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SPORTAGE(AL) > 2002 > G 2.0 DOHC > Engine Control/Fuel System

Engine Control/Fuel System > General Information > Description and Operation

GENERAL DESCRIPTION

EMISSION CONTROL SYSTEM

The engine exhaust gases consist mainly of nitrogen (N2), however, they also contain carbon monoxide (CO), carbon dioxide (CO2), water vapor (H2O), oxygen (O2), nitrogen oxides (NOx), and hydrogen (H2), as well as various other unburned hydrocarbons (HC). Three of these exhaust gases, CO, NOx, and HC, are major air pollutants. Their emissions must be controlled.

The vehicle contains a sequential multiport fuel injection (SFI) system classified as a multi-point, pulse time, mass air flow, fuel injection system. This system supplies the engine with the air/fuel mixture necessary for combustion. An air induction system and fuel injection system work in conjunction with an electronic engine control system which consists of various sensors, switches, and the engine control module (ECM). All sensors and switches are connected to the ECM which interprets the data received from them and

computes the timing and duration (pulse width) that the electrically operated injectors are energized.

The basic fuel requirement of the engine is detected from the data supplied to the ECM by the mass air flow (MAF) sensor. The ECM measures the amount of air drawn into the engine. Additional sensors and switches measure engine coolant temperature, engine speed, exhaust oxygen content, and number 1 cylinder top dead center.

The various sensors and switches detect any changes in the operating conditions and send signals to the ECM. This allows the ECM to control the injectors opening duration (pulse width) and maintain optimum exhaust emissions control and engine performance for all conditions.

The three way catalytic converter is mounted in-line between the header pipe and the muffler. The catalytic metals are thin-coated on a honeycomb-shaped, high temperature ceramic. The honeycomb is mounted inside the converter shell which is surrounded by a heat shield. It reacts with exhaust gases to convert them to less harmful products and therefore reduce the pollutant levels to within legally-prescribed limits. Refer to Exhaust System, Group 20.

Component Descriptions

Component Function Remark

A/C Cut Relay Controls A/C operation according to vehicle conditions and sends A/C operation condition signals to ECM Controls condenser fan operation

A/C Switch Controls battery power to A/C relay Normally open type

Air Cleaner Filters air entering throttle body Dry type

Camshaft Position (CMP) Sensor Detects No. 1 cylinder TDC; sends signal to ECM Installed at rear of cylinder head

Canister Close Valve Closes air inlet to evaporative emissions canister at ignition OFF for evaporative emissions system leak detection and vapor leakage inspection Located on front of evaporative emission canister

Chassis Acceleration Sensor Detects vertical chassis movement on rough terrain and sends signal to ECM For engine misfire detection determination

Check Valve Maintains pressure in the fuel tank and regulates vapor flow to the evaporative emissions canister Located in evaporative system lines next to the fuel tank

Crankshaft Position (CKP) SensorDetects crank shaft angle from flywheel rotation and sends signal to ECM

1. SGT signal

2. For engine misfire detection

Data Link Connector (DLC) Centralized service connector for on-board diagnosis For on board diagnosis and service/inspection

EGI Main Relay Supplies battery power to electrical devices 1. Normally open type

2. Controlled by ECM

Engine Control Module (ECM) Detects the following:

1. A/C operation

2. Air/fuel ratio (oxygen concentration)

3. Cranking Signal

4. Engine coolant temperature

5. Engine speed

6. Ignition ON signal

7. In-gear condition (A/T only)

8. Intake air amount

9. Intake air temperature

10. No. 1 piston TDC (compression stroke)

11. Throttle valve opening angle

Controls operation of following:

