ECM LOGIC IMPROVEMENT FOR PISTON RING NOISE SENSING SYSTEM (SC209A) – 2020-2021 Kia Soul & 2021 Seltos

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April 13, 2021 NHTSA CAMPAIGN NUMBER: 21V259000

Improperly Heat-Treated Piston Oil Rings

A damaged engine may stall, increasing the risk of a crash. In addition, oil may leak onto hot exhaust components, increasing the risk of a fire.

 

NHTSA Campaign Number: 21V259

Manufacturer Kia Motors America

Components ENGINE

Potential Number of Units Affected 147,249

 

Summary

Kia Motors America (Kia) is recalling certain 2020-2021 Soul, and 2021 Seltos vehicles equipped with 2.0L Nu MPI engines. The piston oil rings may not have been properly heat-treated, which may result in engine damage.

 

Remedy

Kia will notify owners, and dealers will inspect and, if necessary, replace the engine, free of charge. In addition, Kia will deploy Piston Ring Noise Sensing System (PNSS) software. The recall began June 11, 2021. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC209.

 

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

 


 

This bulletin provides information to update the Piston Ring Noise Sensing System software logic of the Engine Control Module (ECM) system on some 2020-2021MY Soul (SK3) produced from November 24, 2018 through October 24, 2020 and some 2021MY Seltos (SP2) vehicles produced from November 20, 2019 through October 15, 2020 equipped with 2.0L Nu MPI (Atkinson) engines.

This software update is a preventative measure to alert the driver of potential damage to the piston oil ring. As described in this bulletin, follow the procedure outlined below to apply the improved logic for the Piston Ring Noise Sensing System to the ‘Engine’ system using the KDS ECU Upgrade function. To confirm that the latest reflash has been applied to a vehicle you are working on, verify the ROM ID using the table on page 4. 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.

 

ECU Upgrade Procedure:

To correct this condition, the ECU should be reprogrammed using the KDS download, as described in this bulletin.

 

Upgrade Event Name
576. SK3 NU 2.0ATK ENGINE ECU UPGRADE (PISTON-RING NOISE SENSING SYSTEM)
577. SP2 NU 2.0ATK ENGINE ECU UPGRADE (PISTON-RING NOISE SENSING SYSTEM)

 

NOTICE

  • Confirm a fully charged battery (12.3 volts or higher is necessary) is used or utilize a fully charged jump starter box connected to the battery.
  • Ensure the KDS GDS is sufficiently charged at 60% or higher prior to reflash.
  • All ECU upgrades must be performed with the ignition set to the ‘ON’ position unless otherwise stated.
  • Damaged VCI II units should not be used and promptly replaced.
  • 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 application.

 

IMPORTANT

It is recommended to ALWAYS check the Electronic Parts Catalog (EPC) to locate the ECU Part Number respective to Auto/Manual Mode ROM IDs. DO NOT reference the parts label affixed to the ECU.

 

NOTICE

Before attempting an ECU upgrade on any Kia model, make sure to first determine whether the applicable 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.

 

ROM ID INFORMATION TABLE:

Upgrade Event #576 (SK3)

Model EM TM IMMO ECU P/No. ROM ID
Previous New
SK3 (20MY) Nu 2.0L MPI CVT Yes 39171 2ELC0 SKASP2KS6B0A

SKASP2KS6B1A

SKASP2KF6B7A

SKASP2KF6B9A
No 39173 2ELC0 SKASP2JS6B0A

SKASP2JS6B1A

SKASP2JF6B7A

SKASP2JF6B9A
6MT Yes 39171 2ELD0 SKAUP2AS6B0A

SKAUP2AS6B1A

SKAUP2AS6B1B

SKAUP2AF6B7A

SKAUP2AF6B9A
No 39173 2ELD0 SKAUP2US6B0A

SKAUP2VS6B1A

SKAUP2VS6B1B

SKAUP2UF6B7A

SKAUP2UF6B9A
SK3 (21MY) CVT Yes 39171 2ELC1 SKBSP2KS6B2A

SKBSP2KS6B7A

SKBSP2KF6B9A
No 39173 2ELC1 SKBSP2JS6B2A

SKBSP2JS6B7A

SKBSP2JF6B9A
6MT Yes 39171 2ELD1 SKBUP2AS6B2A

SKBUP2CS6B7A

SKBUP2CF6B9A
No 39173 2ELD1 SKBUP2VS6B2A

SKBUP2VS6B7A

SKBUP2VF6B9A

 

Upgrade Event #577 (SP2)

Model EM TM IMMO ECU P/No. ROM ID
Previous New
SP2 (21-22MY) Nu 2.0L MPI CVT Yes 39171 2EPT0

39171 2EPV0

SPCUP2KS6D2A

SPAUP2KS6D2A

SPAUP2KS6D5A

SPAUP2KF6D7A
No 39173 2EPT0

39173 2EPV0

SPCUP2JS6D2A

SPAUP2JS6D2A

SPAUP2JS6D5A

SPAUP2JF6D7A

 

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.

 

NOTICE

Prior to performing the ECU upgrade, be sure to check that the KDS is fully charged.

 

1. Connect the VCI-II to the OBD-II connector, located under the driver’s side of the instrument panel.

 

NOTICE

The ECU upgrade function on KDS operates wirelessly. It is not necessary to perform the upgrade via USB cable.

 

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 #576 (SK3) or #577 (SP2).

 

NOTICE

The vehicle must be identified in Vehicle Selection to download an Event for that vehicle.

 

6. Select Auto Mode.

 

CAUTION

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.

 

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 #576 (SK3) or #577 (SP2), 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.

 

CAUTION

Do not touch the system buttons (like ‘Back’, ‘Home’, ‘etc.’) while performing ECU Upgrade.

 

9. If a “Communication Fail” screen appears, verify that the VCI-II and KDS are communicating properly. Select ‘OK’ and restart the procedure from step 4.

 

NOTICE

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.

 

10. When instructed on the KDS, turn the ignition OFF for ten (10) seconds then back on. Select ‘OK’ to continue.

11. Once the upgrade is complete, select ‘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 normal operation of the vehicle.

 

Manual Upgrade Procedure:

NOTICE

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.

 

Manual Mode ECU Upgrade Passwords

Menu Password
SK3 Nu 2.0ATK CVT +IMMO/SMK : 39171-2ELC0 5191
SK3 Nu 2.0ATK CVT -IMMO : 39173-2ELC0 5192
SK3 Nu 2.0ATK 6MT +IMMO/SMK : 39171-2ELD0 5193
SK3 Nu 2.0ATK 6MT -IMMO : 39173-2ELD0 5194
SK3 Nu 2.0ATK CVT +IMMO/SMK : 39171-2ELC1 5195
SK3 Nu 2.0ATK CVT -IMMO : 39173-2ELC1 5196
SK3 Nu 2.0ATK 6MT +IMMO/SMK : 39171-2ELD1 5197
SK3 Nu 2.0ATK 6MT -IMMO : 39173-2ELD1 5198
SP2 Nu 2.0ATK CVT +IMMO/SMK : 39171-2EPT0/V0 5201
SP2 Nu 2.0ATK CVT  -IMMO : 39173-2EPT0/V0 5202

 

1. Within the ECU Upgrade screen displayed, select Manual Mode.

2. Select the Engine system under the System selection menu. Select Upgrade Event #576 (SK3) or #577 (SP2) and select Upgrade to continue.

3. Select the appropriate control unit part number with reference to the ROM ID Information Table on page 3, 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. Select OK.

7. Once the upgrade is complete, select 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.

 

AFFECTED VEHICLE RANGE:

Model Production Date Range
Soul (SK3) November 24, 2018 to October 24, 2020
Seltos (SP2) November 20, 2019 to October 15, 2020

 

REQUIRED TOOL:

Tool Name Figure Comments
KDS Kia Diagnostic System

 


SC209 – 2020-2021 MY SOUL & 2021 MY SELTOS PISTON OIL RING
SAFETY RECALL CAMPAIGN
Q & A
(FOLLOW-UP NOTICE)

December 2, 2021

 

THIS IS A FOLLOW-UP NOTICE TO ADVISE THAT THE PISTON-RING NOISE SENSING SYSTEM SOFTWARE IS NOW AVAILABLE.

 

Q1. What type of campaign is Kia conducting?

Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign to inspect and replace, if necessary, the engine on certain 2020-2021 MY Soul and certain 2021 MY Seltos vehicles.

 

Q2. What vehicles are affected by the recall?

Certain 2020-2021 MY Kia Soul vehicles manufactured from November 24, 2018 through October 24, 2020 and  certain 2021 MY Kia Seltos vehicles manufactured from November 20, 2019 through October 15, 2020 equipped with 2.0L Nu    MPI engines.

 

Q3. How many vehicles are affected by this recall?

Approximately 125,400 Soul vehicles and 21,849 Seltos vehicles are affected by this recall.

 

Q4. What is the concern with the Piston Oil Ring?

During production at the supplier, the piston oil rings in the affected vehicles may have been improperly heat-treated resulting in excessive oil ring hardness.  Excessive oil ring hardness can lead to chipping of the piston oil ring’s outer periphery and scuffing of the engine cylinder bore.  A scuffed cylinder bore can lead to increased oil consumption which will eventually result in abnormal noise from the engine and/or illumination of the oil pressure warning lamp.  If the vehicle is continually operated in this condition, connecting rod bearing seizure can occur.  A seized connecting rod bearing can result in engine damage, thereby increasing the risk of an engine stall and/or in certain cases a fire, due to a connecting rod puncturing the engine block allowing engine oil to leak onto a hot exhaust.  An engine stall increases the risk of a crash.  A fire increases the risk of injury.

 

Q5. Can you describe the recall campaign and fix?

If it has not been done already, dealers will inspect, and if necessary, replace the engine (SC209).  In addition, and as a preventative measure, dealers will also install the Piston-ring Noise Sensing System software (SC209A) to alert the driver of potential damage to the piston oil ring.

 

Q6. How will owners of the affected vehicles be notified?

Kia will send a follow-up letter notifying the owners of the affected vehicles by first-class mail on December 7, 2021 advising customers that the Piston-ring Noise Sensing System software is now available.

 

Q7. What should vehicle owners do when they receive the notification?

Upon receipt of the notification letter, owners are to contact their authorized Kia dealer to arrange for the inspection, and if necessary, engine replacement to be performed.  If increased oil consumption, abnormal engine noise and/or illumination of the oil pressure warning lamp occur, vehicle owners are advised to contact Kia Roadside Assistance to have their vehicle towed to the nearest authorized Kia dealership.

Upon receipt of the follow-up letter, owners are to contact their authorized Kia dealer to arrange to have the software installed.  If the customer has yet to complete the inspection, customers should have both the inspection, and if necessary, engine replacement performed, and then followed by the software update.

 

Q8. How was the issue discovered?

Through the regular monitoring of field information.

 

Q9. Will this cost vehicle owners any money?

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

 

Q10. What about customers who may have already paid to have this situation corrected?

If the customer has incurred expense to remedy this issue 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 (Contact Kia) of www.kia.com OR mail their documentation with the completed Request for Reimbursement Form included with this letter directly to Kia for review and consideration at the following address:

Consumer Assistance Center Kia America, Inc.
P.O. Box 52410
Irvine, CA  92619-2410
1-800-333-4542

 

Q11. How long will the repair take?

The actual time required to perform the remedy repair will take approximately one (1) to two (2) hours.  However, their vehicle may be needed longer, depending on the result of the inspection.  If an engine replacement is necessary, the estimated time required is 8 hours or more.  Therefore, it is recommended that owners schedule a service appointment to minimize inconvenience.  Owners can also contact their authorized Kia dealer for an exact estimate of how long they may need the vehicle. (Most Kia dealers have online appointment scheduling via their dealership websites to maximize convenience.)

 

A12. 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 authorized Kia dealership or call Kia’s Consumer Assistance Center at 1-800333-4KIA (4542), Monday through Friday, 5 AM to 6 PM Pacific Standard Time, or via the internet at www.kia.com (Owner’s Section).

 


2020-2021 MY Soul & 2021MY Seltos Piston Oil Ring Chronology

Basis of Safety Defect Determination 573.6(c)(6)

 

October to December 2020

Kia Motors North America (KMNA) becomes aware of 2020MY Soul VOQ (11365951) filed October 23, 2020 involving customer complaint of engine noise and stall while stopped. KMNA reviews its internal records and confirms engine had seized. KMNA sends VOQ to Kia Motors Corporation (KMC) for their review.  KMC requests engine be sent to Korea. KMNA advises NHTSA’s Office of Defects Investigation (ODI) during its November 3rd meeting its findings and plans to collect engine for KMC’s further analysis. Engine shipped to KMC on December 17, 2020 after difficulties in obtaining engine due to customer having traded vehicle in to usedcar dealer. KMNA begins review of replacement claims for Nu 2.0L MPI engines to identify instances of loss of motive power.

 

January 2021

Results of engine replacement claims data through December 31, 2020 shows that instances of loss of motive power while driving is very low [2020-2021 Soul: 0.07%; 2021 Seltos: 0.05%].  KMNA sends claim data to KMC for its review.

KMC receives VOQ engine (11365951) on January 6, 2021 and subsequently conducts tear down inspection. Inspection reveals chipped piston oil ring, bore scratched and connecting rod bearing seized. KMC shares investigation results with KMNA.

KMNA advises ODI of KMC’s findings on January 26, 2021 during its monthly meeting. KMNA continues to monitor the field.

 

February 5-28, 2021

As part of KMNA’s monitoring efforts, engine replacement warranty claim data is updated through 1/31/2021. No significant increase of instances of loss of motive power while driving [20212021 Soul: 0.08%; 2021 Seltos: 0.07%]. KMNA sends updated data to KMC.

