SC223 – Brake Master Cylinder – 2020-2021 Kia Rio

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A printed copy is for reference only; publication information can be updated at any time. Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical publications are listed in ‘Service Releases’ and has the latest service information that has been released. GROUP MODEL Safety Recall Campaign 2020-2021MY Rio (SC) NUMBER DATE SC223 January 2022 SAFETY RECALL CAMPAIGN 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. SUBJECT: 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.  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 Brake Master Cylinder Assembly BRAKE MASTER CYLINDER REPLACEMENT (SC223) Page 2 of 4 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC223 Rio (SC) January 2022 SUBJECT: 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 System → Air Cleaner → Repair procedures” chapter in the applicable Shop Manual on KGIS. 3. Remove the brake fluid from the master cylinder reservoir with a syringe. 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. 5. Remove the master cylinder (C) from the brake booster after loosening the mounting nuts (D). A B Tightening torque for Tightening torque for Flare NutFlare Nut:: ABS: 10.1 ABS: 10.1 –– 12.312.3 lb.ft (lb.ft (13.7 13.7 –– 16.716.7 N.m)N.m) ESC: 13.7 ESC: 13.7 –– 16.616.6 lb.ft (lb.ft (18.6 18.6 –– 22.622.6 N.m)N.m) Tightening torque for Tightening torque for Mounting NutsMounting Nuts:: 86.4 86.4 –– 139.2 lb.in139.2 lb.in ((9.8 9.8 –– 15.715.7 N.m)N.m) C D  •Do Do notnot spill brake fluid on the vehspill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in icle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.contact with the paint, wash off immediately with water. CAUTIONCAUTION Page 3 of 4 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC223 Rio (SC) January 2022 BRAKE SUBJECT: MASTER CYLINDER REPLACEMENT (SC223) 6. 7. 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. 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. Reuse the original master cylinder Reuse the original master cylinder OO–ringring. If damaged, use PN 58591 . If damaged, use PN 58591 17000 to replace it.17000 to replace it.   NOTICENOTICE O-ring  •Do Do notnot reuse the drained fluid.reuse the drained fluid.  •Always use genuine DOT4 brake Always use genuine DOT4 brake ffluid.luid.  •Using a nonUsing a non–genuine DOT4 brake fluid can cause corrosion and decrease the life of the genuine DOT4 brake fluid can cause corrosion and decrease the life of the system.system.  •Make sure that no dirt or other foreign matter is allowed to contaminate the brake fluid.Make sure that no dirt or other foreign matter is allowed to contaminate the brake fluid.  •Do Do notnot spill brake fluid on the vehspill brake fluid on the vehicle as it may damage the paint. If brake fluid comes in icle as it may damage the paint. If brake fluid comes in contact with the paint, wash off immediately with water.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 The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of of the the bleeding procedure and checked after bleeding ebleeding procedure and checked after bleeding each brake caliper. Add fluid as ach brake caliper. Add fluid as required.required. CAUTIONCAUTION BRAKE MASTER CYLINDER REPLACEMENT (SC223) Page 4 of 4 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC223 Rio (SC) January 2022 SUBJECT: AFFECTED VEHICLE RANGE: Model Production Date Range Rio (SC) September 29, 2020 to July 1, 2021 REQUIRED PART: Part Name Part Number Figure Qty. Master Cylinder & Reservoir 58510 H9260QQK 1 Brake Fluid (DOT4) UM010 CH043 1 qt (Max.) WARRANTY INFORMATION: N Code: N99 C Code: C99 Note: Use sublet code ‘X1’ for reimbursement of Kia Brake Fluid (DOT 4, PN UM010 CH043) used for brake system bleeding and fluid adjustment (maximum allowance of $9.00). When necessary, manually enter sublet code ‘X2’ for reimbursement of one roundtrip rideshare expense or up to three (3) days of rental for Brake Master Cylinder replacement. Refer to Warranty Bulletin 2022-02 for claim submission procedures. Claim Type Causal P/N Qty. Repair Description Labor Op Code Op Time Replacement P/N Qty. R 58510 H9260 0 (SC223) R & R Brake Master Cylinder Assy 211M17R0 1.5 M/H 58510 H9260QQK 1 VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference SSCC223223 when accessing the WebDCS system.when accessing the WebDCS system.   NOTICENOTICE

