Fuel Pump Inspection And Jet Nozzle Housing Replacement (SC198) – 2020-2021 Kia Stinger

September 16, 2020 NHTSA CAMPAIGN NUMBER: 20V560000

Insufficient Fuel Supply

Insufficient fuel supply to the engine can result in a loss of drive power, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V560

Manufacturer Kia Motors America

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 635

 

Summary

Kia Motors America (Kia) is recalling certain 2020-2021 Stinger vehicles. The fuel pump’s jet nozzle may have a plastic burr remaining from the manufacturing process, possibly causing a blocked nozzle and an insufficient fuel supply to the engine.

 

Remedy

Kia will notify owners, and dealers will inspect the fuel pump and replace the jet nozzle housing assembly, if necessary, free of charge. The recall began October 29, 2020. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC198.

 

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

 

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	GROUP Safety Recall Campaign	MODEL 2020-2021MY Stinger (CK)
	NUMBER SC198	DATE September 2020
SUBJECT: SAFETY RECALL CAMPAIGN FUEL PUMP INSPECTION AND JET NOZZLE HOUSING REPLACEMENT (SC198)

 

This bulletin provides the procedure to inspect and if necessary, replace the fuel pump’s jet nozzle housing assembly on some 2020-2021MY Stinger (CK) vehicles equipped with either 3.3L T-GDI LAMBDA II or 2.0L T-GDI THETA II engines produced from June 3, 2020 through July 22, 2020. During production of the fuel pump’s jet nozzle housing, a plastic burr may remain after the molding process potentially blocking the nozzle.  A blocked nozzle can result in an insufficient supply of fuel to the engine. An insufficient supply of fuel to the engine can result in a loss of motive power increasing the risk of a crash. Before conducting the procedure, verify that the vehicle is included in the list of affected VINs.

 

NOTICE                                   

There is no charge to the vehicle owner for this repair. Under applicable law, you may not sell or otherwise deliver any affected 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.

 

Inspection Procedure:

IMPORTANT

Prior to begin the inspection, ensure that the fuel level gauge needle is positioned between ¼ to ¾ filled as shown, in order to successfully perform the inspection outlined below. If fuel tank is above ¾ filled, refer to the Fuel Removal Procedure outlined on page 9.

 

1. Activate the Electronic Parking Brake (EPB).

 

2. Turn the ignition to ‘ON’.

 

Note: Engine Off – not running.

 

3. Set the shifter to the Neutral ‘N’ position.

 

4. Install KDS and select ‘Multi Data Analysis’.

 

5a.    Select ‘ENGINE’ and ‘CLU’.

 

5b. Select ‘OK’.

 

6. In the “Item List” menu, select “Battery Voltage.”

 

7. Select, “Fuel Tank Level Sensor 1 Sensor Voltage” and “Fuel Tank Level Sensor 2 Sensor Voltage.”

 

Note: Selected components from the left “Item List” will show on the “Selected Item List” on the right side of the screen.

 

8. Select ‘CLU’ and select “FUEL INPUT.”

 

9. Select ‘OK’.

 

10. Select ‘Graph’.

 

11. Select ‘All’.

 

12. Select ‘OK’.

13. On KDS, take a screen shot of the Multi Data Analysis screen which shows the “ENGINE – Fuel Tank Level Sensor 2 Voltage”.

 

Note: The engine is not running, and the ignition is in the ‘ON’ position.

 

PICTURE 1: Take a screenshot of the ENGINE – Fuel Tank Level Sensor 2 Voltage screen.

 

14. Depress the brake pedal and press the ignition ‘Start’ button on the dash panel. Engine should now be “ON” running.

 

15. Select ‘Reset Min/Max’.

 

16. Keep the engine running for at least 5 minutes and then check the “ENGINE – Fuel Tank Level Sensor2 Sensor Voltage” (Max-Min) reading.

 

On KDS, take a screen shot of the Multi Data Analysis screen.

 

If the difference between Max and Min voltages is more than 0.3V, then no further action is required.

 

If the difference between Max and Min voltage reading  is zero or less than 0.3V, proceed to repair procedure outlined on page 9.

 PICTURE 2: Take a screenshot of the “ENGINE – Fuel Tank Level Sensor 2 Voltage” screen showing MAX and MIN readings.

