2021-2023 Kia Instrument Cluster Replacement and Mileage Setting

Kia Technical Service Bulletin (TSB) PS613 (Rev 1), issued on March 30, 2022, provides updated procedures for Kia instrument cluster replacement and mileage setting using the Kia Diagnostic System (KDS). This bulletin revises an earlier version from June 2019 and aims to streamline the process for technicians, ensuring accurate mileage recording and proper cluster functionality.

The TSB applies to various 2021-2023 Kia models, including the Carnival, EV6, Forte, K5, Niro, Optima, Sorento, Soul, Sportage, and Telluride. It highlights that certain models now allow for mileage setting directly with the KDS, eliminating the need to send the instrument cluster to a third party for adjustment, a method previously referenced in bulletin PS264.

Important Warnings for Owners and Technicians

Kia has issued several critical warnings regarding the Kia instrument cluster replacement process:

• "Once the mileage is registered, it cannot be modified." This emphasizes the importance of accurate input during the mileage setting procedure.
• "Before selecting OK, verify that the input mileage is correct to avoid another (unnecessary) replacement."
• "Only save the mileage one time in a new cluster. Mileage cannot be changed once set and saved."
• "Do not touch any system buttons while performing this function." This instruction is repeated multiple times throughout the bulletin to prevent errors during KDS operations.
• "To prevent mileage increase after cluster replacement, do NOT move the vehicle until variant coding has been performed and mileage has been set." Moving the vehicle prematurely can lead to incorrect mileage registration.
• "Be aware that the cluster should be replaced with a new one again if mileage exceeds 20 miles before performing the CLU variant coding." This strict guideline ensures the integrity of the mileage reading.

Understanding the Procedures

The bulletin outlines two main procedures for handling instrument cluster replacement and mileage setting:

Procedure A: Mileage Setting After Cluster Replacement

This procedure applies to models where mileage can be set directly with the KDS. The steps are as follows:

1. Connect KDS: Connect the VCI-II (Vehicle Communication Interface II) to the vehicle. On the KDS home page, select 'S/W Management'.
2. Select Cluster Module: Navigate to 'Cluster Module' and then choose 'Setting mileage (when replacing with a new cluster)'.
3. Verify VIN: The KDS screen will display the VIN (e.g., KNDMC5C12F6000257). Verify this VIN and select 'OK'. A caution notes that if the original ECU was not assembled to this vehicle, the technician should return to the S/W Management menu.
4. Input Mileage: Input the vehicle's mileage, which must be recorded from the previous cluster. Re-enter the mileage for verification and select 'OK'. Technicians are warned that once registered, mileage cannot be modified.
5. Confirm Setting: Select 'OK' to return to the S/W Management menu. Verify that the mileage displayed on the new cluster is correct.
6. Reprogram Radio Presets: If necessary, reprogram the customer's radio presets.

Procedure B: Cluster Replacement & Mileage Setting

This procedure covers the full replacement process for models requiring it, including recording the 'EOL Code' and performing CLU Variant Coding. The steps are:

1. Record Mileage: Note the current mileage displayed on the instrument cluster in the vehicle.
2. Record EOL Code: Using the KDS, navigate from the Home Page to 'S/W Management', then 'Cluster Module', and finally 'System Identification'. Record the original four-digit variant coding of the cluster, referred to as the "EOL Code" (e.g., DE48).
3. Record Radio Presets: Document the customer's radio presets before disconnecting the battery for cluster removal and installation.
4. Replace Cluster: Replace the instrument cluster. Technicians should refer to the