ with a maximum allowed amount of $29.80 for engine oil & coolant. If necessary, please use sublet code ‘RX’ for rental expense reimbursement which will create a separate ‘N’ claim (example, submitting campaign repair claim ‘12345 A’ with rental sublet ‘RX’ will create a separate rental claim ‘12345 N’). For any related vehicle concerns after the campaign is closed, utilize the normal service parts and procedures. There may be a mandatory parts return request for parts associated with this campaign repair when the catalytic converter and/or engine is replaced.
Model Claim Type Causal P/N Qty. Repair Description Labor Op Code Op Time Replacement P/N Qty.
AM
12-13MY
R
39110 2BCG5
0
(SC176)
ECU Logic
Improvement Only
191025R0
0.3
M/H
N/A
0
(SC176)
Cat Converter Replacement & ECU Logic Improvement
191025R1
DTC Required
1.4
M/H
28510 2BEF1QQK
1
28521 2B400
1
28751 3S000
1
13183 12000
2
(SC176)
Engine Compression Check, Cat Converter Replacement, & ECU Logic Improvement
191025R2
DTCs Required
1.9
M/H
28510 2BEF1QQK
1
28521 2B400
1
28751 3S000
1
13183 12000
2
(SC176)
Engine Compression Check, Short Block Replacement, Cat Converter Replacement, & ECU Logic Improvement
191025R3
DTCs Required
10.5
M/H
28510 2BEF1QQK
1
204X2 2BH00QQK (Non-ISG)
1
205X2 2BH00QQK (ISG)
21110 2BH00QQK
1
PS
14-16MY
R
39110 2BSH5
0
(SC176)
ECU Logic
Improvement Only
191026R0
0.3
M/H
N/A
0
(SC176)
Cat Converter Replacement & ECU Logic Improvement
191026R1
DTC Required
1.4
M/H
28510 2BEF1QQK
1
28521 2B400
1
28751 3S000
1
13183 12000
2
(SC176)
Engine Compression Check, Cat Converter Replacement, & ECU Logic Improvement
191026R2
DTCs Required
1.9
M/H
28510 2BEF1QQK
1
28521 2B400
1
28751 3S000
1
13183 12000
2
(SC176)
Engine Compression Check, Short Block Replacement, Cat Converter Replacement, & ECU Logic Improvement
191026R3
DTCs Required
10.5
M/H
28510 2BEF1QQK
1
204X2 2BH00QQK (Non-ISG)
1
21110 2BH00QQK
1
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference SC176 when accessing the WebDCS system.
NOTICE
**************************************************************************************************************
April 8, 2019
Attention: All Kia Parts & Service Managers
Kia Motors America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign on all 2012-2016 MY Soul vehicles equipped with a 1.6L Gasoline Direct Injection (GDI) engine, manufactured from July 8, 2011 through August 11, 2016, to upgrade the Catalytic Overheating Protection (COP) logic in the Engine Control Unit (ECU). The catalytic converter, if damaged, will also be replaced. Depending on the extent of any damage, the engine may also be replaced.
Under certain conditions, the catalytic converter may become damaged due to overheating caused by an excessive increase of exhaust gas temperatures. If the catalytic converter is damaged, substrate particles can enter the engine combustion chamber and cause abnormal engine combustion. Continuous abnormal engine combustion can result in damage to one or more of the engine’s pistons which can cause piston connecting rod breakage, potentially puncturing the engine block allowing engine oil to escape and potentially contact a hot exhaust surface. These conditions can increase the risk of an engine stall or fire.
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 during the week of April 8, 2019.
PARTS INFORMATION – As the need for Catalytic Converter replacement is expected to be very low, a valid VIN will be required for order entry.
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. A list of Kia Soul vehicle owners affected by this recall can be accessed on WEBDCS. Log onto the site, select the Campaigns Tab, click on Open Campaign Report in the left side menu, and select SC176 to generate the list.
Notices to the affected 2012-2016 MY Soul vehicle owners will be mailed beginning on April 12, 2019. Please start performing the repairs immediately on any affected vehicles currently in your inventory.
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 request to have the recall performed on their 2012-2016 MY Soul vehicles. This Safety Recall 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 Motors 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.
Your prompt attention in completing this recall is appreciated. If you have any questions, please contact your Kia District Parts and Service Manager.
Sincerely,
Neem Van der Reest
Manager, Technical Services & Engineering
Enclosures
SC176
SEOCONTENT-END