2024 Kia Models EGR Valve Assembly Replacement (SC320)

Kia has initiated a Voluntary Emissions Service Campaign, SC320, for certain 2024 Kia Carnival, Sportage, and Niro vehicles. This campaign addresses a potential manufacturing defect in the Exhaust Gas Recirculation (EGR) Valve Assembly. If the EGR valve assembly does not meet Kia's specifications, it can lead to the vehicle releasing air pollutants that exceed Federal and California standards. This condition may also cause the "Malfunction Indicator Lamp (MIL)" to illuminate on the dashboard, indicating a potential Kia Sportage EGR valve fault.

This bulletin, SC320 (Rev 1, dated 11/19/2025), provides detailed procedures for replacing the EGR Valve Assembly to resolve these issues. Kia has revised this bulletin to include additional information, with new or revised sections marked by a black bar in the margin.

Symptoms

Owners of affected 2024 Kia models may notice the following symptom:

• Illumination of the "Malfunction Indicator Lamp (MIL)" on the instrument cluster.

This warning light indicates that the vehicle's emission control system has detected a problem, often related to the Kia Sportage EGR valve fault.

Fault Codes / DTCs

When the "Malfunction Indicator Lamp (MIL)" illuminates, diagnostic trouble codes (DTCs) related to the EGR system may be stored. The following DTCs are associated with this issue:

Code	Description
P040500	Exhaust Gas Recirculation Sensor A Circuit Low
P064200	Sensor Reference Voltage 'A' Circuit Low
P065200	Sensor Reference Voltage 'B' Circuit Low

Diagnosis / Trigger Conditions

The issue is diagnosed when the "Malfunction Indicator Lamp (MIL)" illuminates and one or more of the specified DTCs (P040500, P064200, P065200) are present. These codes indicate a problem with the EGR system's sensor circuit or reference voltage, pointing to a potential Kia Sportage EGR valve fault.

Important Warnings

Owners and technicians should be aware of the following critical information:

• EGR Cooler Removal: The EGR cooler does not need to be removed to gain access to the EGR Valve Assembly during the replacement procedure.
• Proof of Correction Card: Do not complete the Vehicle Emission Recall - Proof of Correction card unless the service campaign work is fully completed. This card is required for vehicle registration renewal in specific states (California, Connecticut, Delaware, Massachusetts, Maine, Maryland, New Jersey, New York, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington).
• Part Ordering: Do not order QQK part numbers for stocking purposes related to this campaign, as supply is very limited. Confirm part availability before scheduling customers and expedite warranty claim filing.

Repair Procedure Summary

The repair involves replacing the EGR Valve Assembly. The procedure varies slightly by model:

For Carnival (KA4) models:

1. Remove the surge tank. This step provides necessary access to the EGR valve area.
2. Loosen bolts securing the EGR cooler to gain additional access to the EGR valve assembly. Note that the EGR cooler itself does not need to be fully removed.
3. Replace the Exhaust Gas Recirculation (EGR) Control Valve (EGR Valve Assembly).
4. Reinstall all removed parts in reverse order of removal.
5. Confirm normal vehicle operation.

For Sportage (NQ5) and Niro P/HEV (SG2 P/HEV) models:

1. Replace the EGR Valve Assembly. This involves accessing the component and removing the old unit.
2. Reinstall all removed parts in reverse order of removal.
3. Confirm normal vehicle operation.

Specific tightening torques are provided for the EGR cooler bolts (13.7 – 17.4 lb.ft or 18.6 – 23.5 N.m for bolt B; 36.2 – 39.8 lb.ft or 40.0 – 53.9 N.m for bolt C) and EGR bolts (13.7 – 17.4 lb.ft or 18.6 – 23.5 N.m).

Required Tools or Parts

The following parts are required for this service campaign:

• Campaign Completion Label: SC320
• Vehicle Emissions Recall Proof of Correction Card: UT160 SC320, UT161 SC320
• EGR Valve Assembly:
  • Carnival (KA4): 28410 3NFBOQQK, 28400 2SOOOQQK
  • Sportage (NQ5): 28400 2S00OQQK
  • Niro HEV/PHEV (SG2 P/HEV): 28450 08HAOQQK
• EGR Service Kit:
  • Carnival (KA4): 28751 3N003QQK
  • Sportage (NQ5): 28751 2500OQQK
• Various Gaskets: Specific to each model (e.g., EGR Pipe Gasket, ETC Gasket, Intake Manifold Gasket, Exhaust Pipe Gasket, O-Ring, EGR Cooler Gasket).
• Coolant: UM022 CH271 (Concentrate, 2 units for NQ5).

Owner Action

If you own a 2024 Kia Carnival, Sportage, or Niro and experience the "Malfunction Indicator Lamp (MIL)" illuminating, or if you are concerned about potential emissions issues, you should contact your authorized Kia dealer. This is a voluntary emissions service campaign, and the repair will be performed free of charge. Refer to Warranty Bulletin 2024-59 for claim submission procedures. Kia also offers reimbursement for one roundtrip rideshare expense or up to three days of rental expense using sublet code 'X2'.

Source: NHTSA ID 11025899