KMC also reviews engine replacement warranty claim data and identifies claims for engines manufactured at its Hwasung plant might contain a potential engine issue.

On February 9, 2021, KMNA engineer conducts inspection of fire incident which occurred on or around January 21, 2021 involving a 2020 Kia Soul due to oil leaking on exhaust. Cause of fire due to hole in block from damaged connecting rod. Underlying cause of hole in block unknown.

 

March-April 5, 2021

On March 9, 2021, KMNA third party fire investigator conducts inspection of fire incident which occurred on February 10, 2021 involving another 2020 Soul. Inspection reveals origin of fire in engine compartment. Fire caused by oil making contact with exhaust following connecting rod puncturing engine block. Underlying cause of hole in block unknown.

KMC works with supplier to further evaluate issue and determine potential cause. Issue with heat treatment process of piston oil ring identified. Correlation between engine replacement claims and piston oil ring chip identified. KMNA evaluates KMC’s investigation results and conducts predictive analysis to confirm potential increase of engine replacement claims.

 

April 6, 2021

KMNA decides to conduct recall. Four (4) fires potentially related to this issue. No known crashes, injuries or fatalities.

 


3 Affected Products

Vehicles

MAKE MODEL YEAR
KIA SELTOS 2021
KIA SOUL 2020-2021

 


21 Associated Documents

Remedy Instructions and TSB

RCRIT-21V259-6320.pdf 1337.027KB

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ISSUED Owner Notification Letter(Part 577)- Soul

RCONL-21V259-9728.pdf 178.735KB

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ISSUED Owner Notification Letter(Part 577)- Seltos

RCONL-21V259-8264.pdf 178.685KB

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Remedy Instructions and TSB

RCRIT-21V259-5341.pdf 1193.101KB

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Recall 573 Report – AMENDMENT 1

RCLRPT-21V259-7245.PDF 215.589KB

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Chronology

RMISC-21V259-7859.pdf 85.928KB

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Recall Acknowledgement

RCAK-21V259-3410.pdf 645.846KB

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Defect Notice 573 Report

RCLRPT-21V259-6845.PDF 215.575KB

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Remedy Instructions and TSB

RCRIT-21V259-0996.pdf 1308.416KB

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Manufacturer Notices(to Dealers,etc) – DEALER PRINCIPAL MEMO

RCMN-21V259-7788.pdf 93.009KB

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Manufacturer Notices(to Dealers,etc) – 6/04/2021

RCMN-21V259-7411.pdf 117.098KB

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Remedy Instructions and TSB

RCRIT-21V259-6499.pdf 1162.789KB

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Recall Quarterly Report #1, 2021-2

RCLQRT-21V259-4402.PDF 211.143KB

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Remedy Instructions and TSB

RCRIT-21V259-2421.pdf 681.49KB

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SC209 – 2020-2021 MY SOUL & 2021 MY SELTOS PISTON OIL RING – Q&A, June 4, 2021

RMISC-21V259-3079.pdf 113.141KB

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ISSUED Owner Notification Letter(Part 577) – December 7, 2021

RCONL-21V259-3253.pdf 302.413KB

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ISSUED Owner Notification Letter(Part 577) – December 7, 2021

RCONL-21V259-9369.pdf 302.411KB

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Manufacturer Notices(to Dealers,etc) – Follow up Notice to ALL DEALER PRINCIPALS: December 2, 2021

RCMN-21V259-5096.pdf 93.426KB

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Manufacturer Notices(to Dealers,etc) – Follow up Notice ALL DEALER PARTS & SERVICE MANAGERS: December 2, 2021

RCMN-21V259-1179.pdf 117.762KB

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SC209 – 2020-2021 MY SOUL & 2021 MY SELTOS PISTON OIL RING SAFETY RECALL CAMPAIGN Q & A (FOLLOW-UP NOTICE): December 2, 2021

RMISC-21V259-4880.pdf 88.915KB

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V259-0392.PDF 211.349KB

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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=21V259&docType=RCL

 


 

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  • Full synthetic formula provides thermal and oxidation stability
SaleBestseller No. 10
Quaker State 550044965 Motor Oil, Synthetic Blend 5W-20 (5-Quart, Single Pack)
  • Synthetic blend 5W-20 engine oil that provides durable wear protection and reduces engine wear
  • Provides corrosion protection against harmful acids generated by engine contaminants
  • Maintains viscosity from start to finish, providing optimal oil film protection
  • Helps engines survive daily commutes from high-speed highway operation to repetitive, stop-and-go driving
  • Combats engine sludge and deposits

Last update on 2024-04-09 / Affiliate links / Images from Amazon Product Advertising API

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