Stop Lamp Switch Replacement (SC077)

Publication date: 2009-06-01
Reference number: SC077

STOP LAMP SWITCH REPLACEMENT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 077, Date of Issue: June 01, 2009

KIA:	2006 - 2007 Sedona (VQ), Sorento (BL), Sportage (KM); 2007 Amanti (GH), 2007 Rondo (UN)
GROUP:	Safety Recall Campaign

Service Information

This bulletin provides information relating to replacement of the stop lamp switch on some 2006 - 2007 Sportage (KM), 2007 Rondo (UN), 2006 - 2007 Sorento (BL), 2007 Amanti (GH) and 2006 - 2007 Sedona (VQ) vehicles within the production date ranges shown below:

SERVICE INFORMATION CHART

Model	Production Date Range	Model	Production Date Range
Sportage (KM)	Jan. 20, 2006 - Jan. 30, 2007	Amanti (GH)	Sep. 20, 2006 - Nov. 20, 2006
Rondo (UN)	Sep. 20, 2006 - Jan. 30, 2007	Sedona (VQ)	Oct. 6, 2005 - Apr. 30, 2006
Sorento (BL)	Jun. 1, 2006 - Nov. 20, 2006	Sedona (VQ)	Sep. 20, 2006 - Nov. 20, 2006

The stop lamp switch may have been damaged during the assembly process. As a result, the stop lamp switch may malfunction causing one or more of the following conditions to exist:

The brake lights may not illuminate when the brake pedal is depressed.
The brake lights may remain illuminated when the brake pedal is released.
On some occasions, when the vehicle is started, the shifter cannot be moved from the Park (P) position.
If the vehicle is equipped with Electronic Stability Control (ESC), the ESC light may illuminate indicating "ESC OFF."
If the vehicle is equipped with Cruise Control, depressing the brake may not deactivate the Cruise Control System
NOTE: There is no charge to the vehicle owner for this repair. Under applicable law, you may not sell or otherwise deliver any affected Sportage, Rondo, Sorento, Sedona or Amanti until it has been repaired pursuant to the procedures set forth in this bulletin.

File Under: Service Campaign

REPLACEMENT PROCEDURES AND STOP LAMP SWITCH IDENTIFICATION

Four (4) replacement procedures using three (3) different part numbers are covered in this bulletin. Each procedure covers specific vehicle models and stop lamp switch part considerations.

Replacement Procedure 1: Sportage (KM) and Rondo (UN), which requires stop lamp switch 93810 3K000QQK.

Replacement Procedure 2: Sorento (BL), which requires stop lamp switch 93810 3K300QQK that comes with a cross-wiring extension harness.

Replacement Procedure 3: Sedona (VQ) in two (2) production ranges - Oct 6, 2005 to April 30, 2006 and September 20, 2006 to November 20, 2006 - which requires stop lamp switch 93810 3K400QQK (no cross-wiring extension harness required).

CAUTION: Sedona vehicles with Power Adjustable Pedals produced between October 6, 2005 and April 30, 2006 had a previous Recall Campaign (SC065) applied. It required repositioning and attachment of the stop lamp switch's wiring harness away from the U-joint of the steering column. It is imperative that this previous Recall Campaign (SC065) not be disturbed or altered in any way when performing Recall Campaign SC077.

Replacement Procedure 4: Amanti (GH), which requires stop lamp switch 93810 3K400QQK (no cross-wiring extension harness required).

STOP LAMP SWITCH ASSEMBLIES REFERENCE

	Stop Lamp Switch Assemblies
	Previous Used	New Design
Model	KM, UN, BL, GH, VQ	KM, UN	BL	GH, VQ
Figure
Part No.	93810 3K000	93810 3K000QQK	93810 3K300QQK	93810 3K400QQK
Remarks	Connector Color: Black	Connector Color: Gray	93810 3K000QQK With Extension Wire	Switch and Connector Color: Gray
Remarks	IMPORTANT: The part number embossed in the body of all new design switches is 93810 3K000. When installing these switches, use only the part number printed on the packaging to properly identify the switch assembly. Pay no attention to the embossed part number on the switch.

Replacement Procedure 1: Sportage (KM) and Rondo (UN) Stop Lamp Switch 93810 3K000QQK - Rondo UN Shown as Example in Following Illustrations

1a. Inspection Procedure - Sportage:
Open the hood and check for a campaign completion label on the driver's side inner fender as shown here.

If label exists, NO FURTHER ACTION IS REQUIRED.

If label does not exist, VERIFY SC077 HAS NOT BEEN DONE on WebDCS before continuing to step two (2) of this procedure.

Fig 1: Campaign Completion Label On Driver's Side Inner Fender

1b. Inspection Procedure - Rondo:

Open the hood and check for a campaign completion label on the driver's side strut tower as shown here.

If label exists, NO FURTHER ACTION IS REQUIRED.

If label does not exist, VERIFY SC077 HAS NOT BEEN DONE on WebDCS before continuing to step two (2) of this procedure.

Fig 2: Campaign Completion Label On Driver's Side Strut Tower

NOTE: WebDCS must be checked to confirm that SC077 has not been previously done on any vehicle without a campaign completion label. WebDCS > Warranty Coverage > Warranty Coverage Inquiry > Check Open Campaign Status
To improve customer satisfaction remember to check for any additional open campaigns before returning the vehicle to the customer.
Slide the drivers seat all the way rearward.
Turn the ignition key to the OFF position and remove the ignition key.

Fig 3: Ignition Key
From underneath the dash area, locate the stop lamp switch.
Disconnect the wiring, and then remove the nuts holding the stop lamp switch assembly.

Remove the original stop lamp switch assembly.

Fig 4: Original Stop Lamp Switch Assembly

NOTE: Using a brake pedal holding device commonly used in wheel alignment procedures may help when removing or installing the stop lamp switch.

Fig 5: Holding Device
Install new stop lamp switch part number 93810 3K000QQK with gray colored connector.
NOTE: The part number embossed in the new design switch is 93810 3K000. When installing the switch, pay attention only to the part number printed on the packaging of the replacement switch assembly.

Fig 6: Stop Lamp Switch With Gray Colored Connector
During installation of the new stop lamp switch be sure to adjust the clearance at the switch and brake pedal stopper to between 1.5 and 2.0 mm.

Fig 7: Adjusting Clearance At Switch & Brake Pedal Stopper

NOTE: Failure to properly adjust the switch may result in Check Engine and/or ESC malfunction indicator lamp illumination!

Fig 8: Clearance At Switch & Brake Pedal Stopper
Check the function of all stop lamps before releasing vehicle back to the customer. Address any concern that may interfere with proper brake lamp operation.
Sportage:
Attach campaign completion sticker SC077 to the driver's side inner fender as shown here.

Fig 9: Campaign Completion Sticker SC077 On Driver's Side Inner Fender

Rondo:

Attach campaign completion sticker SC077 to the driver's side strut tower as shown here.

Fig 10: Campaign Completion Sticker SC077 To Driver's Side Strut Tower

Replacement Procedure 2: Sorento (BL) Stop Lamp Switch 93810 3K300QQK

Inspection Procedure - Sorento:
Open the hood and check for a campaign completion label on the driver's side inner fender as shown here.

If label exists, NO FURTHER ACTION IS REQUIRED.

If label does not exist, VERIFY SC077 HAS NOT BEEN DONE on WebDCS before continuing to step two (2) of this procedure.

Fig 11: Campaign Completion Label On Driver's Side Inner Fender

NOTE: WebDCS must be checked to confirm that SC077 has not been previously done on any vehicle without a campaign completion label. WebDCS > Warranty Coverage > Warranty Coverage Inquiry > Check Open Campaign Status
To improve customer satisfaction remember to check for any additional open campaigns before returning the vehicle to the customer.
Slide the drivers seat all the way rearward.
Turn the ignition key to the OFF position and remove the ignition key.

Fig 12: Ignition Key
From underneath the dash area, locate the stop lamp switch.
Disconnect the wiring, and then remove the nuts holding the stop lamp switch assembly.

Remove the original stop lamp switch assembly.

Fig 13: Stop Lamp Switch Assembly

NOTE: Using a brake pedal holding device commonly used in wheel alignment procedures may help when removing or installing the stop lamp switch.

Fig 14: Holding Device
Install new stop lamp switch part number 93810 3K300QQK with gray colored connector and cross-wiring extension harness.
NOTE: The part number embossed in the new design switch is 93810 3K000. When installing the switch, pay attention only to the part number printed on the packaging of the replacement switch assembly.

Fig 15: Stop Lamp Switch With Gray Colored Connector & Cross-Wiring Extension Harness

NOTE: Be careful not to allow the stop lamp switch extension wire to be routed over-top of the shift lock cable as shown in this example! Wiring needs to be routed below shift lock cable as shown in step 5.

Fig 16: Harness Routed Incorrectly
Stop lamp switch extension wiring is shown here properly routed underneath the shift lock cable.
During installation of the new stop lamp switch be sure to adjust the clearance at the switch and brake pedal stopper to between 1.5 and 2.0 mm.

Fig 17: Adjusting Clearance At Switch & Brake Pedal Stopper

NOTE: Failure to properly adjust the switch may result in Check Engine and/or ESC malfunction indicator lamp illumination!

Fig 18: Clearance At Switch & Brake Pedal Stopper
Check the function of all stop lamps before releasing vehicle back to the customer. Address any concern that may interfere with proper brake lamp operation.
Attach campaign completion sticker SC077 to the driver's side inner fender as shown here.

Fig 19: Campaign Completion Sticker SC077 On Driver's Side Inner Fender

Replacement Procedure 3: Sedona (VQ) Stop Lamp Switch 93810 3K400QQK Two Production Ranges: October 6, 2005 to April 30, 2006 and September 20, 2006 to November 20, 2006

Inspection Procedure: Sedona
Open the hood and check for a campaign completion label SC077 on the driver's side inner fender as shown here.

If label exists, NO FURTHER ACTION IS REQUIRED.

If label does not exist, VERIFY SC077 HAS NOT BEEN DONE on WebDCS before continuing to step two (2) of this procedure.

Fig 20: Campaign Completion Label SC077 On Driver's Side Inner Fender

NOTE: WebDCS must be checked to confirm that SC077 has not been previously done on any vehicle without a campaign completion label. WebDCS > Warranty Coverage > Warranty Coverage Inquiry > Check Open Campaign Status
To improve customer satisfaction remember to check for any additional open campaigns before returning the vehicle to the customer.
Slide the drivers seat all the way rearward.
Turn the ignition key to the OFF position and remove the ignition key.

Fig 21: Ignition Key
Remove the lower dash panel and "T" bar as shown in photo.

Fig 22: Lower Dash Panel & T Bar
On some vehicles (depending on production date and configuration of the air duct) the lower air duct removes easily. If possible to remove easily, do so to provide additional working space.
Otherwise continue with the next step. It is not absolutely necessary to remove this duct.

Fig 23: Air Duct
From underneath the dash area, locate the stop lamp switch to the right of the steering column.
Disconnect the wiring, and then remove the front nut holding the stop lamp switch to the switch's bracket.

NOTE: Removing the switch on some vehicles will require loosening the switch bracket.

Fig 24: Stop Lamp Switch & Bracket
On vehicles that require loosening of the switch bracket, use an extension and swivel socket in the area shown to access the brackets two attachment nuts.

Fig 25: Loosening Switch Bracket Nuts

Photo show location of the two nuts that may need loosening to remove the switch on some vehicles. They do not need to be completely removed; 6 or 7 cranks on the ratchet are usually all it takes.

Fig 26: Holding Device

NOTE: Using a brake pedal holding device commonly used in wheel alignment procedures may help when removing or installing the stop lamp switch.
Install new stop lamp switch part number 93810 3K400QQK with gray colored body and connector.
NOTE: The part number embossed in the new design switch is 93810 3K000. When installing the switch, pay attention only to the part number printed on the packaging of the replacement switch assembly.

Fig 27: Stop Lamp Switch With Gray Colored Body And Connector
During installation of the new stop lamp switch be sure to adjust the clearance at the switch and brake pedal stopper to between 1.5 and 2.0 mm.

Fig 28: Adjusting Clearance At Switch And Brake Pedal Stopper

NOTE: Failure to properly adjust the switch may result in Check Engine and/or ESC malfunction indicator lamp illumination!

Fig 29: Clearance At Switch And Brake Pedal Stopper

CAUTION: Sedona vehicles with Power Adjustable Pedals produced between October 6, 2005 and April 30, 2006 had a previous Recall Campaign (SC065) applied. It required repositioning and attachment of the stop lamp switch's wiring harness away from the U-joint of the steering column. It is imperative that the previous Recall Campaign (SC065) not be disturbed or altered in any way when performing Recall Campaign SC077.

Fig 30: Campaign Completion Label SC077 On Driver's Side Inner Fender

Recall Campaign SC065 addressed the stop lamp switch wiring harness, which before repairing, could rub against the U-joint of the steering column.

Be certain when doing SC077 that this harness is not disturbed or relocated in such a way that allows it to again rub against the U-joint of the steering column.

If necessary, readjust and/or reattach the wiring harness as necessary to meet SC065 standards. See TSB 065 dated September 2006.

Fig 31: Stop Lamp Switch Wiring Harness
Reassemble the vehicle in the reverse order of disassembly.
Check the function of all stop lamps before releasing vehicle back to the customer. Address any concern that may interfere with proper brake lamp operation.
Sedona:
Attach campaign completion sticker SC077 on driver's side inner fender as shown here.

Fig 32: Campaign Completion Sticker SC077 On Driver's Side Inner Fender

Replacement Procedure 4: Amanti (GH) Stop Lamp Switch 93810 3K400QQK

Inspection Procedure - Amanti:
Open the hood and check for a campaign completion label on the driver's side strut tower.

If label exists, NO FURTHER ACTION IS REQUIRED.

If label does not exist, VERIFY SC077 HAS NOT BEEN DONE on WebDCS before continuing to step two (2) of this procedure.

Fig 33: Campaign Completion Label On Driver's Side Strut Tower

NOTE: WebDCS must be checked to confirm that SC077 has not been previously done on any vehicle without a campaign completion label. WebDCS > Warranty Coverage > Warranty Coverage Inquiry > Check Open Campaign Status
To improve customer satisfaction remember to check for any additional open campaigns before returning the vehicle to the customer.
Slide the drivers seat all the way rearward.
Turn the ignition key to the OFF position and remove the ignition key.

Fig 34: Ignition Key
From underneath the dash area, locate the stop lamp switch to the left of the steering column.
Disconnect the wiring, and then remove the nuts holding the stop lamp switch assembly.

Remove the original stop lamp switch assembly.

Fig 35: Original Stop Lamp Switch Assembly

NOTE: Using a brake pedal holding device commonly used in wheel alignment procedures may help when removing or installing the stop lamp switch.

Fig 36: Holding Device
Install new stop lamp switch part number 93810 3K400QQK with gray colored body and connector.
NOTE: The part number embossed in the new design switch is 93810 3K000. When installing the switch, pay attention only to the part number printed on the packaging of the replacement switch assembly.

Fig 37: Stop Lamp Switch With Gray Colored Body And Connector
During installation of the new stop lamp switch be sure to adjust the clearance at the switch and brake pedal stopper to between 1.5 and 2.0 mm.

Fig 38: Adjusting Clearance At Switch & Brake Pedal Stopper

NOTE: Failure to properly adjust the switch may result in Check Engine and/or ESC malfunction indicator lamp illumination!

Fig 39: Clearance At Switch & Brake Pedal Stopper
Reassemble the vehicle in the reverse order of disassembly.
Check the function all stop lamps before releasing vehicle back to the customer. Address any concern that may interfere with proper brake lamp operation.
Amanti:
Attach campaign completion sticker SC077 to the driver's side strut tower as shown here.

Fig 40: Campaign Completion Sticker SC077 To On Driver's Side Strut Tower

AFFECTED VEHICLE RANGE

AFFECTED VEHICLE RANGE REFERENCE

Model	Production Date Range	Model	Production Date Range
Sportage (KM)	Jan. 20, 2006 - Jan. 30, 2007	Amanti (GH)	Sep. 20, 2006 - Nov. 20, 2006
Rondo (UN)	Sep. 20, 2006 - Jan. 30, 2007	Sedona (VQ)	Oct. 6, 2005 - Apr. 30, 2006
Sorento (BL)	Jun. 1, 2006 - Nov. 20, 2006	Sedona (VQ)	Sep. 20, 2006 - Nov. 20, 2006

REQUIRED PART

PART INFORMATION CHART

	Stop Lamp Switch Assemblies
Model	KM, UN	BL	GH, VQ
Part No.	93810 3K000QQK	93810 3K300QQK	93810 3K400QQK
Remarks	Connector Color: Gray	93810 3K000QQK With Extension Wire	Switch and Connector Color: Gray
Remarks	IMPORTANT: The part number embossed in the body of all new design switches is 93810 3K000. When installing these switches, use only the part number printed on the packaging to properly identify the switch assembly. Pay no attention to the embossed part number on the switch.
SC077 Campaign Completion Label - Part Number UM090 SC077 - Qty.1

REQUIRED SST

None

WARRANTY INFORMATION

Fig 41: Warranty Information Chart