GROUP

MODEL

ELE

2025-2026MY
K5 (DL3)
w/2.5L GDI THETA III

NUMBER

DATE

419

June 2026

TECHNICAL SERVICE BULLETIN
SERVICE ACTION: BATTERY WIRING HARNESS
SUBJECT:

COVERING INSPECTION/REPLACEMENT (SA645)

This bulletin provides information for inspecting the 12V battery wiring harness on certain 2025-2026 MY K5
(DL3) vehicles equipped with the Theta III 2.5L GDI engine, produced from February 20, 2024, through March
13, 2026. The subject vehicles may exhibit an illuminated Malfunction Indicator Lamp (MIL) along with a low
engine oil warning light and/or battery warning light displayed on the instrument cluster, caused by abrasion
of the wiring harness over time. One or more of the Diagnostic Trouble Codes (DTCs) listed on page 2 may be
stored. Follow the procedure outlined in this publication to inspect the battery wiring harness and replace the
battery harness bracket, or, if required, replace the battery wiring harness assembly. Before performing this
procedure, confirm that the vehicle is included in the affected VIN range.

 NOTICE
A Service Action is a repair program without customer notification that is performed during the
warranty period. Any dealer requesting to perform this repair outside the warranty period will
require DPSM approval.
Repair status for a VIN is provided on KDealer+ (Service → Warranty Coverage → Warranty
Coverage Inquiry → Campaign Information). Not completed Recall / Service Action reports are
available on KDealer+ (Consumer Affairs → Not Completed Recall → Recall VIN → Select Report),
which includes a list of affected vehicles.
This issue number is SA645.
A printed copy is for reference only; publication information can be updated at any time.
Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical
publications are listed in ‘Service Releases’ and has the latest service information that has been released.
Kia America, Inc. Confidential

Page 2 of 12
SUBJECT:

SERVICE ACTION: BATTERY WIRING HARNESS
COVERING INSPECTION/REPLACEMENT (SA645)

Flowchart:
A KVID photo of the battery harness ‘OK’ condition MUST be attached to the claim using KDS Tablet
Warranty Claim Attachment Tab ‘XX – Other’.

Vehicle In

NO Visible
Abrasion
or Damage.

Battery Wiring
Harness Protective
Covering Inspection
(Page 3)

Visible Exposed
Internal Wiring
or Damage.

With Visible
Minor Abrasion

Wrap the
affected area with
electrical tape.
(Page 4, Step 4c)

Replace the
Battery Wiring
Harness Retaining
Bracket
(Page 5)

Vehicle Out

DTC Description:
U012D00/F1 – Lost Communication with Generator Control Module
U111200/F1/F2/F3 – LIN Communication Error
P061500/F0 – Starter Relay ‘A’ Circuit Low
P061600/F0/F1/F2 – Starter Relay Circuit Low
P061700/F0/F1/2 – Starter Relay Circuit High
P250B00 – Engine Oil Level Sensor Circuit Range/Performance
P250C00 – Engine Oil Level Sensor Circuit Low
P250F00 – Engine Oil Level Too Low
U066800 – Lost Communication with Engine Oil Level Sensor Circuit
U028700/F1/2 – Lost Communication with Transmission Fluid Pump Module
Printed document copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: SA645 K5 (DL3) June 2026

Kia America, Inc. Confidential

Replace The
Battery Harness
Assembly
(Page 6)

Page 3 of 12

SERVICE ACTION: BATTERY WIRING HARNESS

SUBJECT:

COVERING INSPECTION/REPLACEMENT (SA645)

Inspection Procedure:
1.

Remove the air duct (A).

2.

Remove the air cleaner box (B) only.
Note: The hoses do not need to be removed
for inspection.

Tightening torque for hose clamp:
2.2 – 3.6 lb.ft (2.9 – 4.9 N.m)
Tightening torque for air cleaner box bolts:
5.8 – 7.2 lb.ft (7.8 – 9.8 N.m)

3a.

Locate the ATF warmer (D) and inspect the
battery wiring harness (C) for damage where it
may make contact against the ATF warmer (D).

TECH TIP
Inspect the bottom area of the battery
wiring harness (C) using a telescoping
mirror closest to the ATF warmer.

3b.

Take one (1) clear photo of the battery wiring
harness (C) covering condition next to the ATF
warmer (D).

 IMPORTANT
Refer to steps 4a - 4e for sample
images needed. Take one (1) photo of
the required OK or NG conditions.

Printed document copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

Kia America, Inc. Confidential

TSB: SA645 K5 (DL3) June 2026

Page 4 of 12

SERVICE ACTION: BATTERY WIRING HARNESS

SUBJECT:

COVERING INSPECTION/REPLACEMENT (SA645)
*** Refer to the sample images below to submit the 1 (one) photo requirement from step 3b. ***
4a.

Is there visual damage such as, abrasion and

4b.

penetration of the protective covering and/or
potential damage to the harness internal
wiring?
4b.

•

If there is NO visible damage to the
battery wiring harness (C) covering
(OK). Using KDS Tablet ‘Warranty Claim
Attachment’ tab, take one (1) clear photo of
the battery harness inspection area.
or

4c.

•

If there IS minor abrasion to the battery
wiring harness (C) covering

4c.

(OK). If

there is no internal damage to wiring, then
apply electrical tape to cover the
affected area. Using KDS Tablet ‘Warranty
Claim Attachment’ tab, take one (1) clear
photo of the battery harness (C) affected
area.

4d.

If either conditions described above are (OK),
proceed to the ‘Replacement Procedure:
(Battery Harness Bracket)’ on page 5 and
replace

the

existing

wiring

harness

retaining bracket with an improved part.

4e.

•

4c.

If there IS visible damage to the internal
wiring of the battery harness (C) (NG),
the internal wiring is exposed as shown,
then

proceed

Procedure:

to

(Battery

the

‘Replacement

Wiring

Harness

Assembly)’ on page 6.

4e.
Printed document copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: SA645 K5 (DL3) June 2026

Kia America, Inc. Confidential

Page 5 of 12

SERVICE ACTION: BATTERY WIRING HARNESS

SUBJECT:

COVERING INSPECTION/REPLACEMENT (SA645)

Replacement Procedure: (Battery Harness Bracket)
1a.

Locate the battery wiring harness retaining
bracket (A) above the ATF warmer area shown.

1b.

Loosen the battery wiring harness retaining
bracket bolt (A) and discard the removed
bracket.

2.

Install the new battery harness bracket (A) in
the orientation shown.

Tightening torque for bolt:
7.2 – 8.7 lb.ft (9.8 – 11.8 N.m)

Note: Ensure the bracket’s wiring harness
retaining clip hole (B) is located to the left.

3.

OK

NG

Reinstall all removed parts in reverse order of
removal.

4.

Verify normal vehicle operation.
Printed document copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

Kia America, Inc. Confidential

TSB: SA645 K5 (DL3) June 2026

Page 6 of 12

SERVICE ACTION: BATTERY WIRING HARNESS

SUBJECT:

COVERING INSPECTION/REPLACEMENT (SA645)
Replacement Procedure: (Battery Wiring Harness Assembly)

 NOTICE
Before beginning, set up the vehicle on a lift as you will need to work under the hood and require
to have acces from under the vehicle throughtout this procedure.
1.

Disconnect the battery positive terminal (A).

Tightening torque for nut:
5.8 – 7.2 lb.ft (7.8 – 9.8 N.m)

2.

Remove the fuse box positive terminal (B).

Tightening torque for nut:
5.8 – 7.2 lb.ft (7.8 – 9.8 N.m)

3.

Remove the battery wiring harness retaining
clip (C).

TECH TIP
Use a trim removal tool to disengage
the two (2) clips.

Printed document copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: SA645 K5 (DL3) June 2026

Kia America, Inc. Confidential

Page 7 of 12

SERVICE ACTION: BATTERY WIRING HARNESS

SUBJECT:

COVERING INSPECTION/REPLACEMENT (SA645)

4a.

Disconnect the battery harness connector (D).

4b.

Loosen the two (2) battery harness retaining
bolts (E).

Tightening torque for bolts (E):
5.8 – 8.7 lb.ft (7.8 – 11.8 N.m)

5.

Loosen the battery wiring harness bracket
retaining bolt (F).
Tightening torque for bolt:
7.2 – 8.7 lb.ft (9.8 – 11.8 N.m)

Note: The new battery harness includes a
battery harness bracket (F).
6.

Loosen the two (2) hose clamps and one (1)
band clamp to remove the air intake hose (G).