1. A/C (cutoff)

2. Self-diagnosis function

3. Fuel injection system

4. Idle speed control

5. Monitor function

6. Purge control system

7. Fuel pump control

1. Air conditioning switch

2. Oxygen sensor

3. Ignition switch

4. Engine coolant temperature sensor

5. Crankshaft position (CKP) sensor (SGT signal)

6. Ignition switch

7. Transmission range switch (A/T)

8. Mass air flow sensor

9. Intake air temperature sensor

10. Camshaft position (CMP) sensor (SGC signal)

11. Throttle position sensor

12. A/C cut relay

1. Kia Data Pro Scan Tool & MIL

2. Injector

3. Idle air control valve

4. Engine monitor output to DLC

5. Purge solenoid valve

6. Fuel pump relay

Engine Coolant Temperature (ECT) Sensor Detects engine coolant temperature and sends signal to ECM Installed near thermostat

Evaporative Emission Canister Stores fuel tank vapors (engine stopped) -

Fuel Filter (High Pressure Side) Filters fine dirt particles in fuel discharged from the fuel pump -

Fuel Filter (Low Pressure Side) Filters fuel in fuel tank Installed onto fuel pump assembly

Fuel injector Injects fuel into intake port Controlled by signals from ECM

Fuel Pressure Regulator Regulates fuel pressure supply to injectors Controlled by intake manifold vacuum

Fuel Pump Supplies fuel from fuel tank to fuel under pressure Actuated by fuel pump relay Installed

Fuel Pump Relay Controls battery power to fuel pump 1. Normally open type

2. Actuated by ECM fuel pump control signal or by jumping data link connector terminal #1 to B+

Fuel Tank Pressure Sensor Detects vapor leakage and monitors purge valve operation Located on the fuel tank

Heated Oxygen Sensor (Front) Detects oxygen density in exhaust gas and sends signal to ECM 1. Located in exhaust manifold

2. For air/fuel mixture adjustment

Heated Oxygen Sensor (Rear) Detects oxygen density in exhaust gas and sends signal to ECM 1. Located downstream of catalytic converter

2. For catalytic converter efficiency evaluation

Idle Air Control (IAC) Valve Supplies intake air to engine, bypassing throttle valve 1. For idle speed control

2. Actuated by ECM idle speed control signal

Ignition Coils Supplies secondary voltage to spark plugs Mounted directly above spark plugs

Ignition Control Module Controls operation of ignition coils Incorporated into ECM

Ignition Switch Starts engine and controls battery power to electrical devices -

Intake Air Temperature Sensor Detects air intake temperature and sends to ECM. Installed on air cleaner assembly

Intake Manifold Supplies intake air to all cylinders -

Knock Sensor Detects detonation in the combustion chamber(s) and sends signal to ECM The ECM will retard ignition timing based on input signal

Main Relay Supplies current to output devices and ECM -

Mass Air Flow (MAF) Sensor Detects amount of intake air and sends signal to ECM Hot film type

Positive Crankcase Ventilation (PCV) Valve Sends blow-by gas in crankcase into intake manifold (dynamic chamber) 1. Actuated by intake manifold vacuum

2. For blow-by gas recirculation

Purge Solenoid Valve Controls Fuel vapor from charcoal canister to intake manifold (dynamic chamber) 1. For purge control

2. Actuated by RCM purge control signal

Resonance Chamber Reduces intake air suction noise and increases engine torque -

Rollover Valve Restricts fuel from entering the evaporative system in a vehicle rollover Located in the evaporative system lines next to the fuel tank

Starter Crank engine by rotating flywheel ring gear -

Three Way Catalytic Converter Reduces HC, CO, and NOx in exhaust through chemical reaction For exhaust gas emissions reduction

Throttle Body Controls intake air amount -

Throttle Position Sensor Detects throttle valve opening angle and sends signal to ECM Installed on throttle body

Transmission Control Module Controls functions of transmission for better performance and shift quality Located below instrumental panel behind left lower trim panel

Transmission Range Switch Detects shift lever position and sends signal to ECM 1. For idle speed control

2. Load/no-load determination

Engine Control/Fuel System > General Information > Repair procedures

ON-VEHICLE SERVICE

ENGINE TUNE-UP

Basic Inspection

Engine Oil

1. Remove the engine oil level gauge and check the engine oil level and condition.

2. Add or change the oil as necessary.

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Engine Coolant

Never remove the radiator cap while the engine is hot.