 

Fuel Removal Procedure: (Only required if fuel level reading is over ¾ full)

1a. Save customer radio presets.

 

1b. Ensure that the ignition is switched to “OFF” and the engine is not running by pressing the ignition ‘STOP’ button on the dash panel.

 

2. Remove the fuel pump relay located in the right side of the trunk area.

 

3a. Press the ‘START’ button to start the engine and let it stumble and stall. (Appx. 30 seconds to 1 minute if engine is hot).

 

3b. Press the ‘STOP’ button to switch the ignition to “OFF”.

 

3c. Reinstall the fuel pump relay from previous step 2.

 

4a. Open the hood, remove engine cover and disconnect GDI pump electrical connector (A). Carefully remove GDI pump sound insulation (B).

 

4b. Reconnect the GDI connector (A) after removing the sound insulation (B).

 

5. Using a pick tool, remove the low pressure fuel tube plastic clip (D) from the fuel tube (C) / GDI

 

6. Using a ‘U’ shaped trim removal tool, remove the low side fuel tube (C) from the GDI pump by applying light pressure to the fuel tube towards the pump, then insert the trim tool and press the release towards the fuel tube. Slide the fuel tube off from the GDI pump

 

7. Connect the low fuel pressure tube (C) just disconnected from the GDI pump, to an external hose in order to gain additional length to drain fuel into a container (5 gal. recommended).

 

IMPORTANT

Ensure the external hose is secure and tight to the low fuel pressure line end and container.

 

WARNING

Fuel vapors are flammable. Death or serious injury can result if they are ignited. Make sure there are no open flames  or smoking in the area of the repair. Adequate ventilation is necessary to prevent a build-up of fumes which could ignite, causing fire or explosion.

 

8a. Connect KDS and select “actuation test” with IG ‘ON’. No engine start is necessary.

 

8b. Select ‘Start’ to activate the fuel pump relay and it will continuously drain fuel until “Stop” is pressed.

 

8c. Select “fuel pump relay” with “fuel level” selected in “data analysis” “fuel level” is selected to help monitor fuel level in the tank while draining fuel from the tank

 

8d. Once the “Fuel Level” “Value” shows 75%, the activation test can be stopped.

 

Proceed to the perform the ‘Inspection Procedure’ on page 2 or ‘Replacement Procedure’ on page 11.

 

9. Reinstall all removed parts in the reverse order of removal.

 

Replacement Procedure:

1a. Save customer radio presets.

 

1b. Ensure that the engine is not running by pressing the ignition ‘STOP’ button on the dash panel.

 

2a. Remove the low pressure fuel pump assembly (A) by referring to the “Engine Control/Fuel System → Fuel Delivery System → Low Pressure Fuel Pump → Repair procedures” chapter in the applicable Shop Manual on KGIS.

 

CAUTION

Whenever the high pressure  fuel fuse, fuel pipe or delivery pipe are removed immediately after shutting off the engine, an injury may be caused the release of high pressurized fuel.

 

2b.

NOTICE

SST Fuel Pump Locking Ring Wrench P/N 09310 B8100 is required.

 

WARNING

Fuel vapors are flammable. Death or serious injury can result if they are ignited. Make sure there are no open flames  or smoking in the area of the repair. Adequate ventilation is necessary to prevent a build-up of fumes which could ignite, causing fire fire or explosion.

 

2c. Carefully disconnect the sub – fuel hose (C) from the jet nozzle housing (D) to remove the fuel pump assembly (A).

 

IMPORTANT

When removing the fuel pump assembly, be careful not to deform the sender gauge unit.

 

3. Place the fuel pump on a clean table/surface.

 

To remove the jet nozzle housing from the fuel pump assembly:

 

1) Push the tab (E) in the direction shown to release jet nozzle housing (D).

 

2) Pull up on the jet nozzle housing to detach it from the fuel pump.

 

4. Insert and rotate a small flathead screwdriver as shown to detach the jet nozzle (F) from the housing (D).

 

NOTICE

Flexible hose connected to the nozzle is not separable. DO NOT attempt to disconnect.

 

5a. Insert the jet nozzle (F) to the new jet nozzle housing (D) in the same reverse order of removal.

