SC272 – Brake Booster – 2023 Kia Sportage

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-410 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Kia America, Inc. Submission Date : JUN 07, 2023 NHTSA Recall No. : 23V-410 Manufacturer Recall No. : SC272 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 : 98,944 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2023-2023 Kia Sportage Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : GAS Descriptive Information : Certain 2023 model year Sportage vehicles manufactured at the Kia Georgia plant from January 12, 2022 to February 15, 2023. 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 Customer Care Center or their Kia dealer. Production Dates : JAN 12, 2022 – FEB 15, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The brake booster diaphragm may become misaligned resulting in an internal vacuum leak. An internal vacuum leak can cause loss of brake assist. A loss of brake assist can result in hard pedal feel and increased effort during pedal application thereby increasing stopping distances. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A loss of brake assist increases the risk of a crash. Description of the Cause : Internal vacuum leak due to a misaligned brake booster diaphragm. Identification of Any Warning that can Occur : None. Part 573 Safety Recall Report 23V-410 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : BOOSTER ASSY-BRAKE Component Description : Brake Booster Assembly Component Part Number : 59110-CW200 Supplier Identification : Component Manufacturer Name : Mobis Mexico Address : Los Ramones Kms. 13-15 Localidad La Arena Pesquería Foreign States 66679 Country : Mexico Chronology : See attached document titled “2023MY Sportage Brake Booster Chronology”. 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 brake booster and if necessary, replace it with a new one. 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 : The brake booster diaphragm is properly aligned. Identify How/When Recall Condition was Corrected in Production : Kia Georgia implemented an inspection procedure to confirm proper brake booster diaphragm alignment. This inspection procedure was applied to vehicles produced beginning on 2/16/2023. Recall Schedule : Description of Recall Schedule : The planned dealer notification begin and end date is June 12, 2023. The planned owner notification begin and end date is July 21, 2023. Planned Dealer Notification Date : JUN 12, 2023 – JUN 12, 2023 Planned Owner Notification Date : JUL 21, 2023 – JUL 21, 2023 Part 573 Safety Recall Report 23V-410 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 * 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 2023MY Sportage (NQ5a) NUMBER DATE SC272 June 2023 SAFETY RECALL CAMPAIGN BRAKE BOOSTER INSPECTION & REPLACEMENT (SC272) This bulletin provides information to inspect and, if necessary, replace the brake booster assembly on certain 2023MY Sportage (NQ5a) vehicles, produced from January 12, 2022 through February 15, 2023. The brake booster diaphragm in the subject vehicles may become misaligned, resulting in an internal vacuum leak. An internal vacuum leak can cause loss of brake assist. A loss of brake assist can result in hard pedal feel and increased effort during pedal application, thereby increasing stopping distances and the risk of a crash. Follow the procedure outlined in this publication to inspect for an excess gap seal between the inner and outer shell and, if necessary, replace the brake booster assembly on the applicable vehicle. Before conducting the procedure, verify the vehicle is included in the list of affected VINs. Reference images of a No Good (NG) and (OK) diaphragm seal. 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.  NOTICE To assure complete customer satisfaction, always remember to refer to KDealer+ 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 t he vehicle before returning it to the customer.  NOTICE BRAKE BOOSTER INSPECTION AND REPLACEMENT (SC272) 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: SC272 Sportage (NQ5a) June 2023 SUBJECT: Inspection and Replacement Procedure: 1. 2. Open the hood. Remove the battery tray (A) by referring to “Engine Electrical System → Charging System → Battery → Removal and Installation (Battery Tray)” in the applicable Shop Manual on KGIS. 3. 4. Disconnect the master cylinder brake fluid sensor connector (B). Disconnect the brake booster vacuum sensor connector (C). 5. Detach the the brake master cylinder (D) by loosening the two (2) retaining bolts/screws. Note: DO NOT disconnect the brake lines. This is a simplified method to allow removal of the brake booster. 5. Remove the brake booster (E) by referring to “Brake System → Brake System → Brake Booster → Removal and Installation (from step 2)” in the applicable Shop Manual on KGIS. Note: Image shown for reference use only. The master cylinder must remain attached to brake lines. D+ E+ B+ C+ A+ 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: SC272 Sportage (NQ5a) June 2023 SUBJECT: BRAKE BOOSTER INSPECTION AND REPLACEMENT (SC272) 6. Using a feeler gauge, set a thickness of 0.75mm and place the brake booster (E) on a flat surface as shown. 7. Inspect the outer and inner shell gap between ALL gasket tab points (16 total), around the outer circumference area of the brake booster. Note: The feeler gauge should not be able to be inserted between any check point of the inner and outer shell outlined area shown. 8a. 8b. • If the feeler gauge is able to be inserted between both of the shells with an excess gap of 0.75mm or more (NG), replace the brake booster assembly with a new part in the reverse order of removal. • If the feeler gauge is not able to be inserted between both of the shells using the 0.75mm setting (OK), then reinstall the removed brake booster assembly in the reverse order of removal. 6. 7. Reinstall all removed parts in the reverse order of removal. Confirm normal vehicle operation. E+ BRAKE BOOSTER INSPECTION AND REPLACEMENT (SC272) 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: SC272 Sportage (NQ5a) June 2023 SUBJECT: AFFECTED VEHICLE RANGE: Model Production Date Range Sportage (NQ5a) January 12, 2022 to February 15, 2023 REQUIRED TOOL: Tool Name Part Number Figure Comments Feeler Gauge N/A Locally Sourced REQUIRED PART: Part Name Part Number Figure Qty. Brake Booster Assembly 59110 CW200QQK 1 WARRANTY INFORMATION: N Code: N99 C Code: C99 Note: When necessary, manually enter sublet code ‘X2’ for reimbursement of one roundtrip rideshare expense or up to three (3) days of rental for brake booster replacement. Refer to Warranty Bulletin 2023-18 for claim submission procedures. Claim Type Causal P/N Qty. Repair Description Labor Op Code Op Time Replacement P/N Qty. R 59110 CW200 0 (SC272) Brake Booster Inspection 231A15I0 0.6 M/H N/A 0 (SC272) Brake Booster Inspection and Replacement 231A15R0 0.7 M/H 59110 CW200QQK 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 SSC272C272 when accessing the when accessing the KDealer+KDealer+ system.system.   NOTICENOTICE

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SC272 June 12, 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 certain 2023 MY Sportage vehicles manufactured at a Kia assembly plant in the U.S. from January 12, 2022 to February 15, 2023. The brake booster diaphragm may become misaligned resulting in an internal vacuum leak. An internal vacuum leak can cause loss of brake assist. A loss of brake assist can result in hard pedal feel and increased effort during pedal application thereby increasing stopping distances. A loss of brake assist also increases the risk of a crash. All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Kia dealers are to inspect the brake booster and if necessary, replace it 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 mailing notices to the affected vehicle owners beginning on July 21, 2023. 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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SC272 June 12, 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 certain 2023 MY Sportage vehicles manufactured at a Kia assembly plant in the U.S. from January 12, 2022 to February 15, 2023. The brake booster diaphragm may become misaligned resulting in an internal vacuum leak. An internal vacuum leak can cause loss of brake assist. A loss of brake assist can result in hard pedal feel and increased effort during pedal application thereby increasing stopping distances. A loss of brake assist also increases the risk of a crash. All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Kia dealer. Kia dealers are to inspect the brake booster and if necessary, replace it with a new one. 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 during the week of June 12, 2023. 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 July 21, 2023. 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 Campaign 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 Enclosures

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