1. Remove the coolant gauge from the coolant reservoir.

2. Check the coolant for a level between the L and F marks of the gauge.

3. Add coolant if necessary.

Battery

1. Check for corrosion on the battery posts and for loose and corroded cable connections. If necessary, remove and clean/replace the cable clamps.

2. Reattach cables to the posts and tighten clamps.

3. Check that the electrolyte level is between the upper level and lower level marks on the side of the battery.

4. Add distilled water if necessary.

5. Check the specific gravity of the battery with a hydrometer.

Gravity: 1.27 - 1.29 (at 68°F〔20°C〕)

Air Cleaner Element

Inspection

1. Loosen air intake hose clamp at the mass air flow sensor.

2. Disconnect air hose from mass air flow sensor.

3. Remove six screws retaining air cleaner housing and lift housing unit.

4. Remove air cleaner from beneath air cleaner housing.

Do not use compressed air to clean the air cleaner element.

5. Inspect air cleaner element for excessive dirt, damage, or oil.

6. Replace the cleaner element if necessary.

Installation1. Lift the air cleaner housing unit and install the air cleaner beneath the housing unit.

2. Lower the housing unit and replace six retaining screws to hold the unit in place.

3. Reattach air intake hose to the mass air flow sensor and tighten the retaining clamp.

Ignition Timing Inspection

1. Apply the parking brake.

2. Warm up the engine to normal operating temperature.


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3. Turn off all electrical loads.

4. Connect a tachometer and a timing light to the engine.

5. Verify that engine idle speed is correct using one of the three methods explained in on vehicle service under Idle Speed inspection.

Idle Speed (transmission NEUTRAL): 820 +/-50 rpm.

Ignition timing is not adjustable.

6. Verify ignition timing using the marks on the crankshaft pulley and the timing mark on the timing belt cover are aligned.

Ignition Timing : BTDC 6° +/- 6° (at idle speed)

7. If the timing is not within the specified range, replace the ECM.

Idle Speed



3. Turn OFF all electrical loads.

4. Use one of the three methods of inspecting idle speed:

A. Connect a tachometer to the Data Link

Connector (DLC) IG-terminal. (This terminal is for connecting the positive lead of non-inductive tachometers only.)

B. Use inductive pick-up on spark plug wire to measure idle speed.

C. Connect Kia Data Pro Scan Tool to the Data Link Connector (DLC) and then refer to the KIA Data Pro Scan Tool instruction manual for retrieval of engine idle speed information.

The idle speed is not adjustable. The idle speed is automatically controlled by the Engine Control Module through the Idle Air Control (IAC) Valve.

5. Check that idle speed is within the specified range. Idle speed (transmission in NEURTAL): 820+/-50 rpm

6. Remove the diagnostic tool used to retrieve the idle speed.

7. Turn engine OFF.

Engine Control/Fuel System > General Information > Specifications

SPECIFICATIONS

Engine Control/Fuel System > Engine Control System > Engine Control Module (ECM) > Repair procedures

ENGINE CONTROL MODULE (ECM)

Removal

1. Take out two screws and remove lower right side trim panel below the instrument panel, on the passenger side of the vehicle.

2. Pull back carpet to expose the ECM.

3. Remove four nuts retaining the ECM to the floorboard mounting bolts.

4. Remove the ECM from the mounting bolts.

5. Disconnect the ECM connector.


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Installation

1. Attach the connector to the ECM.

2. Mount the ECM onto the mounting bolts in the floorboard.

3. Install four nuts to retain the ECM on the mounting bolts.

4. Put carpet back in place.

5. Hold trim panel in place and install the two retaining screws.

Engine Control/Fuel System > Engine Control System > Engine Control Module (ECM) > Specifications

ECM Terminal Voltage Chart

TERMINAL SIGNALCONNECTED

TO

TEST

CONDITIONVOLTAGE

C211-1 Fuel pump relay control Fuel pump relayKey ON/Engine OFF B+

Idle < 2.0 V

C211-2 Idle speed control - closing Idle air control valveKey ON/Engine OFF 3.3~3.6 V

Idle 6.0 V

C211-3 Fuel injector control Fuel injector #1Key ON/Engine OFF B+

Idle B+


Idle B+

C211-5 - - - -

C211-6 Injector ground Ground Constant < 1.0 V

C211-7 - - - -

C211-8 MIL control Malfunction indicator lightKey ON/Engine OFF < 1.0 V

Idle (No DTC Found) B+

C211-10 Rear HO2S sensor ground Rear Heated Oxygen sensorKey ON/Engine OFF 0.1 - 0.8 V

Idle 0.3 V

C211-11 Front HO2S sensor ground Front heated oxygen sensorKey ON/Engine OFF 0.1 - 0.8 V

Idle 0.3 V

C211-12 Front HO2S input Front heated oxygen sensorKey ON/Engine OFF Approx. 0.45 V

Idle 0.1 - 0.9 V

C211-13 - - - -

C211-14 Mass air flow sensor ground Mass air flow sensorKey ON/Engine OFF 0.01 V

Idle 0.03 V

C211-15 - - - -

C211-16 Crankshaft position sensor output - A terminal Crankshaft position sensorKey ON/Engine OFF 1.5 - 1.6 V

Idle 1.5 - 1.6 V

C211-17 - - - -

C211-18 Canister close valve input Canister close valveKey ON/Engine OFF B+

Idle B+

C211-19 - - - -

C211-20 - - - -

C211-21 - - - -

C211-22 - - - -

C211-23 Engine coolant temperature output to TCM Transmission control moduleKey ON/Engine OFF 0.61 V

Idle 0.73 V

C211-24 - - - -

C211-25 Ignition coil control Ignition coil (cyl 1 & 4)Key ON/Engine OFF B+

Idle B+

C211-26 Battery voltage BatteryKey ON/Engine OFF B+

Idle B+

C211-27 EGI main relay control EGI main relayKey ON/Engine OFF 0.9 V

Idle 0.9 V

C211-28 ECM ground GroundKey ON/Engine OFF 0.01 V

Idle 0.01 V

C211-29 Idle air control valve - opening coil Idle air controlKey ON/Engine OFF 9.85 V

Idle 10.5 V

C211-30 Rear HO2S heater ground Rear heated oxygen sensor Key ON/Engine OFF < 0.3 V


Idle B+


Idle B+

C211-33 - - - -

C211-34 Output stage ground GroundKey ON/Engine OFF 0.01 V

Idle 0.02 V

C211-35 - - - -

C211-36 Purge solenoid control Purge solenoid valveKey ON/Engine OFF B+

Idle B+

C211-37 Front HO2S heater control Front heated oxygen sensorKey ON/Engine OFF 0.0 V

Idle 0.3 - 0.5 V


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C211-38 Throttle position signal output Transmission control moduleKey ON/Engine OFF 10.8 V

Idle 12 V

C211-39 Rear HO2S input Rear heated oxygen sensorKey ON/Engine OFF 0.45 V

Idle 0.6 - 0.7 V

C211-41 Mass air flow sensor input Mass air flow sensorIdle (800 rpm) 0.9 - 1.1 V

3300 rpm 1.8 - 2.0 V

C211-42 Vehicle speed input Instrument clusterKey ON/Engine OFF 5.54 V

Idle 5.72 V

C211-43 Crankshaft position sensor input - B terminal Crankshaft positionKey ON/Engine OFF 1.6 V

Idle 1.6 V

C211-44 Camshaft position sensor input Camshaft position sensorKey ON/Engine OFF 5.04 V

