Campaign - O2 Sensor/PROM Update

VOLUME
3

GROUP
Campaign

NUMBER
028

MODEL
Optima

DATE
March 2003

SUBJECT
Service Campaign: Optima Oxygen Sensors





This bulletin provides information on a service campaign to replace oxygen sensors and to reprogram the ECM in 2001 MY Optima 2.5L V6 models.

Some 2001 MY Optima models with 2.5L V6 engines may experience MIL illumination with oxygen sensor related DTCs. To reduce incidence of MIL illumination, Kia is conducting a service campaign to install improved oxygen sensors and to reprogram the ECM in all 2001 MY Optima models with 2.5L V6 engines.

* 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.

REPAIR PROCEDURE:

1. Position vehicle on a hoist but do not raise.





2. Open hood, disconnect bank 2 sensor 1 connector at front corner of left cylinder head and remove connector from bracket.





3. Disconnect bank 1 sensor 1 connector at rear corner of right cylinder head and remove connector from bracket.





4. Raise vehicle on hoist and using suitable 02 sensor socket, remove both front (pre-catalyst) oxygen sensors.





5. Install new oxygen sensors, black wire sensor on bank 1 (bulkhead side) and gray wire sensor on bank 2 (radiator side). Torque to 29 - 36 lb-ft (40 - 50 Nm).

6. Lower vehicle and reconnect sensor connectors, reinstall connectors onto brackets.

REPROGRAMMING PROCEDURE:

* NOTICE
Clear any stored diagnostic trouble codes before reprogramming ECM.





7. Connect OBDII cable to the Hi-Scan Pro as shown.





8. Remove the program card from the upper slot on the Hi-Scan Pro tool and insert the reprogramming card.





9. Connect the Hi-Scan Pro to the vehicle OBDII connector located under the dash on the driver side.

10. Turn ignition key to the "on" position.





11. Turn the Hi-Scan Pro tool on, select "OPTIMA 2.5 02 SENSOR" and press the "ENTER" key.





12. Select "OPTIMA 2.5 01MY [AUTO MODE]" and press the "ENTER" key.

13. At the prompt, enter the password "0525" and press the "ENTER" key. Reprogramming will proceed automatically.





14. After "REPROGRAMMING COMPLETED" message is displayed (approximately five minutes), turn the ignition key to the "OFF" position and disconnect the Hi-Scan Pro from the vehicle.





15. Start the engine and confirm normal operation.

* NOTICE
If the reprogramming did NOT complete properly or was interrupted, repeat the process using the following procedure.

16. Select "OPTIMA 2.5 02 SENSOR" and press the "ENTER" key.





17. Select "OPTIMA 2.5 01MY [ERROR MODE]" and press the "ENTER" key.





18. At the prompt, enter your password "7100" and press the "ENTER" key. Reprogramming will complete automatically.





19. After "REPROGRAMMING COMPLETED" message is displayed (approximately five minutes), turn the ignition key to the "OFF" position and disconnect the Hi-Scan Pro from the vehicle.

20. Start the engine and confirm normal operation.

AFFECTED PRODUCTION RANGE:

2001 MY Optima 2.5L V-6





PART NUMBER INFORMATION:





WARRANTY INFORMATION: