Recall - Side Air Bag Harness Inspection/Replacement
VOLUME2
GROUP
Campaign
NUMBER
020
MODEL
Optima
DATE
May 2001
SUBJECT
Safety Recall: Side Air Bag Wire Harness
This bulletin provides information related to a recall on 2001 MY Optima models to correct a potential malfunction of the driver SAB (side air bag). The wire harness for the driver SAB, located under the driver seat cushion, may be mis-routed in such a way that it can be cut or punctured in the seat adjuster mechanism. If the wire harness is cut or punctured, the driver SAB may not deploy in an accident, or could deploy without an accident or impact.
To correct this situation, Kia is recalling affected 2001 MY Optima models to inspect, reposition and if necessary, replace the driver SAB wire harness.
* NOTICE
There is no charge to the customer for this repair. Under applicable law, you may not sell or otherwise deliver any affected 2001 Optima until it has been repaired, pursuant to the procedures set forth in this bulletin.
WARNING
Failure to follow procedures, or failure to adhere to Warnings, Cautions and Notices could result in personal injury and/or unnecessary vehicle damage/repairs.
INSPECTION PROCEDURE:
1. Open left rear door.
2. Check the door at the location indicated for a yellow dot sticker.
3. If a yellow dot sticker exists on the door, NO FURTHER ACTION IS REQUIRED.
4. If a yellow dot sticker DOES NOT exist on the door, continue on to Repair Procedure.
REPAIR PROCEDURE:
1. Using either switch buttons (power seat) or manual adjusting knobs/lever, adjust driver seat all the way forward and raise seat cushion to its highest position.
2. Reach under the seat, unhook trim flap retaining clips.
* NOTICE
Procedures shown are with seat removed for procedure clarity only. Seat does not need to be removed for inspection or repositioning of SAB harness.
3. Locate driver SAB wire harness on underside of cushion.
4. Carefully inspect SAB wire harness at section indicated for damage or evidence of having been pinched or cut by seat adjustment mechanism. (Open protective split wrap tubing and inspect individual wires.)
5. A. If no wire harness damage is found, position wire harness and secure it to cushion spring with wire-tie as shown.
B. If wire harness has been pinched, but insulation on wires has not been cut or punctured, tape the wires at the pinch location then wire-tie harness to cushion spring as in step 5A.
Reconnect trim flap. Install campaign completion label on left rear door in position indicated. NO FURTHER ACTION IS REQUIRED.
If wire harness has been cut or punctured, continue on to step 6.
6. Remove head rest.
7. Remove trim covers from seat mounting locations, loosen and remove 2 nuts and 2 bolts, moving seat fore and aft for access.
8. Disconnect negative battery cable and wait 30 seconds. Tilt seat backwards then reach under, remove harness clips from seat cushion frame as required then disconnect seatbelt buckle switch connectors (S-08 and I-15) and [if equipped] power seat connector (P-01).
9. Remove SAB connector (S-05) from clip, and disconnect it from harness by pulling back locking sleeve.
Note:
The SAB wire harness may be wire-tied to the seat cushion spring. If so, cut the wire-tie.
10. Carefully lift seat and remove from vehicle. Position on suitable work surface, and protect upholstery.
11. Firmly pull lower end of seat back rear cover away from seat to release attaching clips, then move cover down and remove.
12. Remove screw and lumbar support handle.
13. Remove hog-rings and plastic tabs attaching upholstery panels then fold back upholstery to allow access to seat back attaching bolts.
14. Remove two mounting bolts from each side, and remove seat back.
15. Feed upholstery on new seat back behind cross bar, position in place, then secure with two bolts on each side.
16. Wrap upholstery around cross bar and seat back corners, then fasten upholstery with plastic tabs and with hog-rings. Use Snapon YA808 upholstery pliers or equivalent.
17. Reinstall lumbar support handle and secure with screw.
18. Reinstall seat back rear cover by first moving up then pushing lower half firmly towards seat back to snap attaching clips to seat back frame.
19. Position SAB wire harness and secure it to seat cushion spring with wire-ties as shown. Make sure to leave sufficient slack to allow for seat back adjustment without pulling or stretching harness.
20. Reposition seat cushion trim flap over crossbar as shown and re-attach retaining clips.
21. Lift seat into vehicle and position it over mounting locations. Take care to avoid damaging connectors as seat is being placed in vehicle.
22. Tilt seat backwards, then reach under and connect seat belt buckle switches (S-08 and I-15), power seat (P-01) [if equipped] and SAB connectors (S-05). Fasten SAB connector in retaining clip, then re-attach harness clips to seat bottom.
23. Re-connect negative battery cable.
24. Secure seat to floor by installing 2 nuts and 2 bolts, moving seat fore and aft for access. Torque nuts to 26 lb-ft and bolts to 40 lb-ft. Reinstall trim covers over mounting locations.
25. Reinstall head rest.
26. Connect scan tool, check for air bag DTC's and clear drivers SAB related codes. (If any non-related DTC's are found, repair/correct as required.)
27. Install campaign completion label on left rear door frame in position indicated.
AFFECTED PRODUCTION RANGE:
2001 MY Optima models produced from 10/15/00 to 3/21/01.
PART NUMBER INFORMATION:
WARRANTY CLAIM INFORMATION: