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 are expected to be 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
2017-2018MY 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 |
4 Associated Documents
Defect Notice 573 Report
RCLRPT-22V836-1914.PDF 214.158KB
RCLRPT-22V836-1914
Recall 573 Report – November 14, 2022
RCLRPT-22V836-8535.PDF 214.171KB
RCLRPT-22V836-8535
2017-2018MY Niro Hybrid PRA Chronology
RMISC-22V836-4393.pdf 83.308KB
RMISC-22V836-4393
Recall Acknowledgement
RCAK-22V836-8180.pdf 645.057KB
RCAK-22V836-8180
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V836&docType=RCL
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Last update on 2023-02-26 / Affiliate links / Images from Amazon Product Advertising API
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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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