2024 Kia Telluride Recall: Engine Valve Springs May Break

A 2024 Kia Telluride owner heard a pop while driving, then saw smoke coming from the engine compartment. The dealer inspected the SUV in November 2023 and found a hole in the engine block. The Kia safety office examined it days later and logged broken internal parts, a breach on the front side of the block and localized melting on the shield beneath the engine.

That engine opened the investigation behind recall 24V077, filed February 7, 2024. It covers 2,872 Tellurides from the 2024 model year, built from October 1 through December 6, 2023, whose valve springs can crack from fatigue and break while the SUV is moving. A broken spring can cost the V6 its drive power. The damage can also put a hole in the engine block, which raises the risk of fire. Dealers replace the engine sub-assembly free of charge.

Owner letters went out April 5, 2024. Kia's quarterly report of April 20, 2026 counts 2,788 of the 2,872 vehicles as remedied.

The Issue

Every intake and exhaust valve in the engine rides on a coil spring. The camshaft pushes the valve open; the spring snaps it shut against its seat, several hundred times a minute even at idle. A spring that cannot close its valve leaves the cylinder without compression and the valve exposed to a rising piston.

The springs in this recall, part number 22221-3L310, came from Daewonkangup, a supplier in Haman-gun, South Korea. Some were marred while being made. That flaw gives fatigue cracks a starting point, and each compression cycle grows the crack until the coil snaps. Under a scanning electron microscope, every broken spring Kia examined showed fatigue cracking, and every spring it evaluated had been made on the same day.

Affected Models

Vehicle	Model Year	Build Dates	Estimated Units
Kia Telluride	2024	Oct. 1 to Dec. 6, 2023	2,872

Kia found the recall population in vehicle and supplier production records, and the affected SUVs were built out of VIN order, so the check runs one VIN at a time through a Kia dealer or Kia Customer Care. All of them came from a Kia assembly plant in the U.S. Tellurides built December 7 through 10, 2023 were repaired at the plant before they shipped, and engines installed from December 11 on carry undamaged springs.

Chronology and Investigation

The dealer's report on the smoking Telluride reached Kia on November 15, 2023. The safety office's inspection followed on November 20 and 21, and Kia arranged to take the engine for study.

Between December 5 and 15, Kia's product quality team saw a growing number of engine replacements on low-mileage 2024 Tellurides and began collecting engines. A first pass through field data turned up 47 dealer technical cases involving those replacements, and the safety office escalated the matter. From December 18 through January 10, 2024, Kia pulled engines, found damaged valves and broken springs, and shipped the parts to headquarters in Korea.

The microscope work ran January 23 to 29. On January 31, headquarters told the U.S. safety office that the springs could be damaged during manufacture at the supplier and traced the likely scope to an engine production window. Kia America decided to recall the SUVs that day, filed with NHTSA on February 7, and notified dealers on February 12.

Hyundai filed campaign 24V106 on February 13, 2024 for 4,245 Palisade SUVs from the 2024 model year built August 21 through October 12, 2023, listing the same spring part number and the same supplier. Its parent company passed along Kia's recall determination for vehicles with springs from the suspect lot on January 31. According to Hyundai's filing, the flaw traces to the supplier's spring drawing die, which was replaced July 26, 2023, and the supplier added a durability inspection for new springs in early January 2024.

Reported Incidents

When Kia decided to recall, it had identified 83 unique VINs potentially tied to the broken springs through warranty claims, dealer technical cases and customer complaints received between October 25, 2023 and January 26, 2024.

The chronology records one fire, the localized melting found on the first car. Hyundai counted 18 Palisade incidents from October 30, 2023 through January 25, 2024. Neither automaker reported a crash, injury or fatality tied to the springs.

What Owners Should Do

Run the VIN at NHTSA.gov or Kia's recall page, or call Kia customer service at 1-800-333-4542 and reference recall SC296.

If the engine starts making abnormal noise, lights the check engine lamp or runs rough, Kia's owner letter says to pull over somewhere safe and call Kia Roadside Assistance at 1-800-333-4542, or go to kia.rsahelp.com, for a tow to the nearest Kia dealer.

Owners who paid for a related repair before the recall can ask for reimbursement under Kia's General Reimbursement Plan. Submit receipts online through the Owners section of kia.com, or mail them with the reimbursement form to Kia Customer Care, P.O. Box 52410, Irvine, CA 92619-2410. Kia aims to answer within 60 days.

Symptoms to Watch For Before the Valve Spring Fails

Abnormal engine noise. A broken spring lets its valve float out of step with the camshaft, and the valvetrain noise changes.

A check engine light. A cylinder that loses compression produces misfires the engine computer can flag.

Rough running. The V6 shakes or stumbles at idle or under load as one cylinder stops pulling its share.

A pop followed by smoke. That sequence came before the hole in the block on the November 2023 car. Pull over and shut the engine off.

How Long Will the Recall Repair Take?

Kia's owner letter estimates about eight hours or more. Its service bulletin allows dealers 8.4 hours of labor on a front-drive Telluride and 8.7 hours with all-wheel drive. Technicians lift the engine and transaxle out together, move the intake manifold, high-pressure fuel pump, injectors, wiring harness, alternator and air conditioning compressor to the new engine sub-assembly, then reinstall everything, refill oil and coolant, recalibrate the steering angle sensor and road test the SUV.

The bulletin calls engine supply limited, tells dealers not to order engines for stock and requires a valid VIN for each engine order. Dealers can bill Kia for one round-trip rideshare or up to three days of rental car for the engine replacement.

Bottom Line

Kia expects about 3 percent of the 2,872 engines to carry a flawed spring, and a failure can leave the SUV without power in traffic or start a fire beneath it. By my subtraction, the April 2026 report leaves 84 vehicles without a logged remedy. The same report lists 37 owners Kia could not reach by mail and 10 SUVs scrapped, stolen or exported.

Run the VIN on any used 2024 Telluride built in the fall of 2023 before buying it. An SUV whose owner never received the letter can still change hands with the original engine.

Find your Kia Telluride recall information: https://www.kia.com/us/en/recall

Recall 24V077 (February 2024) covers 2024 Tellurides built October 1 through December 6, 2023 with valve springs damaged during manufacture at supplier Daewonkangup. Hyundai recalled 4,245 2024 Palisades under 24V106 for the same part number from the same supplier.

Hyundai's Palisade campaign 24V106, filed six days after this one, uses the same remedy, an engine sub-assembly replacement, and traces the damaged springs to a spring drawing die the supplier replaced on July 26, 2023.