Recall - Throttle Cable Replacement
VOLUME3
GROUP
Campaign
NUMBER
042
MODEL
Sedona
DATE
March 2005
SUBJECT:
RECALL CAMPAIGN: THROTTLE CABLE ASSEMBLY REPLACEMENT
This bulletin provides information related to a recall campaign for 2002 and 2003 Sedona vehicles produced from 3/20/01 through 4/3/03.
On some 2002 and 2003 Sedona vehicles, moisture can get into the throttle cable during normal vehicle operation. In freezing conditions, and if excessive moisture has accumulated inside the cable, resistance to movement can occur. Under certain circumstances, the throttle cable may jump out of position.
To correct this situation, Kia is recalling all affected 2002 and 2003 Sedona models to replace the throttle cable at no charge to the vehicle owner. The new cable has improved seals in various areas.
Only Sedona vehicles produced from 3/20/01 through 11/7/01 will at the same time have a guide clip installed on the throttle body assembly in order to ensure that the new cable does not move out of position. Vehicles manufactured beginning on 11/8/01 already have an extended guide on the bell crank which keeps the cable in position.
* NOTICE
There is no charge to the vehicle owner for this repair. Under applicable law, you may not sell or otherwise deliver any affected 2002-2003 Sedona until it has been repaired, pursuant to the procedures set forth in this bulletin.
INSPECTION:
^ If label exists, Campaign 5C042 has been completed - NO FURTHER ACTION IS REQUIRED.
^ If Campaign SC042 label DOES NOT EXIST, continue on to REPLACEMENT PROCEDURE.
Note:
Campaign completion must be verified on the Warranty Coverage Validation screen, prior to performing repairs (KSS Main Menu - Option 3, Item # 22).
REPLACEMENT PROCEDURE:
1. Remove the engine cover.
2. Disconnect the electrical connector on the MAF sensor. Remove the air intake tube with MAF attached as shown.
3. Remove the throttle cable free-play adjustment clip.
4. Remove throttle cable retaining grommet from accelerator cable bracket.
5. Manually open the throttle body to wide open throttle (WOT) and disconnect the throttle cable from the bell crank.
6. Remove the throttle cable retaining bolt attached to the air filter box.
7. Disconnect the plastic retaining clip from the top of the accelerator pedal assembly, as shown.
8. Remove the accelerator cable from the vehicle; the accelerator end will have to be guided out through the bulkhead access hole.
INSTALLATION PROCEDURE:
1. Route the new throttle cable through the bulkhead into the passenger compartment, as shown.
2. Install the accelerator cable end, route cable through accelerator pedal and snap clip into place.
3. Route the cable around the bell-crank properly, ensure the cable is routed behind the cable retainer, as shown below. On vehicles built between 3/20/01 - 11/7/01, install a bell crank cable retaining clip, as shown.
* NOTICE
Ensure that ALL vehicles within the production range of 3/20/01 - 11/7/01 have a clip installed.
4. Install the accelerator cable retaining grommet in the accelerator cable bracket as shown.
5. Adjust the throttle cable free-play/cable deflection to .040~.120" (1~3 mm). Install the throttle cable free-play adjustment clip.
* NOTICE
Throttle cables that are adjusted too tight may set a TP sensor DTC.
6. Check the cable and hose routings to ensure that they do not interfere with the throttle or cruise control cables. Depress acceleration pedal to wide open throttle (WOT) several times to ensure proper operation.
7. Install the intake air tube, tighten clamps and connect the MAF electrical connector to the sensor.
8. Install the accelerator cable retaining bolt.
9. Install the engine cover.
10. Start the engine and verify proper engine operation.
11. Install SC042 Campaign Completion Label onto bulkhead to the right of the master cylinder.
AFFECTED PRODUCTION RANGE:
2002-2003MY Sedona vehicles with production dates from 3/20/01 through 4/3/03.
PART NUMBER INFORMATION:
WARRANTY CLAIM INFORMATION: