NHTSA ID Number: 10159244
Manufacturer Communication Number: TSBELE179
TSB/Document Date: 2019-04-30
Summary
TSB: HALOGEN LOW BEAM BULB CONNECTOR REPLACEMENT - This bulletin provides the procedure to replace the halogen low beam bulb connector on some 2011 - 2013MY Sorento (XMa) vehicles, produced from October 24, 2009 through January 31, 2013, which may experience an inoperable low beam bulb due to poor terminal contact at the low beam bulb connector. This condition on the affected headlamp does not affect the other low beam. In addition, the high beams continue to function at all times.
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TSB/Document ID: TSBELE179
Replacement Service Bulletin Number:
MFR Communication Date: 2019-04-19
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
GROUP
ELE
MODEL
2011-2013MY
Sorento (XMa)
NUMBER
179
DATE
April 2019
TECHNICAL SERVICE BULLETIN
HALOGEN LOW BEAM BULB
CONNECTOR REPLACEMENT
SUBJECT:
This bulletin provides the procedure to replace the halogen low beam bulb connector on some
2011 - 2013MY Sorento (XMa) vehicles, produced from October 24, 2009 through January 31,
2013, which may experience an inoperable low beam bulb due to poor terminal contact at the
low beam bulb connector. This condition on the affected headlamp does not affect the other
low beam. In addition, the high beams continue to function at all times. Follow the procedure
outlined in this bulletin to replace the low beam bulb connector.
IMPORTANT
This TSB is part of Warranty Extension WTY012. Only the affected headlamp low
beam connector should be replaced. If the low beam bulb is inoperative due to
damage by the electrical connector from poor terminal contact, replace the low beam
bulb after fulfilling the KVID requirement:
Remove the affected halogen low beam bulb from the
headlamp and take one (1) KVID photo of the damaged
bulb terminal(s) (Attachment Type: ‘XX’). Ensure the
affected area of the terminal is clearly visible in the
photo.
File Under:
Circulate To:
X General Manager
X Service Advisors
X Technicians
X Service Manager
X Parts Manager
X Body Shop Manager
X Fleet Repair
Page 2 of 6
SUBJECT:
HALOGEN LOW BEAM BULB CONNECTOR REPLACEMENT
Service Procedure:
1. Record or retain the customer’s radio
presets using the Memory Saver.
2.
Disconnect
terminal.
the
negative
(-)
3.
Remove the low beam dust cap (A) on
one side of the vehicle.
Headlamp was removed from the vehicle for
demonstration purposes only.
A
4.
Disconnect the low beam bulb connector
(B). If the low beam bulb terminal(s)
is/are damaged, remove the bulb from
the headlamp and take one (1) KVID
photo of the damaged bulb terminal(s)
(Attachment Type: ‘XX’).
Ensure the affected area of the terminal
is clearly visible in the photo (see page
1).
TSB: ELE179 Sorento (XMa) April 2019
B
Page 3 of 6
SUBJECT:
5.
HALOGEN LOW BEAM BULB CONNECTOR REPLACEMENT
With a pair of wire cutters, remove the
old low beam bulb connector (C) from
the low beam bulb wiring harness.
NOTE: cut the wires as close to the
base of the connector as possible.
6.
With a pair of wire strippers, strip 10mm
(0.4”) from the two (2) low beam bulb
wiring harness.
7.
Insert one (1) heat shrink tube (D) onto
each of the two (2) wires of the new
connector (E).
C
E
D
TSB: ELE179 Sorento (XMa) April 2019
Page 4 of 6
SUBJECT:
8.
HALOGEN LOW BEAM BULB CONNECTOR REPLACEMENT
Use the butt splice connectors (F)
provided to join the new connector and
low beam bulb wires. Match the wires of
the new connector and low beam bulb
wires by the wire color, as shown.
F
9.
Crimp the butt splice connectors at two
(2) locations (G) of each connector for
both wires.
G
10. After crimping both wires, perform a pull
test on each of the crimped sections to
verify a secure connection.
11. Slide the two (2) heat shrink tubes (D)
over the two (2) crimped butt splice
connectors.
D
TSB: ELE179 Sorento (XMa) April 2019
Page 5 of 6
SUBJECT:
HALOGEN LOW BEAM BULB CONNECTOR REPLACEMENT
12. With a heat gun, shrink both heat shrink
tubes (D) tightly over the crimped joints.
NOTE: set the heat gun to between
200°F and 300°F.
D
CAUTION
To prevent damage to the wires
and headlamp, do NOT use an
open flame, such as a torch or
lighter, to shrink the tubes. Use
caution not to damage the wires
or headlamp when using any
source of heat.
13. Install the new connector (E) to the low
beam bulb.
E
14. Reconnect
terminal.
the
negative
(-)
15. Verify proper operation of the low beam
bulbs and then reinstall the dust cap (A).
A
16. Verify that the customer’s radio presets
were retained. Reprogram if necessary.
TSB: ELE179 Sorento (XMa) April 2019
Page 6 of 6
SUBJECT:
HALOGEN LOW BEAM BULB CONNECTOR REPLACEMENT
AFFECTED VEHICLE RANGE:
Model
Production Date Range
Sorento (XMa)
October 24, 2009 through January 31, 2013
REQUIRED PART:
Part Name
Part Number
Figure
Bulb Connector Kit
92165 1U000QQK
RELATED PART:
Part Name
Part Number
Halogen Bulb
18649 55009S
Figure
WARRANTY INFORMATION:
N Code: I11 C Code: ZZ3
Claim
Type
W
Causal
P/N
Qty.
Repair
Description
Labor Op
Code
Op
Time
Replacement
P/N
Qty.
91407
2K050
0
Halogen Low Beam Bulb
Connector Replacement, LH
92165F02
0.3
M/H
92165
1U000QQK
1
91407
2K050
0
Halogen Low Beam Bulb
Connector Replacement, RH
92165F03
0.3
M/H
92165
1U000QQK
1
91407
2K050
0
Halogen Low Beam Bulb
Connector Replacement,
Both (LH & RH)
92165F04
0.4
M/H
92165
1U000QQK
2
Note: Halogen low beam bulb should only be replaced if inoperative due to poor terminal
contact. If replacing low beam halogen bulb(s), photo(s) must be attached using the KVID app as
a Warranty Claim Attachment type ‘XX - Others’.
NOTICE
Do not replace the headlamp or operable bulb for this concern. Any associated
claims for headlamp or bulb replacement are subject to review and chargeback.
TSB: ELE179 Sorento (XMa) April 2019
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