Campaign SA061 - Alternator Inspection/Replacement
GROUP ElectricalNUMBER 014 [Rev 1]
MODEL 2011MY Sorento [XM] w/3.5L engine
DATE February 2011
SUBJECT:
2011 SORENTO 3.5L ALTERNATOR REPLACEMENT COMBINED TSB/SERVICE ACTION (SA061)
This bulletin provides information relating to some 2011 Sorento (XM) equipped with 3.5L engine produced between 7/12/2010 to 9/18/2010 which may exhibit a condition where the battery light/charging system tell-tale will be illuminated. In some cases, this could lead to a no charge condition. This may be caused by an fault within the internal voltage regulator.
To improve customer satisfaction KIA is launching this Service Action and replacing the alternator on all affected 3.5L Kia Sorento (XM) vehicles that fall within the vehicle production range.
For vehicles not in affected VIN list, but with a customer complaint, perform the following repair instructions outlined in this bulletin and submit a warranty claim per "customer complaint" information.
*NOTICE
*NOTICE
A Service Action is a repair program without customer notification that is performed during the warranty period. Any dealer request to perform this repair outside the warranty period will require DPSM approval.
Repair status for a VIN is provided on WebDCS (Service > Warranty Coverage > Warranty Coverage Inquiry > Campaign Information). Not Completed Recall/Service Action reports are available on WebDCS (Consumer Affairs > Not Completed Recall > Recall VIN > Select Report).
This issue number is SA061.
Service Procedure:
1. Record the customer pre-set radio stations and disconnect the negative battery cable.
2. Remove the 3 screws and air intake duct.
3. Raise the vehicle and remove front splash shield.
4. Remove the three front roll-stop mounting bolts, disconnect the electrical connector from NC compressor and lower the vehicle.
5. Support the engine with floor jack as shown. Ensure a block of wood is used which covers the whole lower oil pan area.
Failure to use the proper size block of wood can cause damage to the oil pan.
4" X 6" X 2" piece of wood is recommended to prevent oil pan damage.
6. Remove the front engine mount mounting plate, 2 nuts and 2 bolts.
7. Remove mounting plate from vehicle.
8. Remove power steering hose from bracket and remove mounting bracket from vehicle.
9. Remove serpentine belt from the alternator only.
10. Safely jack the engine up approximately 6 (six) inches with the floor jack supporting the engine assembly.
11. Remove the dust cap and retaining bolt from the idler pulley then remove pulley and bolt.
12. Remove the alternator upper mounting bolt. Disconnect the battery terminal from the rear of alternator.
a) Disconnect the plastic retaining wire tie from the retaining bracket.
b) Disconnect the electrical connector from the rear of alternator.
c) Loosen but do not remove the lower alternator bolt, the alternator will slip out of the lower bracket.
d) Carefully remove the alternator from the vehicle.
Installation:
Install alternator and tighten the mounting bolts to 19-26 lbs. ft. (26-33Nm).
a) Connect the battery terminal to rear of alternator and tighten to 11 lbs. ft. (14 Nm).
b) Connect the electrical connector to rear of alternator
c) Clip wire harness retainer into bracket
d) Install the idler pulley and tighten to 39-42 lbs. ft. (53-57 Nm).
e) Install the serpentine belt as shown with correct routing.
f) Lower the engine and install the front engine mounting plate, tighten bolts to 47-61 lbs. ft. (63-83 Nm).
g) Install the Power steering hose bracket and tighten bolt to 11 lbs. ft. (14 Nm).
h) Install the engine air intake duct and connect battery cable.
i) Raise the vehicle and connect A/C compressor electrical connector.
j) Install the front roll-stopper retaining bolts, tighten to 36-47 lbs. ft. (49-63 Nm).
k) Install the front splash shield and lower the vehicle.
I) Reprogram customer pre-set stations and set the clock to the correct time.
AFFECTED PRODUCTION RANGE
REQUIRED PARTS
KIA WARRANTY CLAIM SUBMISSION REQUIREMENTS
SERVICE ACTION WARRANTY CLAIM INFORMATION
STANDARD WARRANTY CLAIM INFORMATION