Campaign - Battery Cable Repair/Replacement

VOLUME
3

GROUP
Campaign

Number
035 (Revised)

MODEL
Sephia

DATE
January 2004

SUBJECT

Service Campaign:
Battery Cable Chafing Inspection, Repair and Replacement

This bulletin provides information on a service campaign to inspect the "positive" (+) battery cable and repair or replace the cable if necessary on 1998, 1999, and 2000 model year Sephia vehicles with automatic transmissions produced from 9/3/98 through 1/16/00.

To determine if a battery cable damage problem does exist, owners of affected vehicles are being notified to bring their vehicles to a Kia dealer for inspection of the "positive" battery cable. Use the procedures in this bulletin to inspect and if necessary, repair or replace the battery cable if damage is found.

WARNING
Failure to follow procedures, or failure to adhere to Warnings, Cautions and Notices could result in severe personal injury, death, and/or unnecessary vehicle damage/repairs.

* NOTICE
There is no charge to the customer for this inspection and/or repair. Under applicable law, you may not sell or otherwise deliver any affected 1998-2000 Sephia until it has been inspected, and/or repaired pursuant to the procedures set forth in this bulletin.

INSPECTION PROCEDURE:





1. Open hood and check for 5C035
Campaign Completion Label on bulkhead above master cylinder. If label exists, NO FURTHER ACTION IS REQUIRED. IF NO LABEL EXISTS, GO TO NEXT STEP.





2. Loosen air intake hose clamp at throttle body.

3. Disconnect electrical connectors at MAF and IAT sensors, remove DLC from bracket on air cleaner.

4. Remove two bolts and one nut securing air cleaner and remove air cleaner.





5. Inspect the positive battery cable at the three locations shown.





5a. Location A :

Check for interference or chafing between positive battery cable and sheet metal at rear transaxle mount or air cleaner bracket.





5b. Location B:

Check for interference or chafing between positive battery cable and transmission dipstick tube. Note whether battery cable is routed in front of or behind transmission dipstick tube.

Cable should be routed in front of dipstick tube. If not, loosen retainer near transaxle mount and reroute. Photo shows cable routed in front of dipstick which is the proper routing.





5c. Location C:

Check for interference or chafing between positive battery cable and transaxle shift cable.

If NO interference or chafing exists, go to Step 9.





6. If outer conduit is worn through exposing the inner battery cable, replace cable.





7. If conduit is wearing through, inner battery cable not exposed, add protective conduit at locations A, B or C as required (go to Step 8).





8. Install protective conduit (Repair Kit P/N QKSUB 67 001 contains two protective conduit sleeves) around cable, secure with three cable-ties, snip off excess cable-tie.

9. Reinstall air cleaner in reverse order of removal.

WARNING
Make sure there is no interference after inspection, repair or replacement of battery cable. If necessary, reposition the battery cable to correct any interference.





10. Apply SC035 Campaign Completion Label to bulkhead above master cylinder.

* NOTICE
All damaged battery cables that require replacement, will be requested for return to KMA through the Warranty Parts Return System. The damaged cable must be received at KMA to receive claim payment for the replace OP Code 035032R1.

AFFECTED PRODUCTION RANGE:

Selected 1998-2OOOMY Sephia models.





PART NUMBER INFORMATION:





WARRANTY CLAIM INFORMATION: