Recall SC211 – 2022 Kia Carnival MPI Fuel Rail Lot Inspection And Replacement

April 21, 2021 NHTSA CAMPAIGN NUMBER: 21V277000

Fuel Rail Tube May Leak

A damaged fuel rail tube may leak fuel, increasing the risk of a fire.

 

NHTSA Campaign Number: 21V277

Manufacturer Kia Motors America

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 2,744

 

Summary

Kia Motors America (Kia) is recalling certain 2022 Carnival vehicles. The plastic fuel rail tube may have been damaged.

 

Remedy

Kia will notify owners, and dealers will inspect, and if necessary, replace the multi-port injection fuel rail, free of charge. The recall began April 30, 2021. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC211.

 

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	MODEL
	Safety Recall Campaign	2022MY Carnival (KA4)
	NUMBER	DATE
	SC211 (Rev 1, 04/28/2021)	April 2021
SAFETY RECALL CAMPAIGN
SUBJECT: MPI FUEL RAIL LOT INSPECTION  AND REPLACEMENT (SC211)

 

NOTICE

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.

 

This bulletin provides information to check the LOT Number of the MPI fuel rail (also known as the low pressure fuel delivery pipe) on some 2022MY Carnival (KA4) vehicles produced from January 27, 2021 through March 25, 2021.  During production at the supplier, the assembly jig for the MPI fuel rail was improperly adjusted which could result in damage to the plastic fuel rail tube.  A damaged plastic fuel tube can cause fuel to leak, thus increasing the risk of fire. Follow the procedure outlined in this bulletin to inspect the LOT number and, if required, replace the MPI fuel rail (A).  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:

1. Open hood and remove the engine cover and locate the MPI fuel rail LOT decal (A).

 

(Refer to image for location area).

 

2. Using a video scope, check the LOT number of the MPI fuel rail (refer to the sample image/number below).

 

1b14131Y = Produced 1/31 (January 31^st.)

 

3a. If the 5th through 7th digit value of LOT  number is between 120 and 215, the MPI fuel rail will need to be replaced. Refer to MPI fuel rail produced from January 20 page 3 for replacement.

 

3b. If the 5th through 7th digit value is lower than 120 or over 215, the vehicle does not require MPI fuel rail replacement. No further action is required.

 

3c. NOTICE

REQUIREMENT:

Using the Warranty Claim Attachment feature on KVID, take one (1) clear KVID photo showing the LOT label shown on step 2. (Attachment Type: ‘XX’).

 

IMPORTANT

MPI fuel rail produced from January 20 through February 15 will need to be replaced.

MPI fuel rail produced before January 20 or after February 15 does not require replacement.

 

NOTICE

If any concerns arise during/after the inspection procedure , open a Techline case online.

 

Replacement Procedure:

 

1. Open the junction box cover and remove the fuel pump fuse.

 

2. Start the vehicle and allow it to idle and wait until the engine stops by itself due to fuel exhaustion in the fuel line.

 

NOTICE

Release Residual Pressure during the Fuel Delivery Pipe replacement is required.

 

3a. Remove the surge tank by referring to the “Engine Mechanical System → Intake and Exhaust System → Surge tank → Removal and Installation” chapter in the applicable Shop Manual on KGIS.

 

3b. DO NOT remove High Pressure Fuel Pipes as they DO NOT need to be removed to replace the MPI Fuel Rail.

 

4a. Disconnect the low pressure fuel pipe quick connector.

 

4b. Disconnect the fuel feed tube quick-connector using a clip remover tool

 

Note: Block the pipe/connection(s) to prevent contamination).

 

4c. Remove the eight (8) intake manifold retaining bolts.

Torque Specifications:
20.2 – 23.1 lb.ft (27.5 – 31.4 N.m,
2.80 – 3.20 kgf.m)

 

NOTICE

Reuse the intake manifold gaskets if the vehicle has 5,000 miles or less. Replacement is not required.

 

5. Replace the MPI fuel rail (A) using ALL of the additional parts supplied in the kit (ex. O-rings and clips).

 

6. Using a set of side cutters, remove the five (5) cable ties shown.

 

7. Remove the MPI fuel rail & injector assembly from the intake manifold after loosening the mounting bolt.

Torque Specifications:
7.2 – 8.7 lb.ft (9.8 – 11.8 N.m,
1.00 – 1.20 kgf.m)

 

8. Disconnect the injector connectors and remove the injector wiring from the delivery pipe

 

9. Remove the injectors from the delivery pipe after removing the fixing clip. Be sure to place injectors on a clean surface to prevent contamination.

 

10. Replace the injector ‘Upper O-ring & Lower O-ring’ from kit.

*Apply engine oil to the new injector O-rings prior to installation.

 

NOTICE

Carefully remove the injectors and ensure to keep new O rings from dirt/debris. Ensure to install the new blue /mint and black injector O rings in the location shown. Injector Remover SST 09351 C3700 may be required to remove a stuck injector.

 

11. Install the new MPI fuel rail in the reverse order of removal.

 

12. After replacing the MPI fuel rail, ensure the following:

• No fuel leak is present

• No DTCs stored

• Vehicle operates normally

 

AFFECTED VEHICLE RANGE:

Model	Production Date Range
Carnival (KA4)	January 27, 2021 to March 25, 2021

 

REQUIRED PART:

Part Name	Part Number	Figure	Qty.
Fuel Delivery Pipe Service Kit	35304-3NGCXQQK		1 Service Kit Includes 1 Fuel Delivery Pipe, 12 Injector O-Rings, 6 Injector Clips, and 6 Cable Ties

 

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	35304-3NGC0	0	(SC211) MPI Fuel Rail LOT Inspection	211056R1	0.2 M/H	N/A	0
			MPI Fuel Rail LOT Inspection and Replacement	211056R2	1.5 M/H	35304-3NGCXQQK	1

 

Note: Refer to Warranty Bulletin 2021-08 for claim submission procedures. If replacing the MPI fuel rail, a photo of the LOT number must be attached using the KVID app as a Warranty Claim Attachment type ‘XX – Other’.

 

NOTICE

VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference SC211 when accessing the WebDCS system.

 

TSB: SC211 Carnival (KA4) April 2021

 

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IMPORTANT SAFETY RECALL

(NHTSA Recall Number: 21V-277)

This notice applies to your vehicle: (Insert VIN)

 

April 30, 2021

 

Dear Kia Carnival 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 certain 2022 MY Kia Carnival vehicles.  The defect can result in fuel leaking thereby increasing the risk of a fire and injury.  Our records indicate that you own or lease one of the potentially affected vehicles.

 

What Is The Problem?

The MPI fuel rail (also known as low-pressure fuel delivery pipe) on your vehicle may have been improperly assembled during production at the component supplier, resulting in damage to the plastic fuel rail tube.  A damaged plastic fuel rail tube can cause fuel to leak.  Leaking fuel increases the risk of fire, thereby increasing the risk of injury.

 

Kia Will Inspect and If Necessary Replace the MPI Fuel Rail At No Cost To You.

 

Kia has advised its authorized dealers to inspect the MPI fuel rail to determine whether the fuel rail falls within the affected supplier lot production range.  If the lot number on the MPI fuel rail falls within the affected range, the MPI fuel rail will be replaced with a new one.  This work will be performed at Kia’s expense at no cost to you.  The actual time required to perform the repair will be approximately two (2) to three (3) hours.  However, your vehicle may be needed longer.  We recommend scheduling a service appointment to minimize inconvenience.  Please contact your dealer for an exact estimate of how long they may need your vehicle for this repair.  

 

What Should You Do? 

• In the interest of the safety of your passengers, as well as your own safety, please immediately contact your authorized Kia dealer to arrange for the recall repair to be conducted.

• If fuel smell and/or leakage is detected, immediately TURN OFF your engine, and do not drive your vehicle. Instead, please contact Kia Roadside Assistance at 1-800-333-4542 to request to have your vehicle towed to the nearest authorized Kia dealership.

• 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 copy of 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

 

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. 

 

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SC211 – 2022 MY CARNIVAL MPI FUEL RAIL
SAFETY RECALL CAMPAIGN
Q & A

April 22, 2021

 

Q1. What type of campaign is Kia conducting?

Kia Motors 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 MPI fuel rail on certain 2022 MY Kia Carnival vehicles.

 

Q2. What vehicles are affected by the recall?

Certain 2022 MY Kia Carnival vehicles manufactured from January 27, 2021 through March 25, 2021.

