NHTSA ID Number: 11033992
Manufacturer Communication Number: TSB_ELE419
TSB/Document Date: 2026-06-18
Summary
TECHNICAL SERVICE BULLETIN: SERVICE ACTION: BATTERY WIRING HARNESS 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.
Tightening torque for band clamp:
2.2 – 3.6 lb.ft (2.9 – 4.9 N.m)
7.
Disconnect the throttle body connector and
loosen the four (4) bolts to remove the throttle
body (H).
Tightening torque for bolt:
7.2 – 8.7 lb.ft (9.8 – 11.8 N.m)
Note: DO NOT reuse the throttle body
gasket.
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 8 of 12
SERVICE ACTION: BATTERY WIRING HARNESS
SUBJECT:
COVERING INSPECTION/REPLACEMENT (SA645)
8.
Disconnect the alternator B+ terminal (I) after
removing the retaining nut.
Tightening torque for nut (I):
13.7 – 18.1 lb.ft (18.6 – 24.5 N.m)
9.
Remove the cooling fan (J) by referring to
“Engine Mechanical System → Cooling System
→ Cooling Fan → Removal and Installation” in
the applicable Shop Manual on KGIS.
Note: Vehicle will need to be raised.
CAUTION
When removing the cooling fan (J), be
careful to NOT bend/kink the hardline
degassing hose (K). If the degassing
hose (K) becomes damaged and needs
to be replaced, they must be claimed
separately under Warranty or Goodwill.
Please refer to Goodwill Reason Code
Guide
for
Previously
Completed
Campaign Repairs (in warranty) or
Consequential
Damage
(out
of
warranty). DO NOT open a Techline
case for a damaged degassing hose (K).
10.
Disconnect the oil level sensor connector (L)
and clip.
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 9 of 12
SERVICE ACTION: BATTERY WIRING HARNESS
SUBJECT:
11a.
COVERING INSPECTION/REPLACEMENT (SA645)
Disconnect the starter connector (M).
Note: You may need to raise and lower the
vehicle to access and complete some of the
remaining steps.
The intake manifold is removed for illustration purposes only. The
intake manifold does NOT need to be removed.
11b.
Open the starter B+ terminal cover (N).
11c.
Disconnect the starter B+ terminal (O) after
removing the nut.
Tightening torque for nut:
8.7 – 10.1 lb.ft (11.8 – 13.7 N.m)
The intake manifold is removed for illustration purposes only. The
intake manifold does NOT need to be removed.
For models equipped with Idle-Stop-Go
(ISG) ONLY:
11d.
Disconnect the ISG connector (P).
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 10 of 12
SERVICE ACTION: BATTERY WIRING HARNESS
SUBJECT:
COVERING INSPECTION/REPLACEMENT (SA645)
12.
Remove the battery wiring harness assembly
(Q) from the vehicle.
Note: Ensure the three (3) wiring harness
retaining
are
detached
before
removing
the
harness
harness
assembly.
13.
Install
the
new
assembly (P) in the reverse order of removal.
14.
Reinstall all removed parts in reverse order of
removal.
15.
Clear any stored DTCs.
16.
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.
TSB: SA645 K5 (DL3) June 2026
Kia America, Inc. Confidential
Page 11 of 12
SERVICE ACTION: BATTERY WIRING HARNESS
SUBJECT:
COVERING INSPECTION/REPLACEMENT (SA645)
AFFECTED VEHICLE RANGE:
Model
Production Date Range
K5 (DL3)
February 20, 2024 to March 13, 2026
REQUIRED PART:
Part Name
Part Number
Figure
Bracket
91931 L2070QQK
Throttle Body Gasket
28411 2S000
Qty.
Comments
1
N/A
1
N/A
*
N/A
91855 L2541QQK
*
Non-ISG
(Has Red Tape)
Battery Harness
1
91855 L2551QQK
With ISG
*
N/A
(Has Blue Tape
and Extra Connector)
As
Needed
Locally Sourced
*Note: The replacement part numbers will require a VIN entry for parts ordering. DO NOT order these
parts for stocking purposes, related to this Service Action. Supply is very limited. Until supply stabilizes,
please confirm part availability before scheduling customers. Please be sure to expedite warranty claim
filing.
*PartsEye will place replenishment orders based on the dealers’ on-hand supply. Please refer to Parts
bulletin PB MI-25-08 for information related to Parts Eye Campaign ordering.
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 12 of 12
SERVICE ACTION: BATTERY WIRING HARNESS
SUBJECT:
COVERING INSPECTION/REPLACEMENT (SA645)
WARRANTY INFORMATION:
N Code: N99 C Code: C99
Claim
Type
Causal P/N
Qty.
Repair
Labor Op
Op
Replacement
Description
Code
Time
P/N
Qty.
(SA645)
Battery Wiring
Harness Covering
Inspection (OK) +
260063R0*
0.5
M/H
91931 L2070QQK
1
Bracket Installation
(and taping, if needed)
V
91855 L2551
0
91855 L2541QQK
(SA645)
or
Battery Wiring
Harness Covering
Inspection (NG) +
1
91855 L2551QQK
260063R1
1.3
M/H
Battery Wiring
Harness Replacement
28411 2S000
1
Note: When substitute transportation is provided, manually enter sublet code ‘X2’ for rental expense
reimbursement or one roundtrip rideshare expense.
*A KVID photo of the battery harness ‘OK’ condition MUST be attached to the claim using KDS Tablet
Warranty Claim Attachment Tab ‘XX – Other’ for labor op 260063R1. If needed, use sublet code ‘X1’ for
labor op 260063R0 with a maximum allowed amount of $0.90 per vehicle for electrical tape.
NOTICE
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference
SA645 when accessing the KDealer+ system.
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
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Last update on 2026-06-29 / Affiliate links / Images from Amazon Product Advertising API
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TSB/Document ID: TSB_ELE419
Replacement Service Bulletin Number:
MFR Communication Date: 2026-06-02
MFR Internal Campaign ID/Software Version: SA645
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System: ELE
MFR Component Subsystem:
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