TSB_ELE225

GROUP
ELE
MODEL
2021MY
Forte (BDm)
NUMBER
225
DATE
December 2020
TECHNICAL SERVICE BULLETIN
SERVICE ACTION: LED HEADLAMP
REPLACEMENT (SA455)
SUBJECT:
This bulletin provides the procedure to replace the LED headlamp(s) on certain 2021MY Kia
Forte (BDm) vehicles produced from October 28, 2020 through November 24, 2020. The LED
headlamps installed on certain 2021MY Forte (BDm) vehicles may be assembled with the
inappropriate LED Drive Module (LDM) and may turn ON the indicator lamp in the instrument
cluster via IBU. The condition has no effect on normal operation for the low or high beams. Before
conducting the procedure, verify the vehicle is included in the list of affected VINs.
 IMPORTANT
THE INSPECTION MUST BE PERFORMED PRIOR TO PART(S) ORDERING TO
DETERMINE IF ANY HEADLAMP ASSEMBLY REQUIRES REPLACEMENT.
Service Action
Description
SA455A
Replace Left Headlamp
SA455B
Replace Right Headlamp
SA455C
Replace Both Headlamps
Comments
Includes Headlamp Aiming
 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 WebDCS (Service → Warranty Coverage →
Warranty Coverage Inquiry → Campaign Information). Not completed Recall / Service
Action reports are available on WebDCS (Consumer Affairs → Not Completed Recall
→ Recall VIN → Select Report), which includes a list of affected vehicles.
This issue number is SA455.
Printed TSB copy is for reference only; information may be updated at any time.
Always refer to KGIS for the latest information.
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 7
SUBJECT:
LED HEADLAMP INSPECTION AND REPLACEMENT (SA455)
 IMPORTANT
The inspection must be performed prior to part(s) ordering to determine if any
headlamp assembly requires replacement.
Replacement Procedure (SA455 A/B/C):
1 Replace the left and/or right headlamp(s)
by referring to the “Body Electrical System
→ Lighting System → Headlamps →
Repair procedures” chapter in the
applicable Shop Manual on KGIS.
Headlamp Aiming, Best Practices:
1. Inflate the tires to the specified pressure and remove any loads from the vehicle
including the driver.
2. The vehicle should be placed on a flat level floor.
3. The headlamps should be aimed with the proper beam-setting equipment, and
in accordance with the equipment manufacturer's instructions.
4. If using a wall chart, lowering the ambient light will assist in headlamp
adjustment.
2.
Vehicle distance from the wall chart
19.7 Feet
(6 Meters)
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SA455 Forte (BDm) December 2020
Page 3 of 7
LED HEADLAMP INSPECTION AND REPLACEMENT (SA455)
SUBJECT:
3.
Verify proper operation and vertical
aiming of headlamps and perform vertical
adjustments using the banner, if
necessary.
Note: Headlamp beam cut-off line
should be below the red dotted line.
 NOTICE
Refer to ‘Inspection Station Setup Procedure, Attachment 1’
outlined on page 6 for headlamp
aiming.
4.
5.
Center line of the vehicle should align with the
BLUE vertical line.
Note:
•
All lamp beams are below the red
dotted line
•
LED lamp should light the two
outer squares, center square
should have some shading.
Aim the headlamps so the brightest portion
falls on the vertical lines as shown in Step 4.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SA455 Forte (BDm) December 2020
Page 4 of 7
LED HEADLAMP INSPECTION AND REPLACEMENT (SA455)
SUBJECT:
Faulty Headlamp Scrap Procedure:
1.
2.
Carefully drill a ¼ inch hole (A) through
the lens of the old headlamp assembly.
A
With a permanent marker, clearly write
the last six numbers of the VIN and RO
open-date on the lens.
Example shown •
•
3.
Last six of VIN: 012345
RO Open Date: 11/28/18
Take and submit one (1) KVID* photo of
each drilled and marked headlamp to
attach to Warranty claim.
•
Drilled hole, last six of VIN, and RO
open date MUST be clearly visible in
photo(s).
o If replacing one headlamp one
photo is required for warranty claim
submission.
o If replacing both headlamps two
individual photos are required for
warranty claim submission.
*KVID must be used for photo submission.
Other sources are not supported.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SA455 Forte (BDm) December 2020
Page 5 of 7
SUBJECT:
LED HEADLAMP INSPECTION AND REPLACEMENT (SA455)
AFFECTED VEHICLE RANGE:
Model
Production Date Range
Forte (BDm)
October 28, 2020 through November 24, 2020
REQUIRED TOOL:
Tool Name
Tool Number
Forte LED Headlamp
Aim Banner
HLABN M7000
Figure
Comments
Included in dealer tool
kit
RELATED PART:
Part Name
Part Number
LED Headlamp (LH)
92101 M7200QQK
LED Headlamp (RH)
92102 M7200QQK
Figure
WARRANTY INFORMATION:
N Code: N99 C Code: C99
Claim
Type
Causal P/N
Qty.
V
92101 M7200
0
V
92102 M7200
0
V
92101 M7200
0
Repair
Description
(SA455A)
Replace (1) Left
Headlamp and Aim
(SA455B)
Replace (1) Right
Headlamp and Aim
(SA455C)
Replace (2) Right and
Left Headlamp and
Aim
Labor Op
Code
Op
Time
Replacement
P/N
Qty.
200M20R0
0.8
M/H
92101 M7200QQK (LH)
1
200M20R1
0.8
M/H
92102 M7200QQK (RH)
1
92101 M7200QQK (LH)
1
200M20R2
0.9
M/H
92102 M7200QQK (RH)
1
Note: For attaching KVID image(s), use attachment type ‘XX: Other’. KVID must be used
for photo submission. Other sources are not supported.
If necessary, enter sublet code ‘X2’ for a maximum allowance of 2 days for substitute
transportation.
 NOTICE
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers
should reference SA455 when accessing the WebDCS system.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SA455 Forte (BDm) December 2020
Page 6 of 7
SUBJECT:
LED HEADLAMP INSPECTION AND REPLACEMENT (SA455)
Inspection Station Set-up Procedure, Attachment 1:
At a blank wall* with at least 7ft. width of space,
measure and mark at two (2) locations: 0in. and
7ft. (84in.).
*If a blank wall is not available, refer to
Attachment 1 on page 8 for an example of a
custom mobile stand.
From the 0in mark (A) at the wall, measure
and mark a spot 21.4ft. (257. 25in.) away from
and perpendicular to the wall.
A
Repeat step 2 but from the 7ft. mark (B) at the
wall.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SA455 Forte (BDm) December 2020
Page 7 of 7
SUBJECT:
LED HEADLAMP INSPECTION AND REPLACEMENT (SA455)
Measure and ensure the distance is 7ft.
between both new marks (C).
C
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: SA455 Forte (BDm) December 2020