 

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

Approximately 2,744 vehicles are affected by this recall.

 

Q4. What is the concern with the MPI Fuel Rail?

During production at the supplier, the assembly jig for the MPI fuel rail (also known as the low-pressure fuel delivery pipe) was improperly adjusted which could result in damage to the plastic fuel rail tube. A damaged plastic fuel rail tube can cause fuel to leak. Leaking fuel increases the risk of fire, thereby increasing the risk of injury.

 

Q5. Can you describe the recall campaign and fix?

Dealers will be instructed to inspect the MPI fuel rail to determine whether the fuel rail falls within the affected supplier lot production range. If the lot number on the MPI fuel rail falls within the affected range, the MPI fuel rail will be replaced 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 will owners of the affected vehicles be notified?

Kia will notify the owners of the affected vehicles by first-class mail on April 30, 2021.

 

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

Upon receipt of the notification letter, owners are to contact their Kia dealer to arrange for the repair to be performed.

If fuel smell is detected, vehicle owners are advised to contact the closest authorized Kia dealership to have their vehicle towed to the dealer.

 

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 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 Motors 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 two (2) to three (3) hours.

However, their vehicle may be needed longer. Therefore, it is recommended that owners schedule a service appointment to minimize inconvenience. Owners can also contact their 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 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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2022MY Carnival MPI Fuel Rail Chronology

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

 

April 5, 2021Kia Motors North America, Inc. (KMNA) receives fuel smell and leaking complaint for a 2022 Carnival. Dealer identifies fuel leaking from fuel rail.April 10, 2021

KMNA sends complaint identified on April 5^th to Kia Motors Corporation (KMC) for its review and investigation.

 

April 12, 2021

KMNA receives second fuel smell complaint regarding the 2022 Carnival. Dealer confirms fuel leaking from fuel rail. KMNA sends second complaint to KMC for their review and immediate investigation.

 

April 13, 2021

KMNA is notified of two additional complaints of fuel leaking from fuel rail. KMNA issues new Pre-Delivery Inspection (PDI) instructions to dealers to inspect entire fuel line route from fuel tank to the injector rails. KMC begins plant and port inspection of 2022MY Carnival for fuel leaking condition. Simultaneously, inspection of Carnival vehicles at U.S. ports also begins. KMC begins to work with supplier to identify cause of issue.

 

April 14, 2021

KMNA is notified of 3 additional reports of fuel leaking from the MPI fuel rail tube. KMC and Kia Motors America, Inc. (KMA) inspect 1,430 vehicles at plants/ports and found no damaged plastic MPI fuel rail tubes.

 

April 15, 2021

KMC advises KMNA of investigation results and identifies improper adjustment of the MPI fuel rail assembly jig at the supplier. Estimated affected lot identified by supplier based on its production records. KMNA makes decision to conduct recall. Seven (7) complaints related to this condition. No known fires, accidents, injuries or fatalities.

 

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1 Affected Product

Vehicle

MAKE	MODEL	YEAR
KIA	CARNIVAL	2022

 

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11 Associated Documents

Remedy Instructions and TSB

RCRIT-21V277-4576.pdf 731.556KB

 

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Miscellaneous Document – SC211 – 2022 MY CARNIVAL MPI FUEL RAIL SAFETY RECALL CAMPAIGN Q & A April 22, 2021

RMISC-21V277-2970.pdf 120.104KB

 

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Manufacturer Notices(to Dealers,etc)- SC211 – Dealer Parts & Service Manager Memo

RCMN-21V277-6689.pdf 72.132KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V277-9699.pdf 156.965KB

 

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Manufacturer Notices(to Dealers,etc)- SC211 – Dealer Principal Memo

RCMN-21V277-8722.pdf 66.005KB

 

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Chronology

RMISC-21V277-3963.pdf 154.221KB

 

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Recall Acknowledgement

RCAK-21V277-7976.pdf 645.714KB

 

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Remedy Instructions and TSB

RCRIT-21V277-7264.pdf 361.703KB

 

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Defect Notice 573 Report

RCLRPT-21V277-1363.PDF 213.693KB

 

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V277-7576.PDF 211.315KB

 

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Recall Quarterly Report #1, 2021-2

RCLQRT-21V277-2110.PDF 211.131KB

 

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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=21V277&docType=RCL

 

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