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Charging System (ENG010)

Publication date: 2003-05-01
Reference number: ENG010

CHARGING SYSTEM

CHARGING SYSTEM

TECHNICAL SERVICE BULLETIN

Reference Number(s): ENGINE 010, Date of Issue:  May 2003
KIA: Sedona
GROUP: Engine
AFFECTED PRODUCTION RANGE: 2002 and 2003 Sedona models produced before 2/28/03.

SUBJECT

This bulletin provides information related to charging system changes in 2003MY Sedona models to improve alternator output during high ambient temperature severe operating conditions.

Some 2002 and 2003MY Sedona models built before 2/28/03 production may experience battery discharge when operated in high ambient temperatures for extended periods of time at low speeds or at idle with A/C, headlamps and other accessories on. Typically this results in customers reporting an inability to restart vehicle. To reduce incidence of battery discharge complaints, the following changes were made from 2/28/03 production:

For 2002 and 2003MY Sedona complaint vehicles produced before 2/28/03, the revised parts and logic software have been made available for use as a field fix.

Refer to the field fix procedures outlined.

Fig 1: Old & New Alternators
G00305022

BATTERY TEST

Test battery using Micro 570 Tester, refer to TSB, SST 002 , MIDTRONICS BATTERY TESTER for instructions.

Fig 2: Testing Battery With Micro 570 Tester
G00305023

ALTERNATOR INSTALLATION PROCEDURE

  1. Disconnect battery negative cable.
  2. Loosen nut on drive belt tensioner pulley. See Fig 3 .
    Fig 3: Loosening Nut On Drive Belt Tensioner Pulley
    G00305024
  3. From under vehicle, loosen belt tensioning bolt. See Fig 4 .
    Fig 4: Loosening Belt Tensioning Bolt
    G00305025
  4. Remove drive belt.
  5. Loosen clamp securing fresh air duct to air cleaner housing.
  6. Remove two bolts securing fresh air duct to upper radiator support and remove fresh air duct. See Fig 5 .
    Fig 5: Removing Fresh Air Duct
    G00305026
  7. Detach wire harness retainers from upper radiator support. See Fig 6 .
    Fig 6: Detaching Wire Harness Retainers
    G00305027
  8. Detach hood release cable retainer from upper radiator support. See Fig 7 .
    Fig 7: Detaching Hood Release Cable Retainer
    G00305028
  9. Remove two bolts securing hood latch to upper radiator support.
  10. Disconnect both horn electrical connectors. See Fig 8 .
    Fig 8: Removing Hood Latch Bolts & Disconnecting Horn Connectors
    G00305029
  11. Remove three bolts from each end of upper radiator support, remove support. See Fig 9 .
    Fig 9: Removing Upper Radiator Support
    G00305030
  12. Disconnect electrical connectors from both engine cooling fans.
  13. Remove bolts securing cooling fans, remove both engine cooling fans, (left one first).
  14. Insert a piece of cardboard behind radiator to protect radiator fins when removing alternator. See Fig 10 .
    Fig 10: Inserting Cardboard Behind Radiator
    G00305031
  15. Disconnect electrical connections at back of alternator. See Fig 11 .
    Fig 11: Disconnecting Alternator Connectors
    G00305032
  16. Remove alternator brace bolt and lower mounting bolt from alternator.
    NOTE: Lower mounting bolt will interfere with body before clearing alternator. Remove bolt with alternator.
  17. Loosen but do not remove upper mounting bolt. See Fig 12 .
    Fig 12: Upper Mounting, Lower Mounting & Brace Bolt Locations
    G00305033
  18. Remove two bolts securing upper alternator bracket to engine. See Fig 13 .
    Fig 13: Removing Upper Alternator Bracket Bolts
    G00305034
  19. Slide alternator straight up until it clears lower mount, remove lower mounting bolt and remove alternator from vehicle.
  20. Transfer upper alternator bracket to new alternator, leave bolt loose. See Fig 14 .
    Fig 14: Transferring Upper Alternator Bracket To New
    G00305035
  21. Install alternator into place. Start lower mounting bolt before installing alternator onto lower mounting bracket. See Fig 15 .
    Fig 15: Installing Alternator
    G00305036
  22. Install upper alternator bracket bolts, brace bolt and torque all alternator mounting bolts.
  23. Install new drive belt and adjust tension.
  24. Reconnect alternator electrical connections.
  25. Reinstall engine cooling fans in reverse order of removal.
  26. Reinstall upper radiator support, using caution not to pinch hood release cable at left radiator mount. See Fig 16 .
    Fig 16: Reinstalling Upper Radiator Support
    G00305037
  27. Reattach harness retaining clips and hood release cable retainer to upper radiator support.
  28. Reinstall bolts securing hood latch to upper radiator support.
  29. Reconnect horn connectors.
  30. Reinstall fresh air duct.
  31. If:
    • The vehicle has OEM battery, continue on to Battery Cover Installation below.
    • The vehicle has a replacement battery, reconnect negative battery cable and continue on to ECM REPROGRAMMING PROCEDURE  .

BATTERY COVER INSTALLATION

NOTE: Battery cover will only fit OEM battery.
  1. Disconnect both battery cables.
  2. Loosen "J" bolts and remove battery hold-down. See Fig 17 .
    Fig 17: "J" Bolt Locations
    G00305038
  3. Slide battery cover down over battery.
  4. Reinstall hold-down and reconnect battery cables. See Fig 18 .
    Fig 18: Battery Cover Installed
    G00305039

ECM REPROGRAMMING PROCEDURE

  1. Remove program card from the upper slot of the Hi-Scan Pro and insert the reprogramming card. See Fig 19 .
    Fig 19: Inserting Reprogramming Card
    G00305040
  2. Connect reprogramming adapter to Hi-Scan Pro.
  3. Connect DLC adapter to reprogramming adapter cable.
  4. Connect power supply adapter to Hi-Scan Pro.
  5. Connect reprogramming adapter power supply cable to Hi-Scan Pro power supply adapter. See Fig 20 .
    Fig 20: Power Supply, Reprogramming & DLC Adapters
    G00305041
  6. Connect power supply adapter to vehicle battery.
  7. Connect Hi-Scan Pro to under hood DLC located near vehicle battery. See Fig 21 .
    NOTE: Any interruptions will prevent proper reprogramming. Make sure connectors are securely and completely inserted. Leave ignition key in the "ON" position during reprogramming.
    Fig 21: Under Hood DLC Location
    G00305042
  8. Turn ignition key to the "ON" position.
  9. Turn Hi-Scan Pro on and select "14. SEDONA 3.5D 02/03MY BATTERY DRAIN" and press the "ENTER" key. See Fig 22 .
    Fig 22: Selecting "14. SEDONA 3.5D 02/03MY BATTERY DRAIN"
    G00305043
  10. Select "01. SEDONA 02/03MY BATT. DRAIN [AUTO]" and press the "ENTER" key. See Fig 23 .
    Fig 23: Selecting "01. SEDONA 02/03MY BATT. DRAIN {AUTO}"
    G00305044
  11. At the prompt, enter your password "0525" and press the "ENTER" key. See Fig 24 .
    Fig 24: Entering Password
    G00305045
  12. Reprogramming will proceed as shown. See Fig 25 .
    Fig 25: Reprogramming In Process
    G00305046
  13. When "REPROGRAMMING COMPLETED" message is displayed, turn ignition key to the "OFF" position and disconnect Hi-Scan Pro from the vehicle. Wait at least 20 seconds, start vehicle and verify normal operation. See Fig 26 .
    NOTE: If reprogramming did not complete properly or was interrupted, repeat the process using the following procedure.
    Fig 26: Reprogramming Completed Message
    G00305047

MANUAL REPROGRAMMING PROCEDURE

  1. Turn ignition key to the "ON" position.
  2. Turn Hi-Scan Pro on and select "14. SEDONA 3.5D 02/03MY BATTERY DRAIN" and press the "ENTER" key. See Fig 22 .
  3. Select "02. SEDONA 02/03MY BATT.DRAIN [ERROR]" and press the "ENTER" key. See Fig 27 .
    Fig 27: Selecting "02. SEDONA 02/03MY BATT.DRAIN {ERROR}"
    G00305048
  4. Select vehicle model year from the list and press the "ENTER" key. See Fig 28 .
    Fig 28: Selecting Model Year
    G00305049
  5. At the prompt, enter your password from the password table and press the "ENTER" key. See Fig 29 .
    Fig 29: Entering Password From Password Table
    G00305050
  6. Manual reprogramming will proceed as shown. See Fig 25 .
  7. When "REPROGRAMMING COMPLETED" message is displayed, turn ignition key to the "OFF" position and disconnect Hi-Scan Pro from the vehicle. Wait at least 20 seconds, start vehicle and verify normal operation. See Fig 26 .

ROM ID TABLE

ROM ID

Model Year PCM P/N Previous ROM ID New ROM ID
'02MY 39110 39600 EH8105-F0 through F6 EH8105-F7
'03MY 39106 39650 EH8487-F0 through F2 EH8487-F3

AFFECTED PRODUCTION RANGE

2002 and 2003 Sedona models produced before 2/28/03.

PART NUMBER INFORMATION

PART NUMBER INFORMATION

Description Previous P/N New P/N
Alternator 37300 39600 37300 39435
Alternator Belt 1K52Y 15 909B 1K52Y 15 909B
Battery Heat Cover N/A 0K52Y 18 590

WARRANTY CLAIM INFORMATION

Fig 30: Warranty Claims Information
G00305051
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