Idle 4.1 - 4.5 V

C211-45 - - - -

C211-46 - - - -

C211-47 Engine RPM to TCM TCMKey ON/Engine OFF 0.04 V

Idle 8 V

C211-48 A/C cut relay control A/C cut relayIdle/A/C OFF B+

A/C ON Approx. 0 V

C211-49 - - - -

C211-50 - - - -

C211-51 - - - -

C211-52 Ignition coil control Ignition coil (cyl 2 & 3)Key ON/Engine OFF B+

Idle B+

C211-53 - - - -

C211-54 Power EGI main relayKey ON/Engine OFF B+

Idle B+

C211-55 Ignition ground GroundKey ON/Engine OFF 0.01 V

Idle 0.01

C211-56 - - - -

C211-57 - - - -

C211-58 Ignition input Ignition switchKey ON/Engine OFF B+

Idle B+

C211-59 Reference voltage Chassis acceleration sensor, fuel tank pressure sensor, throttle position sensorKey ON/Engine OFF 5.04 V

Idle 5.04 V

C211-60 - - - -

C211-61 MIL request Transmission control moduleKey ON/Engine OFF 12.3 V

Idle 13.4 V

C211-62 - - - -

C211-63 - - - -

C211-64 A/C request input A/C relayIdle / A/C OFF 5 V

A/C ON Approx. 0 V

C211-65 A/C compressor clutch operation A/C dual pressure switchIdle / A/C OFF 5 V

A/C ON Approx. 0 V

C211-66 - - - -

C211-67 - - - -

C211-68 ECT output TCMKey ON/Engine OFF(170°F) 0.01 V

Idle(194°F) 13.2 V

C211-69 - - - -

C211-70 Knock sensor input Knock sensor Key ON/Engine OFF 0.03 V

C211-71 Sensor groundChassis acceleration sensor, EGR differential pressure sensor, engine coolant temperature sensor, knock sensor, fuel tank

pressure sensor, throttle position sensor

Key ON/Engine OFF 0.01 V

Idle 0.01 - 0.03 V

C211-72 Ground (A/T only) GroundMTX 5 V

Key ON/(ATX) 0.01 V

C211-73 Throttle position sensor input Throttle position sensorKey ON/Engine OFF 0.6 V

Idle 0.6 V

C211-74 - - - -

C211-76 Fuel tank pressure sensor input Fuel tank pressure sensorKey ON/Engine OFF 2.5 V

Idle 2.5 V

C211-77 Intake air temperature sensor a input Intake air temperature sensorKey ON/Engine OFF(-48°F) 5 V

Idle(123°F) 2.2 V

C211-78 Engine coolant temperature sensor input Engine coolant temperature sensorKey ON/Engine OFF(-40°F) 5 V

Idle(186°F) 1.1 V

C211-79 - - - -

C211-80 Chassis acceleration sensor input Chassis acceleration sensorKey ON/Engine OFF 2.5 V

Idle 2.5 V

C211-83 Diagnosis - K-Line OBD-II data link connectorKey ON/Engine OFF B+

Idle/Communication between ECM to scantool 8 - 10 V

C211-84 - - - -

C211-85 - - - -

C211-86 Park/Neutral input (A/T only) Transmission range switchATX(Except P & N Range) B+

MTX, ATX(P & N Range) 0.01 V

C211-87 - - - -

C211-88 - - - -

Engine Control/Fuel System > Engine Control System > Mass Air Flow Sensor (MAFS) > Repair procedures

MASS AIR FLOW SENSOR (HOT FILM TYPE)

Removal

Do not drop or subject the sensor to shock. Do not put objects inside the sensor.

1. Disconnect the mass air flow sensor connector.

2. Loosen air intake hose retaining clamps on both sides of the mass air flow sensor.

3. Disconnect the air intake hose from the mass air flow sensor.

4. Remove the two bolts attaching the mass air flow sensor to the mounting bracket.

5. Remove the mass air flow sensor.


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Removal

1. Disconnect the connector from the mass airflow sensor by depressing the spring latch.

2. Remove the two bolts from the sensor bracket.

3. Loosen the two hose clamps located adjacent to the sensor housing.

4. Remove the sensor and its housing from the intake duct.

Removal (HOT FILM TYPE)

Do not drop or subject the sensor to shock. Do not put objects inside the sensor.