 

IMPORTANT

Confirm that the new jet nozzle is fully inserted and secured to the housing.

 

5b. Attach the jet nozzle housing (D) back into the fuel pump assembly (A)

 

6. Re-install the fuel pump assembly (A) in the same reverse order of

 

IMPORTANT

Ensure that the sub – fuel hose (C) is properly secured onto the jet nozzle housing (D) (from step 2c) prior to installing the fuel pump assembly.

 

7. Confirm normal vehicle

 

8. Restore customer radio

 

AFFECTED VEHICLE RANGE:

Model	Production Date Range
Stinger (CK)	June 3, 2020 to July 22, 2020

 

REQUIRED TOOL:

Tool Name	Part Number	Figure	Comments
Fuel Pump Locking Ring Wrench	09310 B8100		Drawer #3

 

REQUIRED PART:

Part Name	Part Number	Figure	Qty.
Jet Nozzle Housing Assembly	31122 J5000QQK		1

 

WARRANTY INFORMATION:

N Code: N99 C Code: C99

Claim Type	Causal P/N	Qty.	Repair Description	Labor Op Code	Op Time	Replacement P/N	Qty.
R	35320 2CTB1	0	(SC198) Fuel Pump Inspection	201097R0	0.3 M/H	N/A	0
			(SC198) Fuel Pump Inspection and Jet Nozzle Housing Replacement	201097R1	0.8 M/H	31122 J5000QQK	1

 

Note: Refer to Warranty Bulletin 2020-22 for claim submission procedures.

 

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IMPORTANT SAFETY RECALL

(NHTSA Recall Number: 20V560)

This notice applies to your vehicle: (Insert VIN)

 

October 29, 2020

 

Dear Kia Stinger Owner:

 

Kia has identified a defect in your vehicle that 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 that relates to motor vehicle safety exists in some 2020-2021 MY Kia Stinger vehicles.  The defect can result in an insufficient supply of fuel to the engine.  An insufficient supply of fuel to the engine can result in a loss of drive power, increasing the risk of a crash.  Our records indicate that you own or lease one of the potentially affected vehicles.

 

What Is The Problem?

The fuel pump provides a continuous supply of fuel to the engine via the pump’s jet nozzle.  During production of the fuel pump’s jet nozzle housing, a plastic burr may remain after the molding process, potentially blocking the nozzle.  A blocked nozzle can result in an insufficient supply of fuel to the engine.  An insufficient supply of fuel to the engine can result in a loss of drive power, increasing the risk of a crash.

 

Kia Will Inspect The Fuel Pump And, If Necessary, Will Replace The Fuel Pump’s Jet Nozzle Housing Assembly Free Of Charge At No Cost For Parts Or Labor To You.

 

Kia has advised its authorized Kia dealers to inspect the Fuel Pump and, if necessary, replace the Fuel Pump’s Jet Nozzle Housing Assembly with a new one.  The work will be performed at Kia’s expense at no cost to you.  The estimated time required to repair your vehicle is approximately two (2) hours.  However, your vehicle may be needed longer; therefore, we recommend scheduling a service appointment to minimize any 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 a cover letter 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

 

QR Code Use: 

• A QR Code is a square, 2-dimensional barcode that can be read by mobile devices loaded with an appropriate barcode or QR Code Reader App. The app reads the barcode image and then launches/uploads the specific information the code contains, such as URLs, text, photos, videos.

• With a mobile device, download a QR Code Reader App. With many devices, you can do this through an app store or marketplace.

• Open the QR Code Reader App on your mobile device. The app will utilize your device’s camera.  Center the code in the camera viewing area.  With some apps, the URL or other information will automatically load when the code is recognized.  For others, you may have to snap or take a picture of the QR code.  Refer to the QR Reader Code App instructions. 

SC198

 

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SC198 – 2020-2021 MY KIA STINGER FUEL PUMP
SAFETY RECALL CAMPAIGN
Q & A

September 18, 2020

 

Q1. What type of campaign is Kia conducting?

Kia Motors America, Inc. is conducting a safety recall campaign on certain 2020-2021 MY Kia Stinger vehicles to inspect the fuel pump and, if necessary, replace the fuel pump’s jet nozzle housing assembly with a new one.

