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November 11, 2022 NHTSA CAMPAIGN NUMBER: 22V836000
Electrical Resistance at Main Relay May Cause Fire
Overheated rear seats increase the risk of a fire.
NHTSA Campaign Number: 22V836
Manufacturer Kia America, Inc.
Components HYBRID PROPULSION SYSTEM
Potential Number of Units Affected 27,030
Summary
Kia Motors America (Kia) is recalling certain 2017-2018 Kia Niro hybrid electric vehicles previously recalled under recall 18V-666. The Main Relay within the Power Relay Assembly (PRA) may have inadequate connections between its contacts, causing increased electrical resistance, which can overheat the rear seats.
Remedy
Dealers will inspect the PRA and replace either the PRA or the Main Relay, as necessary, free of charge. Owner notification letters were mailed January 9, 2023. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC256. This recall supersedes NHTSA recall number 18V-666. Vehicles already repaired under the previous recall will need to have the new remedy completed.
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
2017-2018 MY NIRO HYBRID VEHICLES
POWER RELAY ASSEMBLY (PRA) – SAFETY RECALL CAMPAIGN (SC256)
Q & A
January 5, 2023
Q1. What type of campaign is Kia conducting?
A1. Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign to address a defect involving the Power Relay Assembly (PRA).
Q2. What vehicles are affected by the recall?
A2. The 2017-2018 MY Niro Hybrid vehicles manufactured from November 1, 2016 to September 11, 2017 that were previously recalled under 18V666 (SC168). This new recall (SC256) supersedes the previously launched 18V666 (SC168) recall.
Q3. How many customer vehicles are affected by this recall?
A3. Approximately 27,030 vehicles.
Q4. What is the concern with the Power Relay Assembly?
A4. The Power Relay Assembly (PRA) is located underneath the rear seat and consists of various components including the Main Relay. Inadequate connection between the Main Relay contacts can increase electrical resistance thereby generating heat. If sufficient heat is generated, thermal damage may occur to the rear seat, including the potential for a fire. Recall 18V666 addresses this concern by instructing dealers to inspect and replace the PRA if thermal damage is found or replace the Main Relay if no thermal damage is found. However, the subject vehicles may not have had the remedy relay installed during the 18V666 recall repair. As a result, the potential for a fire may still exist.
Q5. Can you describe the recall campaign and fix?
A5. Dealers will inspect the Power Relay Assembly (PRA) for any signs of thermal damage. If any thermal damage is present, the PRA will be replaced with a new one. If no thermal damage is present and the original Main Relay (LS IS CO., Ltd.) is still installed, the Main Relay will be replaced with a new one (Panasonic).
Q6. How will owners of the affected vehicles be notified?
A6. Kia will send a letter notifying owners of the affected vehicles by first class mail beginning on January 9th, 2023.
Q7. What should vehicle owners do when they receive the notification?
A7. Upon receipt of the letter, owners are to contact their authorized Kia dealer to arrange to have the recall performed on their vehicle.
Q8. Where were these vehicles produced?
A8. The affected vehicles were produced at a Kia assembly plant in Korea.
Q9. Will this cost vehicle owners any money?
A9. No. Kia will perform the recall repair free of charge at no cost to the customer.
Q10. What about customers who may have already paid to have this situation corrected?
A10. 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:
Kia Customer Care Center Kia America, Inc. P.O. Box 52410 Irvine, CA 92619-2410 1-800-333-4542
Q11. Are there any restrictions on an owner’s eligibility?
A11. No.
Q12. If a customer has an immediate question, where can they get further information?
A12. The customer can contact their local authorized Kia dealership or call Kia’s Customer Care Center at 1-800-333-4KIA (4542), Monday through Friday, 5 AM to 6 PM Pacific Time, or via the internet at www.kia.com (Owner’s Section).
SC256
January 2023
POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256)
This bulletin provides the procedure to inspect the Power Relay Assembly (PRA) and, if necessary, to replace the PRA or the Main Relay(s) on the 2017-2018MY Niro Hybrid (DE HEV) vehicles produced from November 1, 2016 through September 11, 2017 that were previously recalled under Kia’s SC168. The PRA is located underneath the rear seat and consists of various components including the Main Relay. Inadequate connection between the Main Relay contacts can increase electrical resistance thereby generating heat. If sufficient heat is generated, thermal damage may occur to the rear seat, including the potential for a fire. Kia’s SC168 addresses this concern by instructing dealers to inspect and replace the PRA if thermal damage is found or replace the Main Relay if no thermal damage is found. However, the subject vehicles may not have had the remedy relay(s) installed during the SC168 recall repair. As a result, the potential for a fire may still exist. Follow the procedure outlined in this publication to inspect the PRA for any signs of thermal damage. If any thermal damage is present, the PRA is to be replaced with a new one. If no thermal damage is present and the original Main Relay(s) (LS IS CO., Ltd.) is/are still installed, the Main Relay(s) is/are to be replaced with new one(s) (Panasonic). Before conducting the procedure, verify that the vehicle is included in the list of affected VINs. Note: SC256 supersedes the previously released SC168.
Inspection Procedure:
AFFECTED VEHICLE RANGE:
Model | Production Date Range |
Niro HEV (DE HEV) | November 1, 2016 to September 11, 2017 |
REQUIRED PART:
Part Name | Part Number | Qty. |
Power Relay Assembly (PRA) | 37514 G2100QQK | 1 |
2017-2018MY Niro Hybrid
Power Relay Assembly
Basis of Safety Defect Determination 573.6(c)(6)
September 25, 2018
Kia Motors America, Inc. (KMA) files recall of 2017-2018MY Niro Hybrid vehicles to address inadequate connection between the Main Relay contacts that can increase electrical resistance and generate heat. If sufficient heat is generated, thermal damage may occur to the rear seat, including the potential for a fire. (18V666). Kia dealers instructed to inspect the Power Relay Assembly (PRA) for any signs of thermal damage. If any thermal damage was present, the PRA was to be replaced with a new one. If no thermal damage was present, the Main Relay was to be replaced with a new one.
June 13, 2022
Kia North America (Kia NA) receives Techline case from dealer that identifies customer complaint of burning smell involving a 2017MY Niro (Vehicle #1). Dealer identifies melting of the PRA.
Kia’s record shows Recall 18V666 repair previously completed May 20, 2019.
June 14, 2022
Kia NA receives Techline case involving a 2017MY Niro that identifies customer complaint of vehicle no-start (Vehicle #2). Dealer identifies melting of the PRA. Kia’s record shows Recall 18V666 repair previously completed on August 5, 2019.
June 28, 2022
Kia NA Safety Office engineer inspects Vehicle #2 and collects parts for further evaluation.
July 7, 2022
Kia NA Safety Office engineer inspects Vehicle #1 and finds soot deposits in area of PRA and localized fire damage. Parts are subsequently collected for Vehicle #1 and sent to Kia NA Safety Office for further evaluation.
July 29, 2022
Kia NA Safety Office receives Vehicle # 1 parts from dealer.
August 12, 2022
Kia NA Safety Office evaluates collected parts from Vehicle #1 and Vehicle #2 and identifies parts from both vehicles are the originally installed Main Relays (LS IS CO., Ltd) and not the recall remedy relays (Panasonic).
August 17—September 22, 2022
Kia NA Safety Office conducts preliminary field data analysis and identifies two (2) additional warranty claims with associated Techline cases with thermal damage on original installed Main Relays (dates of receipt 4/20/21 & 1/14/22). Kia’s records show Recall 18V666 previously completed on both vehicles.
September 23, 2022
Kia NA Safety Office escalates the issue to SEL.
October 5—November 3, 2022
Kia NA Safety Office conducts audit of four (4) randomly selected non-incident vehicles that previously had Recall 18V666 repair completed and confirms recall remedy relays (Panasonic) had been installed and no thermal issue found.
October 19—November 3, 2022
Kia NA Safety Office updates field data analysis and identifies one (1) additional warranty claim with thermal damage on originally installed Main Relay (date of receipt 9/30/22) even though Recall 18V666 repair had previously been completed. To date, a total of five (5) fires (localized melting/damage only) identified.
November 4, 2022
Kia NA decides to recall the 2017-2018MY Niro vehicles previously recalled under 18V666. No fatalities, injuries or crashes.
2 Affected Products
Vehicle
MAKE | MODEL | YEAR |
KIA | NIRO | 2017-2018 |
11 Associated Documents
Defect Notice 573 Report
RCLRPT-22V836-1914.PDF 214.158KB
Recall 573 Report – November 14, 2022
RCLRPT-22V836-8535.PDF 214.171KB
2017-2018MY Niro Hybrid PRA Chronology
RMISC-22V836-4393.pdf 83.308KB
Recall Acknowledgement
RCAK-22V836-8180.pdf 645.057KB
Remedy Instructions and TSB
RCRIT-22V836-4904.pdf 1063.787KB
Manufacturer Notices(to Dealers,etc)
Manufacturer Notices(to Dealers,etc)
2017-2018 MY NIRO HYBRID VEHICLES POWER RELAY ASSEMBLY (PRA) – SAFETY RECALL CAMPAIGN (SC256) Q & A January 5, 2023
RMISC-22V836-9024.pdf 111.215KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V836-3152.pdf 239.766KB
Recall Quarterly Report #1, 2023-1
RCLQRT-22V836-8735.PDF 211.146KB
Recall Quarterly Report #2, 2023-2
RCLQRT-22V836-5307.PDF 211.252KB
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https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V836&docType=RCL
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-836 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Kia America, Inc. Submission Date : NOV 14, 2022 NHTSA Recall No. : 22V-836 Manufacturer Recall No. : SC256 Manufacturer Information : Manufacturer Name : Kia America, Inc. Address : 111 Peters Canyon Road Irvine CA 92606 Company phone : 800-333-4542 Population : Number of potentially involved : 27,030 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2017-2018 Kia Niro Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC Descriptive Information : The 2017-2018 model year Niro Hybrid vehicles manufactured from November 1, 2016 to September 11, 2017 that were previously recalled under 18V666. The recall population was determined by a review of supplier and vehicle production 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 Customer Care Center or their Kia dealer. Production Dates : NOV 01, 2016 – SEP 11, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The Power Relay Assembly (PRA) is located underneath the rear seat and consists of various components including the Main Relay. Inadequate connection between the Main Relay contacts can increase electrical resistance thereby generating heat. If sufficient heat is generated, thermal damage may occur to the rear seat, including the potential for a fire. Recall 18V666 addresses this concern by instructing dealers to inspect and replace the PRA if thermal damage is found or replace the Main Relay if no thermal damage is found. However, the subject vehicles may not have had the remedy relay installed during the 18V666 recall repair. As a result, the potential for a fire may still exist. FMVSS 1 : NR Part 573 Safety Recall Report 22V-836 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 FMVSS 2 : NR Description of the Safety Risk : Increased electrical resistance between the main relay contacts can increase the risk of a thermal event, including the potential for a fire. Description of the Cause : The subject vehicles may not have had the remedy relay installed during the 18V666 repair. Identification of Any Warning that can Occur : Illumination of HEV warning light while driving and/or inability to start the vehicle Involved Components : Component Name 1 : Relay-High Voltage Main Component Description : High Voltage Main Relay Component Part Number : 37583-G2000 Supplier Identification : Component Manufacturer Name : LS IS CO., Ltd. Address : 95, Beakbong-ro, Heung deok-gu Chungcheongbuk-do Chungju-si, Foreign States 28439 Country : Korea, Republic of Chronology : See attached document titled “2017-2018MY Niro Hybrid PRA Chronology” Part 573 Safety Recall Report 22V-836 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. Kia will instruct dealers to inspect the Power Relay Assembly (PRA) for any signs of thermal damage. If any thermal damage is present, the PRA will be replaced with a new one. If no thermal damage is present and the original Main Relay (LS IS CO., Ltd.) is still installed, the Main Relay will be replaced with a new one (Panasonic). Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 10, 2022. How Remedy Component Differs from Recalled Component : Proper connection between the Main Relay contacts supplied by Panasonic Identify How/When Recall Condition was Corrected in Production : As identified in Recall 18V666, the recall condition was corrected in production when the Power Relay Assembly supplier was changed from LS IS CO., Ltd., to Panasonic on July 14, 2017. Based on both supplier and vehicle production records, the recalled components were installed in some vehicles produced thru September 11, 2017. Recall Schedule : Description of Recall Schedule : The dealer notification is scheduled to begin and end on January 5, 2023 and the owner notification is scheduled to begin and end on January 9, 2023. Planned Dealer Notification Date : JAN 05, 2023 – JAN 05, 2023 Planned Owner Notification Date : JAN 09, 2023 – JAN 09, 2023 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-836 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Kia