1. Disconnect the mass air flow sensor connector.

2. Loosen air intake hose retaining clamps on both sides of the mass air flow sensor.

3. Disconnect the air intake hose from the mass air flow sensor.

4. Remove the two bolts attaching the mass air flow sensor to the mounting bracket.

5. Remove the mass air flow sensor.

Installation

1. Check mass air flow sensor for damage, replace if necessary.

2. Attach mass air flow sensor to air intake hose and to the mounting bracket.

3. Replace the two bolts to retain the mass air flow sensor to the mounting bracket.

Tighten bolts to 69-96.3 lb-in (7.8-10.8 N•m).

4. Reconnect the sir intake hose to the mass air flow sensor.

5. Tighten the bolts of the retaining clamps on both sides of the mass air flow sensor.

6. Reconnect the mass air flow sensor connector to the sensor.

Inspection

1. Warm up the engine to normal operating temperature and let it idle.

2. Connect a voltmeter between terminal 4 (RED/GRN wire) and ground.

3. Verify that the voltage varies between 0.8V-1.2V.

4. Rev up the engine and verify that voltage varies between 3.5V-4V.

5. If the voltage is not within specification, replace the mass air flow sensor.

Installation

1. Check the two clamps in the intake duct to be sure they are loose enough to allow insertion of the sensor housing.

2. Insert sensor housing into the intake duct with the connector facing to the rear. Note that the arrow on the sensor housing must point towards the engine.

3. Reinstall the two bolts into the sensor bracket.

4. Reconnect the mass airflow sensor connector.

Be sure the lgnition key is in the OFF position before starting this repair

Installation (Hot Film Type)

1. Check mass air flow sensor for damage, replace if necessary.

2. Attach mass air flow sensor to air intake hose and to the mounting bracket.

3. Replace the two bolts to retain the mass air flow sensor to the mounting bracket.

Tighten bolts to 69-96.3 lb-in (7.8-10.8 N·m)

4. Reconnect the air intake hose to the mass air flow sensor.

5. Tighten the bolts of the retaining clamps on both sides of the mass air flow sensor.

6. Reconnect the mass air flow sensor connector to the sensor.


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Inspection (Hot Film Type)

1. Warm up the engine to normal operating temperature and let it idle.

2. Connect a voltmeter between terminal 4 (RED/GRN wire) and ground.

3. Verify that the voltage varies between 0.8V-1.2V.

4. Rev up the engine and verify that voltage varies between 3.5V-4V.

5. If the voltage is not within specification, replace the mass air flow sensor.

Engine Control/Fuel System > Engine Control System > Intake Air Temperature Sensor (IATS) > Repair procedures

Intake Air Temperature Sensor

Inspection1. Turn the ignition switch OFF.

2. Disconnect IAT sensor connector.

3. Using a ohmmeter, measure resistance between terminals 1 and 2 of the IAT sensor.

Resistance: 2.21~2.69 KΩ 68°F = (20°C)

4. If not specified, replace IAT sensor.

5. Connect the IAT sensor.

Removal

1. Disconnect the IAT sensor connector by prying the retainer clip-out of the connector with a pick tool.

2. Remove the IAT sensor from air cleaner assembly.

Installation

1. Install a new washer and the intake air temperature sensor to air cleaner assembly.

2. Connect the intake air temperature connector.

Engine Control/Fuel System > Engine Control System > Engine Coolant Temperature Sensor (ECTS) > Repair procedures

ENGINE COOLANT TEMPERATURE SENSOR

Removal

The engine coolant temperature sensor is near the thermostat.

1. Disconnect the engine coolant temperature sensor connector.

2. Remove the engine coolant temperature sensor.

Installation

1. Install a new washer and the engine coolant temperature sensor onto the engine.

Tighten to 18-22 ft-lb (25-29 N·m).

