SC223 – Brake Master Cylinder – 2020-2021 Kia Rio

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December 1, 2021 NHTSA CAMPAIGN NUMBER: 21V936000

Reduced Braking Performance

Reduced braking performance can cause longer brake pedal travel or extend the distance required to stop the vehicle, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V936

Manufacturer Kia Motors America

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 87

 

Summary

Kia Motors America (Kia) is recalling certain 2020-2021 Rio vehicles. The brake master cylinder may have been manufactured with sharp edges that can damage the inner oil seal, resulting in reduced braking performance.

 

Remedy

Dealers will replace the brake master cylinder, free of charge. Owner notification letters were mailed January 11, 2022. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall SC223.

 

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.nhtsa.gov.

 

Check if your Kia has a Recall

 


BRAKE MASTER CYLINDER REPLACEMENT (SC223)

This bulletin provides information to replace the brake master cylinder on certain 2020-2021MY Rio (SC) vehicles produced from September 29, 2020 through July 1, 2021. During production of the brake master cylinder, the master cylinder body may have been produced with sharp edges due to improper machining by the supplier. As a result, an oil seal in the master cylinder can become damaged during vehicle operation. A damaged oil seal can impair the vehicle’s braking function, such that the driver may experience a spongy brake feel, longer brake pedal travel, and extended stopping distances, thereby increasing the risk of a crash. Follow the procedure outlined in this publication to replace the brake master cylinder. 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.

 

Brake Master Cylinder Replacement Procedure:

1. Remove the battery and battery tray by referring to the “Engine Electrical System → Charging System → Battery → Repair procedures” chapter in the applicable Shop Manual on KGIS.

2. Remove the air cleaner assembly by referring to the “Engine Mechanical System → Intake and Exhaust SystemAir Cleaner → Repair procedures” chapter in the applicable Shop Manual on KGIS.

3. Remove the brake fluid from the master cylinder reservoir with a syringe.

CAUTION

  • Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.

4. Disconnect the brake fluid level switch connector (A) and disconnect the brake tube (B) from the master cylinder by loosening the tube flare nut.

Tightening torque for Flare Nut
ABS: 10.1 12.3 lb.ft ( 13.7 16.7 N.m)
ESC: 13.7 16.6 lb.ft ( 18.6 22.6 N.m)

5. Remove the master cylinder (C) from the brake booster after loosening the mounting nuts (D).

Tightening torque for Mounting Nuts
86.4 139.2 lb.in 9.8 15.7 N.m)

6. Install in reverse order of removal.

Note: Before assembling the brake master cylinder to the booster ensure O-ring is installed in the correct position.

NOTICE

Reuse the original master cylinder O ring . If damaged, use PN 58591 17000 to replace it.

7. After installation, bleed the brake system. Refer to the next section, ‘Brake System Bleeding Procedure’.

 

Brake System Bleeding Procedure:

  1. Bleed the brake system by referring to the “Brake System → Brake System → Repair procedures” chapter in the applicable Shop Manual on KGIS.

CAUTION

  • Do not reuse the drained fluid.
  • Always use genuine DOT4 brake fluid.
  • Using a non genuine DOT4 brake fluid can cause corrosion and decrease the life of the system.
  • Make sure that no dirt or other foreign matter is allowed to contaminate the brake fluid.
  • Do not spill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.
  • The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure and checked after bleeding e ach brake caliper. Add fluid as required.

 

REQUIRED PART:

Part Name Part Number Qty.
Master Cylinder & Reservoir 58510 H9260QQK 1
Brake Fluid (DOT4) UM010 CH043 1 qt (Max.)

 


SC223 – 2020-2021 MY RIO VEHICLES BRAKE MASTER CYLINDER
SAFETY RECALL CAMPAIGN
Q & A
January 6, 2022

 

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 replace the brake master cylinder on certain 2020-2021 MY Rio vehicles.

 

Q2. What vehicles are affected by the recall?

Certain 2020-2021 MY Rio vehicles manufactured from September 29, 2020 through July 1, 2021.

 

Q3. How many vehicles are affected by this recall?

Approximately 87 vehicles are affected by this recall.

 

Q4. What is the concern with the brake master cylinder?