 

Q2. What vehicles are affected by the recall?

Certain 2020-2021 MY Kia Stinger vehicles manufactured from June 3, 2020 through July 22, 2020.

 

Q3. How many customer vehicles are affected by this recall?

Approximately 635 vehicles are affected by this recall.

 

Q4. What is the concern with the Fuel Pump?

The fuel pump provides a continuous supply of fuel to the engine via the pump’s jet nozzle. During production of the fuel pump’s jet nozzle housing, a plastic burr may remain after the molding process, potentially blocking the nozzle. A blocked nozzle can result in an insufficient supply of fuel to the engine. An insufficient supply of fuel to the engine can result in a loss of motive power, increasing the risk of a crash.

 

Q5. Can you describe the recall campaign fix?

Dealers will be instructed to inspect the fuel pump and if necessary, replace the fuel pump’s jet nozzle housing assembly with a new one. Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 11, 2020.

 

Q6. How was the issue discovered?

Through the regular monitoring of field information.

 

Q7. 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 performed.

 

Q8. Will this cost vehicle owners any money?

No. Kia will perform the recall repair at no cost to the customer.

 

Q9. 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 a cover letter 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

 

Q10. How long will the repair take?

The estimated time required to inspect and, if necessary replace the fuel pump’s jet nozzle housing assembly with a new one is approximately two hours. However, the vehicle may be needed longer; therefore, it is recommended that the customer 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 convenience).

 

Q11. How will owners of the affected vehicles be notified?

Kia will be notifying owners of the affected vehicles by first-class mail beginning on October 29, 2020.

 

Q12. Are there any restrictions on an owner’s eligibility?

No.

 

Q13. If a customer has an immediate question, where can they get further information?

The customer can contact their local Kia dealership or call Kia’s Consumer Assistance Center at 1-800-333-4KIA (4542), Monday through Friday, 5 AM to 6 PM Pacific Standard Time, or via the internet @ www.kia.com (Owner’s Section).

 

 

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2020-2021MY Stinger Fuel Pump Chronology
Basis of Safety Defect Determination 573.6(c)(6)

 

July 31, 2020

Kia Motor Corporation (KMC) receives warranty returned fuel pump that was replaced after customer complained of stalling while driving.

 

August 1—September 8, 2020

KMC works with supplier to identify whether potential issue exists with fuel pump. During this process, supplier identifies molding burr in jet nozzle housing.  Further evaluation identifies molding burr may block nozzle within fuel pump limiting fuel supply to engine.  Supplier identifies problematic lot and KMC identifies range of potentially affected vehicle production to be those vehicles produced from 6/3/2020 through 7/22/2020.

 

September 9, 2020

KMC determines that the subject issue can result in a loss of motive power and decides to conduct recall.  Three (3) customer complaints identified in Korean domestic market.  No customer complaints in U.S. market.  No known crashes or injuries.

 

 

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2 Affected Products

Vehicle

MAKE	MODEL	YEAR
KIA	STINGER	2020-2021

 

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11 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-20V560-8721.pdf 156.692KB

 

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Recall Quarterly Report #2, 2021-1

RCLQRT-20V560-9099.PDF 211.221KB

 

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Chronology

RMISC-20V560-8484.pdf 165.025KB

 

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Recall Acknowledgement

RCAK-20V560-1627.pdf 244.812KB

 

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Recall Quarterly Report #1, 2020-4

RCLQRT-20V560-4013.PDF 211.123KB

 

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Manufacturer Notices(to Dealers,etc) – SC198 – Dealer Principal Memo

RCMN-20V560-0770.pdf 61.969KB

 

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Manufacturer Notices(to Dealers,etc) – SC198 – Dealer Parts and Service Manager Memo

RCMN-20V560-3057.pdf 67.38KB

 

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Miscellaneous Document – SC198 – Q & A

RMISC-20V560-4933.pdf 58.061KB

 

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Remedy Instructions and TSB

RCRIT-20V560-1347.pdf 1925.992KB

 

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Defect Notice 573 Report

RCLRPT-20V560-5872.PDF 213.678KB

 

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Recall Quarterly Report #3, 2021-2

RCLQRT-20V560-6015.PDF 211.308KB

 

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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=20V560&docType=RCL

 

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