2. Connect the engine coolant temperature sensor connector.

3. Start the engine and check for coolant leakage.

Inspection


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1. Place the sensor in a beaker of water with a thermometer and heat the water gradually.

2. Measure the resistance of the sensor using an ohmmeter.

WATER TEMPERATURE

°F (°C)Resistance (kΩ)

68°F (20°C) 2.45 ± 0.24

176°F (80°C) 0.322 ± 0.032

3. If resistances are not within specification, replace the engine coolant temperature sensor.

Engine Control/Fuel System > Engine Control System > Throttle Position Sensor (TPS) > Repair procedures

THROTTLE POSITION SENSOR

Inspection

1. Disconnect the connector from the throttle position sensor.

2. Connect an ohmmeter between the sensor terminals 2 and 3.

3. Verify that the resistance increases linearly according to the throttle angle.

Specification:

Measuring Condition Resistance (kΩ)

Fully closed Approx. 2.4

Fully open Approx. 1

4. If the resistance is not as specified, replace the throttle position sensor.

5. Connect the throttle position sensor connector.

6. Reinspect the new throttle position sensor after installation for proper operation.

Voltage Inspection

1. Verify that the throttle is at the closed throttle position.

2. Turn the ignition switch ON.

3. Connect the voltmeter between terminal 3 (YEL/BLK wire) and 2 (GRN/YEL wire) on the throttle position sensor connector.

4. Verify that the throttle valve is at the closed throttle position.

5. Fully open throttle valve and verify that the voltage at terminal 3 is within the specification.

6. If not as specified, replace the throttle position sensor.

Specification

Measuring Condition Voltage (V)

Fully closed 0.5V

Fully open 4.1V

Removal

The throttle position sensor is not adjustable or replaceable. The throttle position sensor is part of the throttle body assembly.

For throttle body installation, refer to Fuel System, Section 22.

Installation

For throttle body installation, refer to Fuel System, Section 22.

Engine Control/Fuel System > Engine Control System > Heated Oxygen Sensor (HO2S) > Repair procedures

HEATED OXYGEN SENSORS

Inspection of Terminal Voltage for the Front & Rear Heated Oxygen Sensor


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2. Run engine at idle speed.

3. Connect a voltmeter between terminal 4 (BLK/RED wire) and ground.

4. Increase and decrease the engine speed quickly several times.

5. Verify that the meter reading varies between 0-1.0V.

Rear oxygen sensor voltage does not fluctuate as quickly as front oxygen sensor.

6. If not as specified, inspect:

A. On-board diagnostic system

B. System inspection

C. Intake manifold vacuum

D. Fuel line pressure

7. If all the systems are normal, replace the heated oxygen sensor.

Inspection of the Front & Rear Heated Oxygen Sensor Heaters

1. Ensure the ignition switch is OFF.

2. Disconnect the heated oxygen sensor connector.

3. Connect an ohmmeter between terminals 2 and 4 and measure the resistance.

Specification: approx. 5Ω (68°F 20°C)

4. If not as specified, replace the heated oxygen sensor.

Tighten to 22-36 lb-ft (30~49 N·m)

5. Reconnect the heated oxygen sensor connector.

Removal

1. Disconnect the heated oxygen sensor connector.

2. With a standard oxygen sensor socket, remove the heated oxygen sensor and washer.

Installation

1. Install the heated oxygen sensor and washer.

Tighten to 22-36 lb-ft (30~49 N·m)

2. Reconnect the heated oxygen sensor connector.

Engine Control/Fuel System > Engine Control System > Knock Sensor (KS) > Repair procedures

KNOCK SENSOR

Inspection

1. With the knock sensor connector still connected, connect a voltmeter between terminal 3 (YEL/GRN) and ground.


3. Tap the engine crossmember bracket with a wrench.

4. Verify that a voltage spike (less than 1V) is output from the knock sensor.

5. If no voltage spike is observed, replace the knock sensor.

Removal

1. Remove intake manifold support bracket.

2. Disconnect wire harness.

3. Loosen bolt and remove sensor.

Installation

1. Install sensor and tighten bolt.

2. Install wire harness.

3. Reinstall intake manifold support bracket.


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Engine Control/Fuel System > Engine Control System > Acceleration Sensor > Repair procedures