During production of the brake master cylinder, the master cylinder body may have been produced with sharp edges due to improper machining by the supplier.  As a result, an oil seal in the master cylinder can become damaged during vehicle operation.  A damaged oil seal can impair the vehicle’s braking function, such that the driver may experience a spongy brake feel, longer brake pedal travel, and extended stopping distances, thereby increasing the risk of a crash.

Q5. Can you describe the recall campaign and fix?

Kia dealers will replace the brake master cylinder with a new one.

 

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

Kia will notify owners of the affected vehicles by first class mail beginning on January 11, 2022.

 

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 to have their vehicle inspected and repaired.  If owners encounter this condition while driving, they should press the brake pedal quickly and repeatedly to shorten the stopping distance.  If this occurs, they should pull over to safe location, not drive their vehicle and contact Kia Roadside Assistance.

 

Q8. How does the vehicle owner know if the recall condition may be occurring in their vehicle?

The driver may experience a spongy brake feel and/or an extended stopping distance when the brake pedal is depressed.

 

Q9. How was the issue discovered?

Through the regular monitoring of field information.

 

Q10. Will this cost vehicle owners any money?

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

 

Q11. 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

 

Q12. How long will the repair take?

The actual time required to perform the repair will be approximately two (2) to three (3) hours.  However, the vehicle may be needed longer.  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.)

 

A13. Are there any restrictions on an owner’s eligibility?

No.

 

Q14. 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 Time, or via the internet at www.kia.com (Owner’s Section).

 


2020-2021MY Rio
Brake Master Cylinder
Basis of Safety Defect Determination 573.6(c)(6)

 

October 26, 2021

Supplier of brake master cylinder notifies Kia Mexico (KMX) of brake related customer complaints in one of Hyundai’s vehicle models sold in Brazilian market. Supplier identifies same brake master cylinder may have been supplied to KMX.

 

October 29, 2021

KMX reviews its records and advises Kia HQ that the Rio vehicles produced at KMX are equipped with the same brake master cylinder as the Hyundai model in Brazilian market.

 

November 3, 2021

KMX notifies the Kia North America (Kia NA) Safety Office of the possible spongy brake issue and identifies that its investigation is ongoing. KMX requests warranty return part for further evaluation.

 

November 4-11, 2021

Kia NA Safety Office meets with Kia HQ to review preliminary engineering information and requests further information from Kia HQ regarding vehicle performance effects of brake master cylinder issue. During this time, Kia Na Safety Office conducts an evaluation of field data and identifies one (1) brake master cylinder replacement warranty claim.

 

November 19, 2021

Kia HQ provides Kia NA Safety Office with further information regarding the potential effects on vehicle brake performance as a result of component analysis and testing conducted by Hyundai.

 

November 23, 2021

Kia NA decides to conduct a recall. No fatalities, injuries, crashes or fires. No customer complaints and one (1) warranty claim.

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
KIA RIO 2020-2021

 


11 Associated Documents

ISSUED Owner Notification Letter(Part 577) – January 11, 2022

RCONL-21V936-6404.pdf 239.059KB

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Remedy Instructions and TSB

RCRIT-21V936-0497.pdf 300.165KB

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Defect Notice 573 Report

RCLRPT-21V936-7711.PDF 213.733KB

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Chronology

RMISC-21V936-0410.pdf 76.82KB

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Recall Acknowledgement

RCAK-21V936-1637.pdf 645.819KB

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SC223 2020-2021 MY RIO VEHICLES BRAKE MASTER CYLINDER, SAFETY RECALL CAMPAIGN Q & A: January 6, 2022

RMISC-21V936-3598.pdf 116.489KB

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Manufacturer Notices(to Dealers,etc) – January 6, 2022

RCMN-21V936-4720.pdf 109.619KB

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Manufacturer Notices(to Dealers,etc) – January 6, 2022

RCMN-21V936-1015.pdf 87.009KB

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Recall Quarterly Report #1, 2022-1

RCLQRT-21V936-5507.PDF 211.122KB

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Recall Quarterly Report #2, 2022-2

RCLQRT-21V936-7493.PDF 211.223KB

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Recall Quarterly Report #3, 2022-3

RCLQRT-21V936-9493.PDF 211.305KB

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Recall Acknowledgement

RCAK-21V936-1637.pdf 645.819KB

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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=21V936&docType=RCL

 


 

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