America, Inc. Submission Date : NOV 11, 2022 NHTSA Recall No. : 22V-836 Manufacturer Recall No. : SC256 Manufacturer Information : Manufacturer Name : Kia America, Inc. Address : 111 Peters Canyon Road Irvine CA 92606 Company phone : 800-333-4542 Population : Number of potentially involved : 27,030 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2017-2018 Kia Niro Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC Descriptive Information : The 2017-2018 model year Niro Hybrid vehicles manufactured from November 1, 2016 to September 11, 2017 that were previously recalled under 18V666. The recall population was determined by a review of supplier and vehicle production 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 Customer Care Center or their Kia dealer. Production Dates : NOV 01, 2016 – SEP 11, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The Power Relay Assembly (PRA) is located underneath the rear seat and consists of various components including the Main Relay. Inadequate connection between the Main Relay contacts can increase electrical resistance thereby generating heat. If sufficient heat is generated, thermal damage may occur to the rear seat, including the potential for a fire. Recall 18V666 addresses this concern by instructing dealers to inspect and replace the PRA if thermal damage is found or replace the Main Relay if no thermal damage is found. However, the subject vehicles may not have had the remedy relay installed during the 18V666 recall repair. As a result, the potential for a fire may still exist. FMVSS 1 : NR Part 573 Safety Recall Report 22V-836 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 FMVSS 2 : NR Description of the Safety Risk : Increased electrical resistance between the main relay contacts can increase the risk of a thermal event, including the potential for a fire. Description of the Cause : The subject vehicles may not have had the remedy relay installed during the 18V666 repair. Identification of Any Warning that can Occur : Illumination of HEV warning light while driving and/or inability to start the vehicle Involved Components : Component Name 1 : Relay-High Voltage Main Component Description : High Voltage Main Relay Component Part Number : 37583-G2000 Supplier Identification : Component Manufacturer Name : LS IS CO., Ltd. Address : 95, Beakbong-ro, Heung deok-gu Chungcheongbuk-do Chungju-si, Republic of Korea 28439 Country : NR Chronology : See attached document titled “2017-2018MY Niro Hybrid PRA Chronology” Part 573 Safety Recall Report 22V-836 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. Kia will instruct dealers to inspect the Power Relay Assembly (PRA) for any signs of thermal damage. If any thermal damage is present, the PRA will be replaced with a new one. If no thermal damage is present and the original Main Relay (LS IS CO., Ltd.) is still installed, the Main Relay will be replaced with a new one (Panasonic). Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 10, 2022. How Remedy Component Differs from Recalled Component : Proper connection between the Main Relay contacts supplied by Panasonic Identify How/When Recall Condition was Corrected in Production : As identified in Recall 18V666, the recall condition was corrected in production when the Power Relay Assembly supplier was changed from LS IS CO., Ltd., to Panasonic on July 14, 2017. Based on both supplier and vehicle production records, the recalled components were installed in some vehicles produced thru September 11, 2017. Recall Schedule : Description of Recall Schedule : The dealer notification is scheduled to begin and end on January 5, 2023 and the owner notification is scheduled to begin and end on January 9, 2023. Planned Dealer Notification Date : JAN 05, 2023 – JAN 05, 2023 Planned Owner Notification Date : JAN 09, 2023 – JAN 09, 2023 * NR – Not Reported
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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 2017-2018MY Niro HEV (DE HEV) NUMBER DATE SC256 January 2023 SAFETY RECALL CAMPAIGN POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) This bulletin provides the procedure to inspect the Power Relay Assembly (PRA) and, if necessary, to replace the PRA or the Main Relay(s) on the 2017-2018MY Niro Hybrid (DE HEV) vehicles produced from November 1, 2016 through September 11, 2017 that were previously recalled under Kia’s SC168. The PRA is located underneath the rear seat and consists of various components including the Main Relay. Inadequate connection between the Main Relay contacts can increase electrical resistance thereby generating heat. If sufficient heat is generated, thermal damage may occur to the rear seat, including the potential for a fire. Kia’s SC168 addresses this concern by instructing dealers to inspect and replace the PRA if thermal damage is found or replace the Main Relay if no thermal damage is found. However, the subject vehicles may not have had the remedy relay(s) installed during the SC168 recall repair. As a result, the potential for a fire may still exist. Follow the procedure outlined in this publication to inspect the PRA for any signs of thermal damage. If any thermal damage is present, the PRA is to be replaced with a new one. If no thermal damage is present and the original Main Relay(s) (LS IS CO., Ltd.) is/are still installed, the Main Relay(s) is/are to be replaced with new one(s) (Panasonic). Before conducting the procedure, verify that the vehicle is included in the list of affected VINs. Note: SC256 supersedes the previously released SC168. SUBJECT: 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. 