SC176 - Engine Control Unit (ECU) Logic - 2012-2016 Kia Soul

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


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


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?
A1. 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?
A2. 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?
A3. Approximately 378,967 vehicles are included in this campaign.

 

Q4. What is the concern with the Engine Control Unit (ECU) Logic?
A4. 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?
A5. 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?
A6. 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?
A7. Through the regular monitoring of field information.

 

Q8. What should vehicle owners do when they receive the notification?
A8. 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?
A9. There have been no deaths or injuries.

 

Q10. Has Kia had any litigation regarding this condition?
A10. No.

 

Q11. Will this cost vehicle owners any money?
A11. 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?
A12. 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?
A13. 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?
A14. 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?
A15. 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

Dear Kia Soul Owner:

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 http://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

12 Associated Documents

Remedy Instructions and TSB

RCRIT-19V120-5381.pdf 1382.59KB

Download (PDF, 1.32MB)


Chronology

RMISC-19V120-6176.pdf 41.126KB

Download (PDF, 40KB)


Recall Acknowledgement

RCAK-19V120-4114.pdf 245.776KB

Download (PDF, 240KB)


Defect Notice 573 Report

RCLRPT-19V120-1711.PDF 213.761KB

Download (PDF, 209KB)


Manufacturer Notices(to Dealers,etc)- April 8, 2019 Attention: All Kia Parts & Service Managers

RCMN-19V120-3267.pdf 28.523KB

Download (PDF, 28KB)


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

Download (PDF, 47KB)


ISSUED Owner Notification Letter(Part 577)

RCONL-19V120-7353.pdf 94.747KB

Download (PDF, 93KB)


Manufacturer Notices(to Dealers,etc)- April 8, 2019 Attention: All Dealer Principals

RCMN-19V120-1021.pdf 29.122KB

Download (PDF, 28KB)


Remedy Instructions and TSB

RCRIT-19V120-4755.pdf 1465.916KB

Download (PDF, 1.4MB)


Remedy Instructions and TSB

RCRIT-19V120-9149.pdf 1460.726KB

Download (PDF, 1.39MB)


Recall Quarterly Report #1, 2019-2

RCLQRT-19V120-0841.PDF 211.157KB

Download (PDF, 206KB)


Remedy Instructions and TSB

RCRIT-19V120-8764.pdf 1391.898KB

Download (PDF, 1.33MB)


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.


Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V120&docType=RCL


 

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Last update on 2019-08-29 / Affiliate links / Images from Amazon Product Advertising API

Last update on 2019-08-29 / Affiliate links / Images from Amazon Product Advertising API

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