Recall - Fuel Pump Sub-Assembly Replacement

Model: Rondo [UN]

Group: Fuel System(14)

Number: KT2008090901

Date: Monday, September 08, 2008

Area: N. America

Subject:
Rondo Fuel Pump Sub-Assembly Replacement
(SC074)

Description:





This bulletin provides information relating to a safety recall campaign to replace the fuel pump motor sub-assembly in 2008-2009MY Rondo LX / EX vehicles with the 2.4L (I-4), built between 11/5/2007 ~ 7/12/2008. All of these vehicles must have their fuel pump motors replaced, unless they have previously been repaired at the port or under this campaign. For information purposes, you should know that these vehicles may exhibit the illumination of the check engine warning lamp for P2191 (System too lean at higher load) / P2187 (System too lean at idle) diagnostic trouble codes or may exhibit a longer than normal start-up time. The cause of the check engine warning lamp illumination / extended cranking is due to poor internal contacts within the electric fuel pump motor, which will result in a reduction
of fuel volume over time. Kia is replacing the electronic fuel pump sub-assembly to correct this condition.

NOTICE
There is no charge to the vehicle owner for this repair. Under applicable law, you may not sell or otherwise deliver any affected 2008-2009 MY Rondo LX/EX until it has been repaired pursuant to the procedures set forth in this bulletin.

AFFECTED VEHICLE RANGE:

2008-2009 Rondo LX / EX 2.4L (I-4) vehicles produced between 11/5/2007 ~ 7/12/2008





PARTS INFORMATION:

Inspection Procedure:





1. Open hood and check for SC074 campaign completion label on the panel above the under hood fuse box. If label exists, NO FURTHER ACTION IS REQUIRED.

If label does not exist, continue to step #2 of the inspection procedure.





2. Open the left rear door and inspect the area above the door check switch for a yellow paint mark. If a yellow paint mark is present above the door check switch, install an SC074 campaign completion sticker on the inner panel above the under hood fuse box. NO FURTHER ACTION IS REQUIRED.

If there is no SC074 campaign completion label or yellow paint mark above the left rear door check switch, continue with the remainder of this service procedure for fuel system depressurization and disassembly of the five / seven passenger options.

Fuel System Depressurizing Procedure:





1. Open the hood and remove under hood fuse box cover.

NOTICE:
Safety Glasses Are Required.





2. Remove the fuel pump relay. Start the engine and run until engine stalls. Crank the engine an additional five (5) seconds; this will ensure the fuel system is depressurized for service.

NOTICE:
Failure to follow this procedure can lead to excessive fuel loss under pressure & hydrocarbon odor during and after the service procedure.








3. Record radio presets and disconnect the negative battery cable.

Seven Passenger Option Service Procedure:





1. Open the second row door(s) and rear hatch. Slide the second row seat(s) forward.





2. Remove the fuel pump cover interior trim.





3. Remove the four (4) fuel pump cover retaining bolts. Push the wiring grommet through the top of the fuel pump cover. Relocate any rear interior floor mat(s).

Continue with the Fuel Pump Service Procedure in this document.

Five Passenger Option Service Procedure:





1. Slide the second row seat(s) forward in the collapsed position. Open the rear storage cover.





2. Remove the four (4) trim tabs and fasteners. Lift the rear storage bin out of the vehicle.





3. Remove the front storage cover trim. Remove the forward storage cover from the vehicle.





4. Remove the two (2) rear fasteners from the forward storage assembly legs. Remove the spare tire kit.





5. Remove the two (2) front storage well fastener(s). Lift the front storage assembly from the vehicle.





6. Remove the four (4) fuel pump cover screws.

Continue with the Fuel Pump Service Procedure in this document.

Fuel Pump Service Procedure (Five/Seven Passenger Models):





1. Disconnect the electrical connector(s) for the FTPS and Fuel Pump. Remove the nut for the Canister Close Valve bracket.

NOTICE:
Safety Glasses Are Required





2. Release the fuel line quick-connect retaining clip and slide it forward. Depress both grey tabs on the fuel line and disconnect the fuel line. Remove the rubber fuel ring from the base of the fuel pump.





3. Using SST# TKET125A, remove the fuel pump retaining ring.





4. Place two ~ three shop towels or plastic covering(s) around the base of the body opening. Remove the fuel pump from the tank and immediately place the fuel pump into a small catch pan. Move the fuel pump to a clean area for the disassembly procedure.

CAUTION:
Avoid spilling fuel in the interior of the vehicle.





5. Remove the fuel pump return hose by releasing the retaining tab and gently prying upward with a flat blade screwdriver.





6. Disconnect the upper sending unit wiring connector by gently depressing the harness connector tab. Disconnect the lower fuel pump motor connector. Cut the tie-wrap from the sending unit wiring.

CAUTION:
Do not pull on the electrical wiring to release the connector tabs. Depress the harness connector tab with a flat blade screwdriver or pick.





7. Release the three (3) pump reservoir retaining tabs. Separate the fuel pump assembly from the reservoir.





8. Compress the top of the fuel pump and remove the c-clip from the upper pump support. Separate the fuel pump upper assembly from the fuel pump assembly.





9. Release the three (3) retaining tabs from the discharge hose using a flat head screwdriver or pick. Discard the old fuel pump assembly.

CAUTION:
Use care not to damage or distort the retaining tabs during disassembly.

NOTICE:
Dispose of old parts according to all laws (local, state, federal) pertaining to this type of part and materials.





10. Remove the old discharge hose o-ring. Install the new o-ring to the discharge hose. Install the three (3) retaining tabs from the discharge hose to the new fuel pump assembly. Ensure proper retention of all three (3) retaining tabs of the discharge hose.






11. Install the fuel pump upper assembly to the new fuel pump assembly. Compress the upper spring assembly and install the supplied c-clip to the upper pump support.





12. Install the fuel pump reservoir to the pump and filter assembly. Ensure proper retention of all three (3) retaining tabs. Install/Route the fuel pump return hose and electrical connector(s) for the sending unit and lower motor assembly.





13. Align the tank and pump locating tab and install the fuel pump into the tank assembly.





14. Using SST# TKET125A, install the fuel pump retaining ring and torque to (57.9 ~ 72.4 lbs-ft / 78.5 ~ 98.1 Nm). Install fuel tank rubber ring.





15. Reinstall the Canister Close Valve bracket & nut. Install fuel line and retaining clip. Reconnect the FTPS and Fuel Pump electrical connector(s).

16. Install the pump cover and four (4) fuel retaining bolts. Install all body components in reverse order of disassembly.





17. Reinstall fuel pump relay and engine compartment fuse & relay cover. Reconnect negative battery cable.

18. Install an SC074 campaign completion sticker on the inner panel above the under hood fuse box.

19. Start vehicle and ensure no MIL illuminations and or RPM fluctuations after the repair.

20. Reprogram radio presets.





WARRANTY CLAIM INFORMATION:

To improve customer satisfaction always remember to refer to WebDCS Warranty Coverage (validation) Inquiry Screen (Service>Warranty Coverage>Warranty Coverage Inquiry) for a list of any additional campaigns that may need to be performed on the vehicle before returning it to the customer.