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 POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) Page 2 of 9 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC256 Niro HEV (DE HEV) January 2023 SUBJECT: Flowchart: Vehicle In Replace HV Main Relays Vehicle Out Replace the PRA Are relays Panasonic with PN 37583 A8000? Remove the Power Relay Assembly (PRA) Remove Relays Is PRA thermal damage present? Take photo. No Using the KVID app, record a continuous video showing the VIN and both HV main relay labels. Yes No Yes All replaced Power Relay Assemblies (PRA) will be collected for inspection and are subject to Warranty review and chargeback. NOTICE Page 3 of 9 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC256 Niro HEV (DE HEV) January 2023 POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) SUBJECT: Inspection Procedure: 1a. 1b. Remove the rear seat cushion (A) by loosening the two (2) 12mm bolts (B). Lift the seat cushion (A) to detach. 2. Remove the left rear door scuff trim (C) by loosening the 10mm retaining bolt (D). 3. Remove the cooling duct (E) by detaching the retaining clip (F). D \ C \ D F E A + B \ D Tightening torque for rear seat cushion bolts (B): 12.3 – 18.8 lb.ft (16.8 – 25.5 N.m) POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) Page 4 of 9 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC256 Niro HEV (DE HEV) January 2023 SUBJECT: 4a. Using the KVID app, record a continuous video starting from the ‘B’ pillar VIN tag. 4b. 4c. Continue recording video by moving to display both HV main relay labels (G). Stop recording video after both HV Main Relay labels were displayed. 5. Inspect and verify if the existing HV Main Relays are labeled ‘Panasonic’ with PN 37583 A8000. • OK – Campaign is complete. Reinstall all removed parts in the reverse order of removal. • NG – Proceed to the ‘Replacement Procedure’ on page 5. Only twenty-four (24) seconds are allotted for the video length. Ensure that a flashlight is illuminating the relays prior to starting the video. NOTICE G Refer to the removed HV main relay images below for samples of the label. The VIN and relay labels MUST be clear and legible in the video. If the labels cannot be clearly read, the warranty claim may be subject to charge back. IMPORTANT Page 5 of 9 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC256 Niro HEV (DE HEV) January 2023 POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) SUBJECT: Replacement Procedure: 1. Disconnect auxiliary 12V battery negative (-) terminal. 2. Shut off the high voltage circuit by referring to the “Hybrid Control System → High Voltage Shut-off Procedures” 3. Remove upper frame (A) after loosening the mounting bolts and nuts. 4. Remove the high voltage battery cover (B) after loosening the mounting bolts and nuts. Failure to follow the High Voltage Shut-off Procedure may result in serious electrical injuries. DANGER Tightening torque for high voltage battery cover: 5.8 – 8.7 lb.ft (7.8 – 11.8 N.m) Tightening torque for mounting nuts (M8): 14.5 – 21.7 lb.ft (19.6 – 29.4 N.m) Tightening torque for mounting nuts (M6): 5.8 – 8.7 lb.ft (7.8 – 11.8 N.m) B A POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) Page 6 of 9 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC256 Niro HEV (DE HEV) January 2023 SUBJECT: 5a. 5b. 5c. 5d. 5e. 5f. Disconnect the high-voltage inverter power cable [+] (C). Disconnect the high-voltage inverter power cable [-] (D). Disconnect the high-voltage battery cable [+] (E). Disconnect the high-voltage battery cable [-] (F). Disconnect the current sensor connector (G). Disconnect 12V connector (H). 6. Remove the PRA (I) by loosening the retaining nuts. Tightening torque for inverter cables [+] and [-] mounting bolt: 5.8 – 8.7 lb.ft (7.8 – 11.8 N.m) Tightening torque for PRA nuts: 5.8 – 8.7 lb.ft (7.8 – 11.8 N.m) HL GK F E D C IN Page 7 of 9 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC256 Niro HEV (DE HEV) January 2023 POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) SUBJECT: 7. Place the PRA on a flat and stable surface. Carefully remove the two (2) HV main relays (J) from the PRA by following the instructions below: • Partially insert two (2) short flat-head screwdrivers between the retaining tabs of the PRA and HV main relays (J). Ensure the PRA tabs are separated from the HV main relays. • Use two (2) large flat-head screwdrivers to carefully pry up the relay (D) from the bottom past the retaining tabs and then lift the relay (J) up from the PRA. INSERT HYPERLINK TO NEW VIDEO J + J N Do not over-insert the short flat-head screwdrivers as damage to the retaining tabs/PRA may occur. CAUTION S c a n For additional tips, information, click the icon or scan the QR code to watch HV relay removal video (Step 7). Click POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) Page 8 of 9 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC256 Niro HEV (DE HEV) January 2023 SUBJECT: 8. Inspect the PRA at the HV main relay large contact areas for thermal damage. • If any sign of thermal damage is present, replace the PRA. Note: Damage should only be present at the large HV main relay terminals. • If no sign of thermal damage is present, replace the two (2) HV main relays. 9. Reinstall all removed components in the reverse order of disassembly. 10. Verify normal vehicle operation. For NG conditions, PHOTOS ARE REQUIRED to be attached to the claim when replacing the PRN. For OK conditions, PHOTOS ARE REQUIRED to be attached to the claim when replacing the relays. Page 9 of 9 Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: SC256 Niro HEV (DE HEV) January 2023 POWER RELAY ASSEMBLY (PRA) OR HV MAIN RELAYS INSPECTION / REPLACEMENT (SC256) SUBJECT: AFFECTED VEHICLE RANGE: Model Production Date Range Niro HEV (DE HEV) November 1, 2016 to September 11, 2017 REQUIRED PART: Part Name Part Number Figure Qty. Power Relay Assembly (PRA) 37514 G2100QQK 1 HV Main Relay Kit 37583 A8000QQK 1 (Includes 2 HV Main Relays) WARRANTY INFORMATION: N Code: N99 C Code: C99 Note: Refer to Warranty Bulletin 2023-01 for claim submission procedures. A KVID video recording showing the VIN and both HV main relay labels is required for all inspections. *For all part replacements, a KVID photo for each of the old part(s) must be taken and attached to the claim using Warranty Claim Attachment type ‘XX – Other’. Claims will be subject to chargeback if photos are not submitted. Claim Type Causal P/N Qty. Repair Description Labor Op Code Op Time Replacement P/N Qty. R 37583 G2000 0 (SC256) PRA Inspection 22190010 0.3 M/H N/A 0 (SC256) PRA Inspection + HV Main Relay Replacement 221900R0 0.8 M/H 37583 A8000QQK 1 (SC256) PRA Inspection + PRA Replacement 221900R1 0.8 M/H 37514 G2100QQK VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference SC256 when accessing the WebDCS system. NOTICE
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Kia America, Inc. Corporate Headquarters 111 Peters Canyon Road, Irvine, CA 92606-1790 USA IMPORTANT SAFETY RECALL (NHTSA Recall Number: 22V836) This notice applies to your vehicle: (Insert VIN) January 9, 2023 Dear Kia Niro Vehicle 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 2017-2018 MY Niro Hybrid vehicles. The defect may cause heat damage to the rear seat, increasing the risk of a fire. Our records indicate that you own or lease one of the potentially affected vehicles. On November 23, 2018, a different recall notice (18V666 or Kia’s Reference # SC168) was sent to vehicle owners regarding the Power Relay Assembly (PRA). This is a new recall and supersedes the previously launched 18V666 recall. What Is The Problem? The Power Relay Assembly (PRA) is located underneath the rear seat of your vehicle and consists of various components including the Main Relay. Inadequate connection between the Main Relay contacts can increase electrical resistance, thereby generating heat. If sufficient heat is generated, thermal damage may occur to the rear seat, increasing the risk of a fire. Recall 18V666 addresses this concern by instructing dealers to inspect and replace the PRA if thermal damage is found or replace the Main Relay if no thermal damage is found. However, your vehicle may not have had the remedy relay installed during the 18V666 recall repair. As a result, the potential for a fire may still exist. Kia Will Inspect And, If Necessary, Replace The Power Relay Assembly or The Main Relay Free of Charge At No Cost To You. Kia dealers will inspect the Power Relay Assembly (PRA) for any signs of thermal damage. If any thermal damage is present, the PRA will be replaced with a new one. If no thermal damage is present and the original Main Relay is still installed, the Main Relay will be replaced with a new one. This recall will be performed free of charge at no cost to you. The estimated time required to perform the recall will be approximately one (1) to two (2) hours. We recommend scheduling a service appointment to minimize your inconvenience. What Should You Do? • WARNING: Do not install a Child Safety Seat on the rear left passenger seat until the recall has been completed. • 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 performed on your vehicle. • The illumination of the HEV warning light while driving and/or the inability to start the vehicle may be an indication of this concern. If either of these conditions occurs, contact Kia Roadside Assistance at 1-800-333-4542 or online at kia.rsahelp.com to request to have your