SC256 Power Relay Assembly – 2017-2018 Kia Niro Hybrid

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 KiaeBay logo America, Inc.

Components HYBRID PROPULSION SYSTEM

Potential Number of Units Affected 27,030

 

Summary

KiaeBay logo Motors America (KiaeBay logo) is recalling certain 2017-2018 KiaeBay logo 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 KiaeBay logo customer service at 1-800-333-4542. KiaeBay logo’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 KiaeBay logo conducting?

A1. KiaeBay logo 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. KiaeBay logo 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 KiaeBay logo 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 KiaeBay logo assembly plant in Korea.

 

Q9. Will this cost vehicle owners any money?

A9. No. KiaeBay logo 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 KiaeBay logo via the Owners section (Contact KiaeBay logo) of www.kia.com OR mail their documentation with the completed Request for Reimbursement Form included with this letter directly to KiaeBay logo for review and consideration at the following address:
KiaeBay logo Customer Care Center KiaeBay logo 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 KiaeBay logo dealership or call KiaeBay logo’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 KiaeBay logo’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. KiaeBay logo’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:

ModelProduction Date Range
Niro HEV (DE HEV)November 1, 2016 to September 11, 2017

 

REQUIRED PART:

Part NamePart NumberQty.
Power Relay  Assembly (PRA)37514 G2100QQK1

 


2017-2018MY Niro Hybrid
Power Relay Assembly
Basis of Safety Defect Determination 573.6(c)(6)

 

September 25, 2018

KiaeBay logo 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). KiaeBay logo 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

KiaeBay logo North America (KiaeBay logo 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.

KiaeBay logo’s record shows Recall 18V666 repair previously completed May 20, 2019.

 

June 14, 2022

KiaeBay logo NA receives Techline case involving a 2017MY Niro that identifies customer complaint of vehicle no-start (Vehicle #2). Dealer identifies melting of the PRA. KiaeBay logo’s record shows Recall 18V666 repair previously completed on August 5, 2019.

 

June 28, 2022

KiaeBay logo NA Safety Office engineer inspects Vehicle #2 and collects parts for further evaluation.

 

July 7, 2022

KiaeBay logo 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 KiaeBay logo NA Safety Office for further evaluation.

 

July 29, 2022

KiaeBay logo NA Safety Office receives Vehicle # 1 parts from dealer.

 

August 12, 2022

KiaeBay logo 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

KiaeBay logo 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). KiaeBay logo’s records show Recall 18V666 previously completed on both vehicles.

 

September 23, 2022

KiaeBay logo NA Safety Office escalates the issue to SEL.

 

October 5—November 3, 2022

KiaeBay logo 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

KiaeBay logo 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

KiaeBay logo NA decides to recall the 2017-2018MY Niro vehicles previously recalled under 18V666. No fatalities, injuries or crashes.

 


2 Affected Products

Vehicle

MAKEMODELYEAR
KIAeBay logoNIRO2017-2018

 


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)

RCMN-22V836-0284.pdf 106.65KB

 


Manufacturer Notices(to Dealers,etc)

RCMN-22V836-5536.pdf 82.442KB

 


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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