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Kia America, Inc. Corporate Headquarters 111 Peters Canyon Road, Irvine, CA 92606-1790 USA IMPORTANT SAFETY RECALL (NHTSA Recall Number: 21V936) This notice applies to your vehicle: (Insert VIN) January 11, 2022 Dear Kia Rio 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 America, Inc. has decided that a defect which relates to motor vehicle safety exists in certain 2020-2021 MY Rio vehicles. The defect can impair the vehicle’s braking function thereby increasing the risk of a crash. Our records indicate that you own or lease one of the potentially affected vehicles. What Is the Problem? 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 normal 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/or extended stopping distances, thereby increasing the risk of a crash. Kia Will Replace the Brake Master Cylinder At No Cost To You. Kia will replace the brake master cylinder with a new one to ensure the integrity of the vehicle’s braking function at no cost to you. The estimated time required to perform the repair will be approximately two (2) to three (3) hours. 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. • WARNING: While driving, if you experience a spongy brake feel and/or an extended stopping distance when you depress the brake pedal, press the brake pedal quickly and repeatedly to shorten the stopping distance. If this occurs, pull over to safe location, do not drive your vehicle and contact Kia Roadside Assistance (online at kia.rsahelp.com or by phone 1-800-333-4542 available 24 hours/day, 365 days/year) to request to have your vehicle towed to the nearest authorized Kia dealership as soon as possible. • To find your nearest dealer, visit www.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): SC223 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 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? 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 http://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 Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. 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. REQUEST FOR REIMBURSEMENT FORM SC223 – 2020-2021 MY RIO VEHICLES BRAKE MASTER CYLINDER SAFETY RECALL CAMPAIGN 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 (MyKia>Contact Us or directly at this link: https://ksupport.kiausa.com/ConsumerAffairs). If you do not have access to a computer or prefer to submit your request by mail, please complete this Request for Reimbursement and mail it to the following address for review and consideration, along with backup documentation: Consumer Assistance Center Kia America, Inc. P. O. Box 52410 Irvine, CA 92619-2410 1-800-333-4542 Please allow at least sixty (60) days for review and response. Customer First Name: Customer Last Name: Attach the following: o Repair Order showing: o Name & address of person paying for the repair o Vehicle Identification Number (VIN) of vehicle repaired o Description of the problem repaired  Date of repair, mileage at the time of repair and total cost of claimed repair expense o Evidence of Payment of Repair showing: o Date of Payment o Amount Paid (e.g., copies of cancelled check or credit card receipt) I certify that the documents attached to this Request for Reimbursement are true and accurate and should be used as the basis for a reimbursement to me under this campaign. CLAIMANT’S SIGNATURE: ____________________________________________ _________________________________________ Signature Print Name Customer Address: Customer City: State: Zip: Phone #: ( ) – Email: Vehicle Identification Number: Mileage at Time of Repair: Date of Repair: / / Amount of Reimbursement Requested $

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SC223 January 6, 2022 ATTENTION: ALL DEALER PRINCIPALS Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign on certain 2020-2021 MY Rio vehicles manufactured 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. Kia dealers will replace the brake master cylinder with a new one. Your Service Manager was sent a 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 vehicles. Kia will start notifying the vehicle owners on January 11, 2022. 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 campaign performed on their vehicles. 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 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. If you have any questions, please contact your Kia District Parts & Service Manager. Sincerely, Kia Service Department Enclosures

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SC223 January 6, 2022 ATTENTION: ALL DEALER PARTS & SERVICE MANAGERS Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign on certain 2020-2021 MY Rio vehicles manufactured 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. Kia dealers will replace the brake master cylinder with a new one. PARTS INFORMATION: Part supply is limited due to the scope of the campaign. A valid VIN will be required for order entry. 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 January 6, 2022. Enclosed you will find a copy of the owner notification letter and a Q&A Guide for recall questions, both of which describe the issue. A list of vehicles 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 SC223 to generate the list. Kia will start notifying vehicle owners on January 11, 2022. Please start performing the repairs immediately on any affected vehicles currently in your inventory. Note that any vehicle owners who have already paid for Brake Master Cylinder repairs related to brake master cylinder concerns can submit a request for reimbursement online via the Owner’s Section of www.kia.com. 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 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 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. If you have any questions, please contact your Kia District Parts and Service Manager. Sincerely, Kia Service Department

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-936 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Kia Motors America Submission Date : DEC 01, 2021 NHTSA Recall No. : 21V-936 Manufacturer Recall No. : SC223 Manufacturer Information : Manufacturer Name : Kia Motors America Address : 111 Peters Canyon Road Irvine CA 92606 Company phone : 800-333-4542 Population : Number of potentially involved : 87 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Kia Rio Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : GAS Descriptive Information : Certain 2020-2021 model year Rio vehicles manufactured at Kia Mexico from 9/29/2020 through 7/1/2021. The recall population was determined by a review of vehicle production and supplier records. The vehicles subject to this recall were not produced in VIN order. Customers seeking information about their specific vehicle will be referred to Kia’s Consumer Assistance Center or their Kia dealer. Production Dates : SEP 29, 2020 – JUL 01, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : 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. FMVSS 1 : NR FMVSS 2 : NR Part 573 Safety Recall Report 21V-936 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of the Safety Risk : Spongy brake feel, longer brake pedal travel, and extended stopping distances can increase the risk of a crash. Description of the Cause : Improper machining of the master cylinder body. Identification of Any Warning that can Occur : None Involved Components : Component Name 1 : Cylinder Assy-Brake Master Component Description : Brake Master Cylinder Assembly Component Part Number : 58510-H9260 Supplier Identification : Component Manufacturer Name : Mando Corporation Mexico Address : Blvd. Campestre # 301, Parque Industrial Server Arteaga, Coahuila Foreign States 25350 Country : Mexico Chronology : See attached document titled “2020-2021MY Rio Brake Master Cylinder Chronology” Part 573 Safety Recall Report 21V-936 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Dealers will replace the brake master cylinder with a new one. Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 11, 2020. How Remedy Component Differs from Recalled Component : The remedy component has a properly machined brake master cylinder body. Identify How/When Recall Condition was Corrected in Production : Based on a review of supplier quality control records and Kia’s vehicle production records, vehicles produced from 7/2/2021 were equipped with properly machined brake master cylinder bodies. Recall Schedule : Description of Recall Schedule : The Dealer Notification is scheduled to begin and end on January 6, 2022, and the Owner Notification is scheduled to begin and end on January 11, 2022. Planned Dealer Notification Date : JAN 06, 2022 – JAN 06, 2022 Planned Owner Notification Date : JAN 11, 2022 – JAN 11, 2022 * NR – Not Reported

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