vehicle towed to the nearest authorized Kia dealership as soon as possible. SC256 • 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): 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: Kia Customer Care 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 Kia Customer Care 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 Customer Care 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, Customer Care 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 2017-2018 MY NIRO HYBRID VEHICLES – POWER RELAY ASSEMBLY (PRA) SAFETY RECALL CAMPAIGN (SC256) 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: Kia Customer Care 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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SC256 January 5, 2023 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 the 2017-2018 MY Niro Hybrid vehicles manufactured from November 1, 2016 to September 11, 2017 that were previously recalled under 18V666 (SC168). This is a new recall and supersedes the previously launched 18V666 recall. The Power Relay Assembly (PRA) is located underneath the rear seat and consists of various components including the Main Relay. Inadequate connection between the Main Relay contacts can increase electrical resistance thereby generating heat. If sufficient heat is generated, thermal damage may occur to the rear seat, including the potential for a fire. Recall 18V666 addresses this concern by instructing dealers to inspect and replace the PRA if thermal damage is found or replace the Main Relay if no thermal damage is found. However, the subject vehicles may not have had the remedy relay installed during the 18V666 recall repair. As a result, the potential for a fire may still exist. Dealers will inspect the Power Relay Assembly (PRA) for any signs of thermal damage. If any thermal damage is present, the PRA will be replaced with a new one. If no thermal damage is present and the original Main Relay (LS IS CO., Ltd.) is still installed, the Main Relay will be replaced with a new one (Panasonic). 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. 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. Note that any vehicle owner who has already paid for related repairs can submit a request for reimbursement online via the Owner’s Section of www.kia.com. Kia will mail notices to the affected vehicle owners beginning on January 9, 2023. Please make personnel in your dealership familiar with the details of this Safety Recall Campaign so they may respond to customer inquiries and requests appropriately. This Safety Recall Campaign is an opportunity for your service department to deliver an exceptional service experience to customers who may not have otherwise scheduled service. Providing customers with easy scheduling and timely service increases the chance they will return to your service department for future service needs. 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 facing Kia District Parts and Service Manager. Sincerely, Kia Service Department Enclosures
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SC256 January 5, 2023 ATTENTION: ALL DEALER PRINCIPALS Kia America, Inc., pursuant to the National Traffic and Motor Vehicle Safety Act, is conducting a Safety Recall Campaign on the 2017-2018 MY Niro Hybrid vehicles manufactured from November 1, 2016 to September 11, 2017 that were previously recalled under 18V666 (SC168). This is a new recall and supersedes the previously launched 18V666 recall. The Power Relay Assembly (PRA) is located underneath the rear seat and consists of various components including the Main Relay. Inadequate connection between the Main Relay contacts can increase electrical resistance thereby generating heat. If sufficient heat is generated, thermal damage may occur to the rear seat, including the potential for a fire. Recall 18V666 addresses this concern by instructing dealers to inspect and replace the PRA if thermal damage is found or replace the Main Relay if no thermal damage is found. However, the subject vehicles may not have had the remedy relay installed during the 18V666 recall repair. As a result, the potential for a fire may still exist. Dealers will inspect the Power Relay Assembly (PRA) for any signs of thermal damage. If any thermal damage is present, the PRA will be replaced with a new one. If no thermal damage is present and the original Main Relay (LS IS CO., Ltd.) is still installed, the Main Relay will be replaced with a new one (Panasonic). 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 mailing notices to the affected vehicle owners beginning on January 9, 2023. What Should You Do? Please make personnel in your dealership familiar with the details of this Safety Recall Campaign so they may properly address recall related issues and promptly respond to customer inquiries and requests. 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 facing Kia District Parts & Service Manager. Sincerely, Kia Service Department Enclosures
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