2024 Kia Sportage EGR Valve Assembly Replacement (SC320)

Kia has initiated a Voluntary Emissions Service Campaign, SC320, to address a manufacturing defect in the Exhaust Gas Recirculation (EGR) Valve Assembly on certain 2024 Kia Sportage, Carnival, and Niro vehicles. This condition means the EGR Valve Assembly may not meet Kia's specifications, potentially causing the vehicle to release air pollutants above federal and California standards. Owners of affected vehicles might notice their Malfunction Indicator Lamp (MIL) illuminating on the dashboard.

Symptoms

Owners of affected 2024 Kia Sportage vehicles may observe the following symptoms:

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

Fault Codes / DTCs

If the Malfunction Indicator Lamp illuminates, diagnostic trouble codes (DTCs) related to the Kia Sportage EGR valve system may be stored in the vehicle's computer. The specific DTCs associated with this issue include:

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 root cause of this issue is an EGR Valve Assembly that was not manufactured to Kia's precise specifications. This manufacturing deviation can lead to improper exhaust gas recirculation, affecting emissions control and potentially triggering the diagnostic trouble codes listed above.

Important Warnings for Owners

Kia has issued specific warnings regarding this service campaign:

• DO NOT COMPLETE THE CARD UNLESS THE SERVICE CAMPAIGN WORK IS COMPLETED. The "Vehicle Emission Recall - Proof of Correction" card should only be filled out after the service campaign work is finished.
• Dealers are advised: DO NOT order these parts for stocking purposes, related to this Campaign. Supply is very limited. Until supply stabilizes, please confirm part availability before scheduling customers.
• For Carnival (KA4) and Sportage (NQ5) models, dealers MUST order the specific EGR Service Kits (PN 28751 3N003QK for KA4 and PN 28751 2S000QK for NQ5).

Repair Procedure Summary

The repair involves replacing the faulty EGR Valve Assembly, particularly for the Kia Sportage EGR valve issue. The general procedure varies slightly by model but follows these steps:

For Carnival (KA4) models:

1. Remove the surge tank (labeled 'A' in the service diagrams) by following the "Engine Mechanical System → Intake and Exhaust System → Surge Tank → Removal and Installation" procedure in the KGIS Shop Manual.
2. Replace the Exhaust Gas Recirculation (EGR) Control Valve (labeled 'B' in the service diagrams). This involves referring to the "Emission Control System → Exhaust Emission Control System → EGR (Exhaust Gas Recirculation) → Removal and Installation" section in the KGIS Shop Manual.
3. Ensure EGR bolts are tightened to a torque of 13.7 - 17.4 lb.ft (18.6 - 23.5 N.m).
4. Reinstall all previously removed parts in the reverse order of removal.
5. Confirm normal vehicle operation after the repair.

For Sportage (NQ5) models:

1. Replace the EGR Valve Assembly (labeled 'C' in the service diagrams) by following the "Emission Control System → Exhaust Emission Control System → Electrical Exhaust Gas Recirculation (E-EGR) Control Valve → Removal and Installation" procedure in the KGIS Shop Manual.
2. Reinstall all previously removed parts in the reverse order of removal.
3. Confirm normal vehicle operation after the repair.

For Niro P/HEV (SG2 P/HEV) models:

1. Replace the EGR Valve Assembly (labeled 'D' in the service diagrams) by following the "Emission Control System → Exhaust Emission System → Electrical Exhaust Gas Recirculation (E-EGR) Control Valve → Removal and Installation" procedure in the KGIS Shop Manual.
2. Reinstall all previously removed parts in the reverse order of removal.
3. Confirm normal vehicle operation after the repair.

Required Parts

The following parts are required for the EGR Valve Assembly replacement:

Part Name	Part Number	Qty.
Campaign Completion Label	UT160 SC320	1
Vehicle Emissions Recall Proof of Correction Card	UT161 SC320	1
For Carnival (KA4) Models:
EGR Valve Assembly	28410 3NFBOQQK	1
EGR Pipe Gasket	28491 3N0OOQQK	2
EGR Service Kit	28751 3N003QQK	1
ETC Gasket	29211 3N300	1
Intake Manifold Gasket	29215 3N350	1
Exhaust Pipe Gasket	28751 A9100	1
Exhaust Pipe Gasket	28751 25000	2
EGR Pipe Gasket	28491 3N010	1
Gasket	28246 3N001	1
EGR Valve Assembly	28400 2SOOOQQK	1
EGR Pipe Gasket	28493 2SO40QQK	1
EGR Pipe Gasket	28493 2SO30QQK	1
Coolant	UM022 CH271	2 gal
For Sportage (NQ5) Models:
EGR Service Kit	28751 2S00OQQK	1
Exhaust Pipe Gasket	28751 28300	1
Exhaust Pipe Gasket	28751 3S100	1
EGR Pipe Gasket	28493 2S010	1
EGR Pipe Gasket	28493 2S020	1
Gasket	28535 2SADO	1
Thermostat Housing Gasket	25623 25600	1
O-Ring	25462 25500	2
EGR Pipe Gasket	28493 2S000	1
EGR Cooler Gasket	28493 2S050	1
For Niro P/HEV (SG2 P/HEV) Models:
EGR Valve Assembly	28450 08HAOQQK	1
EGR Pipe Gasket	28492 070OOQQK	1
EGR Pipe Gasket	28491 08HAOQQK	1

Note: The replacement QQK part numbers will require a VIN entry for parts ordering. Dealers are advised not to order these parts for stocking purposes due to limited supply. For Carnival (KA4) and Sportage (NQ5) models, dealers MUST order the specific EGR Service Kits (PN 28751 3N003QK for KA4 and PN 28751 2S000QK for NQ5).

Warranty Information

This service campaign is covered under warranty with the following details:

• N Code: W17
• C Code: ZZ3
• Claim Type: R (for NQ5 models, others implied as campaign)

Model	Labor Op Code	Op Time (M/H)
Carnival (KA4)	240060R0	1.6
Sportage (NQ5)	240060R1	2.6
Niro P/HEV	240060R2	0.6

Refer to Warranty Bulletin 2024-59 for detailed claim submission procedures. Sublet code 'X2' can be used for reimbursement of one roundtrip rideshare expense or up to three days of rental expense, with supporting documentation.

Owner Action

If you own a 2024 Kia Sportage, Carnival, or Niro, it is recommended to:

1. Check your VIN: You can verify if your vehicle is affected by checking its repair status on KDealer+ (Service → Warranty Coverage → Warranty Coverage Inquiry → Campaign Information). Not completed Recall / Service Action reports are also available on KDealer+ (Consumer Affairs → Not Completed Recall → Recall VIN → Select Report).
2. Contact your Kia dealer: Schedule an appointment to have the EGR Valve Assembly replaced. The repair will be performed free of charge.
3. Proof of Correction Card: If you reside in California, Connecticut, Delaware, Massachusetts, Maine, Maryland, New Jersey, New York, Oregon, Pennsylvania, Rhode Island, Vermont, or Washington, your dealer will provide a "Vehicle Emission Recall - Proof of Correction" card upon completion of the service. This card serves as evidence of campaign completion for vehicle registration renewal in these states. The dealer will also affix a "Campaign Completion Label" under the hood.

NHTSA ID: SC320