September 16, 2020 NHTSA CAMPAIGN NUMBER: 20V560000
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
| 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.
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
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).
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.
2 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| KIA | STINGER | 2020-2021 |
11 Associated Documents
ISSUED Owner Notification Letter(Part 577)
RCONL-20V560-8721.pdf 156.692KB
Recall Quarterly Report #2, 2021-1
RCLQRT-20V560-9099.PDF 211.221KB
Chronology
RMISC-20V560-8484.pdf 165.025KB
Recall Acknowledgement
RCAK-20V560-1627.pdf 244.812KB
Recall Quarterly Report #1, 2020-4
RCLQRT-20V560-4013.PDF 211.123KB
Manufacturer Notices(to Dealers,etc) – SC198 – Dealer Principal Memo
Manufacturer Notices(to Dealers,etc) – SC198 – Dealer Parts and Service Manager Memo
Miscellaneous Document – SC198 – Q & A
RMISC-20V560-4933.pdf 58.061KB
Remedy Instructions and TSB
RCRIT-20V560-1347.pdf 1925.992KB
Defect Notice 573 Report
RCLRPT-20V560-5872.PDF 213.678KB
Recall Quarterly Report #3, 2021-2
RCLQRT-20V560-6015.PDF 211.308KB
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SC198 September 18, 2020 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 certain 2020-2021 MY Kia Stinger vehicles manufactured from June 3, 2020 through July 22, 2020 to inspect the fuel pump and, if necessary, replace the fuel pump’s jet nozzle housing assembly with a new one. 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. 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 in the week of September 21, 2020. PART INFORMATION: As the need for the Jet Nozzle Housing Assembly is expected to be low, a valid VIN will be required for order entry. NOTE: Dealers will be able to submit for reimbursement of alternate transportation expenses in the same manner as normal warranty claims in WebDCS. Enclosed you will find a draft copy of the owner notification letter and a Q&A Guide for recall questions, both of which describe the issue. A list of Kia Stinger 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 SC198 to generate the list. Notices to the affected vehicle owners will be mailed on October 29, 2020. 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 requests to have the recall performed on their 2020-2021 MY Kia Stinger 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, Kia Service Department Enclosures
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SC198 September 18, 2020 Attention: All Dealer Principals Kia Motors America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign on certain 2020-2021 MY Kia Stinger vehicles manufactured from June 3, 2020 through July 22, 2020 to inspect the fuel pump and, if necessary, replace the fuel pump’s jet nozzle housing assembly with a new one. 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. 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 in the week of September 21, 2020. Your Service Manager was sent a draft 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 2020- 2021 MY Kia Stinger vehicles. Kia will notify the affected vehicle owners on October 29, 2020. 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. What Should You Do? Please make certain the appropriate personnel in your dealership are familiar with the details of this recall campaign to ensure proper responses to customer inquiries and requests to have the recall campaign performed on their 2020-2021 MY Kia Stinger vehicles. 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 campaign is appreciated. If you have any questions, please contact your Kia District Parts & Service Manager. Sincerely, Kia Service Department Enclosures
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