Sedona (VQ) Intermittent No-Crank Condition

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Jennifer Parsons
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group Electrical Model Sedona (VQ) NUMBER DATE 012 September 2007 Technical Service Bulletin SUBJECT: Some 2006 2007 Sedona (VQ) vehicles produced before April 18, 2007 may exhibit a customer concern

1 group Electrical Model Sedona (VQ) NUMBER DATE 012 September 2007 Technical Service Bulletin SUBJECT: Some Sedona (VQ) vehicles produced before April 18, 2007 may exhibit a customer concern in which the engine will not crank (starter will not engage) when attempting to start the engine. In some cases, this condition may be caused by higher than normal resistance across the Burglar Alarm Relay located inside the In Panel Module (IPM). This relay is not a serviceable item, and if defective requires the replacement of the IPM. Other concerns such as poor pin connections and other faulty components in the starter s circuit may also cause higher than normal circuit resistance, and should be considered before condemning and replacing the IPM. The following test procedure has been developed to assist you in determining whether the problem is the Burglar Alarm Relay in the IPM, or is related to some other area of the starter s circuit. It s recommended that this TSB be read in its entirety before attempting to perform this test procedure for the first time. Photo shows IPM (on left) and location of non-replaceable Burglar Relay (on right) with cover removed. File Under: Electrical Circulate To: X General Manager X Service Manager X Parts Manager X Service Advisor(s) X Technician(s) X Body Shop Manager X Fleet Repair

Photo shows close-up view of the location of the Start Relay in the FAM. Note how the relay is installed!

2 Page 2 of 11 subject: TESTING PROCEDURE SET-UP 1. Remove the Start Relay from the Front Area Module (FAM), located in the engine compartment. Do NOT touch the IPM, or even remove the cover to access the fuses in the IPM, as this may influence the results of your testing / diagnosis! 2. Photo shows close-up view of the location of the Start Relay in the FAM. Note how the relay is installed! Though it fits (and works) installed 180 from this installed position, the relay needs to be installed as shown to insure the internal contacts' polarity integrity. 3. Prepare T-Connector TCLE 020B for installation. Use the male and female red, and male and female black connectors.

subject: 4. Using a sharp knife or razor blade, remove a portion of the insulation on the red and black leads of T-Connector TCLE-020B as shown in the accompanying photo.

Install the T-Connector to the removed Start Relay. Red female T-Connector pin to Start Relay pin 85. Black female T-Connector pin to Start Relay pin 86. 6a.

3 subject: 4. Using a sharp knife or razor blade, remove a portion of the insulation on the red and black leads of T-Connector TCLE-020B as shown in the accompanying photo. Page 3 of 11 This allows the pin connectors to be fully installed in the FAM connector, and also allows connection of a DVOM (Digital Volt Ohm Meter) at the relay. 5. Install the T-Connector to the removed Start Relay. Red female T-Connector pin to Start Relay pin 85. Black female T-Connector pin to Start Relay pin 86. 6a. Install the T-Connector (with installed Start Relay) to the Start Relay socket in the FAM. Only connect the pull-down portion, pins 85 and Warning 85 WARNING: Injury may result (starter may engage) by improperly connecting the T-Connector to the FAM! Do NOT connect T-Connector to terminals 30 and/or 87!

Red male end to FAM pin 85. Black male end to FAM pin 86. 7.

of the removed Start Relay (red T-Connector wire). 8.

4 Page 4 of 11 subject: 6b. Connect the T-Connector to the FAM Start Relay socket as follows: Red male end to FAM pin 85. Black male end to FAM pin Connect (clip) the negative (black) lead of a DVOM to terminal 85 of the removed Start Relay (red T-Connector wire). 8. Connect (clip) the DVOM positive (red) lead to the battery positive terminal. The DVOM should now read battery voltage.

5 subject: TESTING THE BURGLAR RELAY IN THE IPM 9. Carefully connect the Global Diagnostic System (GDS) Vehicle Communication Interface (VCI) with as little disturbance to the dash area as possible. Access the Actuation screen for the Burglar Alarm Relay as follows: Enter Vehicle Info Select system (BCM) Select sub-system (In Panel Module) Select Actuation Test Expand the Actuation Test screen as shown here IMPORTANT: Do NOT activate the Burglar Relay just yet! 10. Have an assistant HOLD the ignition key in the START position while performing a voltage drop check across the positive portion of the circuit. IMPORTANT: Key must be held in the START position while reading voltage drop! Read and record the voltage drop. A good circuit with very low resistance should show less than 0.50 volt drop. In this example, 0.06 volt drop was found, far less than 0.50 volt. Page 5 of 11 The Burglar Alarm Relay contacts are normally closed and do not normally open at any time. The only time the Burglar Alarm Relay contacts open is during an alarm event, which disables the starter. Actuation of the Burglar Alarm Relay opens these contacts. Tests have indicated that even though an engine cranks and starts, that high resistance in the Burglar Alarm Relay contacts, or other portions of the circuit may exist. This could potentially lead to a customer complaint of intermittent no-start, no-crank.

Page 6 of 11 subject: 11. The photo to the right shows a voltage drop of 2.59 volts, which indicates that there is higher than normal resistance in the circuit, and is a potential concern.

6 Page 6 of 11 subject: 11. The photo to the right shows a voltage drop of 2.59 volts, which indicates that there is higher than normal resistance in the circuit, and is a potential concern. However, it s likely in this case that the vehicle will crank and start. NOTE: Tests indicate that as high as (approximately) 6.0 volt drop still allows the start relay to engage, and the starter to run. Nonetheless, this is a problem and needs to be corrected! 12. Once again, have an assistant HOLD the ignition key in the START (crank) position. Now, open and close the Burglar Relay contacts by choosing start, and then stop on the GDS screen, while the key is held in the START position. Repeat this several times, recording the EXACT voltage drop each time STOP is selected. In this step only the Burglar Alarm Relay s contacts are being moved. With the relay s contacts closed (STOP selected), if the measured voltage drop does NOT vary greatly, the IPM Burglar Alarm Relay is not defective. Instead, other sources of high resistance may exist. Based on your results, use the table below to determine if the Burglar Alarm Relay inside the IPM is defective or that yet another concern exists. Initial voltage drop measured in step 10 Less than 0.50 volt More than 0.50 volt Does the voltage drop in step 12 vary greatly from the voltage drop measured in step 10? No Yes No Yes Do NOT Replace IPM Replace IPM Other Concern Exists X X X X

portion of the Start Relay s pull-down circuit whatsoever. Do NOT replace the IPM.

7 subject: UNDERSTANDING THE RESULTS 13. If the voltage drop is LESS than 0.50 volt, and DOES NOT VARY GREATLY after actuation of the Burglar Relay (STOP selected), the problem most likely is NOT the Burglar Alarm Relay in the IPM, or any portion of the Start Relay s pull-down circuit whatsoever. Do NOT replace the IPM. NOTE: Voltage drop shown is only an example, and will vary between different vehicles. Page 7 of 11 Areas that should be checked include: 30 amp fuse, Key Sw #2, in the FAM Any connection in the load side (terminals 30 87) of the Start Relay circuit, including those at the FAM connectors Battery connections / cables Starter connections Starter motor

8 Page 8 of 11 subject: 14. If the voltage drop is MORE than 0.50 volt, but DOES NOT VARY GREATLY after actuation of the Burglar Relay (STOP selected), the problem is most likely NOT the Burglar Alarm Relay in the IPM, but instead another connection or component in this circuit. Do NOT replace the IPM. NOTE: Voltage drop shown is only an example. Actual results will vary depending on severity of concern. Areas that should be checked include: Ignition switch and its connections Start fuse in the IPM Any connection in the pull-down side of the Start Relay circuit including those at the IPM itself Transaxle Range Switch Connections to and in the FAM, including those at the Start Relay NOTE: G81 may be at fault, however is NOT checked as part of the previous steps. Voltage drop can be checked here by attaching the DVOM leads between Start Relay pin 86 and battery ground.

9 subject: 15. If the voltage drop is MORE than 0.50 volt and VARIES GREATLY after actuation of the Burglar Relay (STOP selected), the problem is most likely the Burglar Alarm Relay in the IPM. IPM replacement will be necessary. Replace the IPM following instructions provided in Kia s service information. (See additional photos and text below) Page 9 of 11 Photo shows example of voltage drop varying greatly after Burglar Relay actuation (STOP selected). In this case a voltage drop of 6.93 volts was recorded (relay contacts closed) as compared to the previously measured voltage drop of 2.59 volts under the same conditions. Voltage drop shown is only an example. Actual results will vary depending on severity of concern. Photo shows example of voltage drop varying greatly after Burglar Relay actuation (STOP selected). In this case a voltage drop of volts was recorded (relay contacts closed) as compared to the previously measured voltage drop of 2.59 volts under the same conditions. Voltage drop shown is only an example. Actual results will vary depending on severity of concern.

10 Page 10 of 11 subject: RE-INSTALLING THE START RELAY 16. Remove the T-Connector from the Start Relay and the FAM. Re-install the Start Relay, noting that the relay needs to be installed as shown in the photo. Take note of the guide molded into and around the Start Relay's connections, and that it is off-set. This guide will help in properly installing the Start Relay to insure proper pin polarity. If improperly installed, the relay will still fit, although not sit flush. It will work either way. HOWEVER, improper installation can lead to premature relay failure.

11 subject: AFFECTED VEHICLE INFORMATION: All Sedona VQ produced before April 18, 2007 PARTS INFORMATION: warranty claim information: Page 11 of 11 Part Name Part Number Description D070FFF Accel & Brake IMS, Keyless Entry w/panic + D/Unlock, Auto Light In-Panel Module (IPM) Keyless Entry w/panic D090FFF + D/Unlock, Auto Light D100FFF Keyless Entry w/panic + D/Unlock Special Service Tool (SST) Information: SST Name Part Number Comment Global Diagnostic System Ensure latest software version K06U-GDS (GDS) is installed FIRST. Sourced from Wire Harness T-Connector TCLE 020B Repair kit TCLES 020A, see Parts Bulletin MI-0008 on kdealer.net Claim Type Causal P/N Qty. N Code D070 (Accel & Brake IMS, Keyless Entry w/panic + D/ Unlock, Auto Light) C Code Repair Description Labor Op Code Time Related Parts 0 N01 C01 IPM Inspection 91956F N/A 0 Qty. W D090 (Keyless Entry w/panic + D/ Unlock, Auto Light) 0 N01 C01 IPM Inspection and Replacement 91956F Refer to Parts Information Table D100 (Keyless Entry w/panic + D/ Unlock) N01: Hard Starting C01: Burnt, Melted

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