Recall - Throttle Cable Freezing

VOLUME
3

GROUP
Campaign

NUMBER
051

MODEL
Sedona

DATE
August 2005

SUBJECT:
RECALL CAMPAIGN: 2003-2005 SEDONA THROTTLE CABLE UPGRADE

This bulletin provides information relating to a recall campaign for 2003, 2004 and 2005 Sedona vehicles produced from 4/4/03 through 1/31/05.





On 2003, 2004 and 2005 Sedona vehicles, moisture can get on the throttle cable during normal vehicle operation. In freezing conditions, and if excessive moisture has accumulated inside the cable, resistance to movement can occur. Kia has outlined an upgrade to the cable (rubber sleeve shortened and sealed per diagram below) to prevent moisture from entering the throttle cable.

* NOTICE
There is no charge to the vehicle owner for this repair. Under applicable law, you may not sell or otherwise deliver any affected 2003-2005 Sedona until it has been repaired, pursuant to the procedures set forth in this bulletin.

INSPECTION:





1. Open hood and check for SC051 Campaign Completion Label.

^ If label exists, Campaign SC051 has been completed - NO FURTHER ACTION IS REQUIRED.

^ If Campaign SC051 label DOES NOT EXIST, continue onto Step 2.





2. Inspect for yellow paint dot on the bulkhead panel above the brake booster.

^ If the paint dot exists, NO FURTHER ACTION IS REQUIRED.

^ If the paint dot DOES NOT EXIST, continue to UPGRADE PROCEDURE.

Note:
Campaign completion must be verified on the Warranty Coverage Validation Inquiry screen, prior to performing repairs (Kia Standard System [KSS] Main Menu - Option 3).

UPGRADE PROCEDURE:





1. To access the rubber sleeve that surrounds the throttle cable, disconnect the MAF electrical connector and loosen the hose clamps on each end of intake air tube. The breather hose will be attached, swing the intake air boot to the side as shown.











2. Measure 50 mm (2 inches) from the end of boot, Gently cut the rest of the rubber boot using a razor knife and discard the cut-off piece of excess hose.

Note:
Do not cut the boot too deep as the cable casing may be damaged.





3. Pull the 50 mm boot back from the throttle cable end.





4. Apply RTV flange sealant to the cable end where it transitions into the adjuster assembly. The sealant should cover the circumference of the joint to seal from moisture entering the cable end.





5. Slide the boot over the RTV sealed joint.





6. Install the wire tie 10 mm from the end of the cut boot. Trim off the excess wire-tie and discard.








7. Trim off the excess wire-tie and discard.





8. Install the air intake boot, tighten the hose clamps and connect the MAF sensor electrical connector.

9. Install the SC051 Campaign Completion label onto the bulkhead to the right of the master cylinder.

AFFECTED PRODUCTION RANGE:

2003-2005 Sedona vehicles with production dates from 4/4/03 through 1/31/05.





PART NUMBER INFORMATION:





WARRANTY CLAIM INFORMATION: