RECALL: Kia Niro EV - Battery Safety Plugs Could Melt, Cause Fire

Due to a potential for the high voltage battery safety plugs to overheat and melt, which could cause the vehicles to stall or catch fire, Kia has issued a recall for more than 2,200 model year 2022 Niro EVs. Owners are advised not to charge their vehicles in garages or other covered structures until repairs are completed.

The high voltage battery safety plug melting has been reported on several occasions, prompting the recall. In July 2023, a dealer reported to Kia that a 2022 Niro EV had failed to enter ready mode and had shut off while being driven. The dealer found that the high voltage battery safety plug had melted after inspecting the vehicle. Despite a comprehensive check by Kia, no further affected vehicles were originally discovered.

But later on, a similar situation was recorded in Portugal, which prompted engineers to look into it more. They tried, but they were unable to reproduce the issue. Not very long after, a second dealer report surfaced, this time about a car that wouldn't start because the safety plug had melted. There was another occurrence with a 12-volt battery that was recorded and it was again related to significant electrical resistance at the terminal of the safety plug.
Though the precise cause is yet unknown, Kia engineers believe the problem may be caused by a manufacturing error in the safety plug's Female-Female connection.

Kia advises 2022 Niro EV drivers to monitor for the EV Service warning light and to be particularly vigilant for signs of smoke or the smell of melting plastic.

Recall notification letters are expected to be mailed by July 19. Kia dealers will replace the faulty safety plugs.

Affected vehicles were manufactured between July 21 and Dec. 2, 2021.

Niro EV owners can contact Kia at 800-333-4542 and reference recall number SC314 for more information.