CHASSIS ACCELERATION SENSOR

Inspection

1. With the component connector still connected, connect a voltmeter between terminal 3 (BLU/GRN) and ground.


3. Tap the chassis acceleration sensor bracket with a wrench.

4. Verify that a voltage spike (less than 1V) is output from the chassis acceleration sensor.

5. If no voltage spike is observed, replace the chassis acceleration sensor.

Removal

1. Remove wire connector from sensor.

2. Loosen and remove fasteners, remove sensor.

Installation

1. Place sensor in position (note that the sensor is directional and must be installed with the connector facing to the rear).

2. Install nuts and tighten.

Engine Control/Fuel System > Engine Control System > Idle Speed Control Actuator (InodeA) > Training Information

Idle Speed



3. Turn OFF all electrical loads.

4. Use one of the three methods of inspecting idle speed:

A. Connect a tachometer to the Data Link Connector (DLC) IG-terminal. (This terminal is for connecting the positive lead of non-inductive tachometers only.)

B. Use inductive pick-up on spark plug wire to measure idle speed.

C. Connect Hi-Scan Tool to the Data Link Connector (DLC) and then refer to the Hi-Scan Tool instruction manual for retrieval of engine idle speed information.

The idle speed is not adjustable. The idle speed is automatically controlled by the Engine Control Module through the Idle Air Control (IAC) Valve.

5. Check that idle speed is within the specified rang.

Idle speed (transmission in NEUTRAL): 820+/-50 rpm

6. Remove the diagnostic tool used to retrieve the idle speed.

7. Turn engine OFF.

Engine Control/Fuel System > Engine Control System > Idle Speed Control Actuator (InodeA) > Repair procedures

Removal

1. Verify that the ignition switch is OFF.

2. Disconnect the IAC Valve connector.

3. Remove the two bolts fastening the IAC Valve to the air pipe.

4. Remove the IAC gasket.

5. Clean the mating surfaces of air pipe and IAC Valve.

Installation

1. Install a new gasket onto the IAC Valve.

2. Position the IAC Valve on the air pipe.

3. Install and tighten the two bolts retaining the IAC Valve to the air pipe.

4. Connect the IAC Valve electrical connector.

Inspection

1. Verify that the ignition switch is OFF.

2. Disconnect the IAC valve connector.

3. Measure IAC valve resistance.

Specification: at 68°F (20°C)

Terminal Ohms

1 - 2 18.5 - 20.1

1 - 3 35.3 - 36.9

2 - 3 16.0 - 17.6

4. If not as specified, replace the IAC valve.


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Inspection (Idle Speed)


2. Start the engine and let it warm up to normal operating temperature.

3. Turn off all electrical loads.

4. Open the cover to the data link connector (DLC) located on the air intake housing.

5. Connect a tachometer to the IG-terminal of the DLC.

The idle speed is controlled automatically by the engine control module through the idle air control (IAC) valve, therefore the idle speed cannot be adjusted.

6. Check that the idle speed is within the specified range.

Idle speed (transmission in neutral):800 ± 50 RPM

7. Remove the tachometer from the DLC IG-terminal.

8. Close the cover to the DLC.

9. Turn off the engine.

Engine Control/Fuel System > Engine Control System > Main Relay > Repair procedures

MAIN RELAY

Inspection of Terminal Voltage

1. Remove the cover from the main fuse block.

2. Place a finger on the main relay.

3. Verify that the relay clicks when the ignition switch is turned ON.

4. Verify that the main clicks when the ignition switch is turned OFF.

5. Remove the relay.

6. Apply battery voltage (B+) to terminal 86 and ground terminal 85 of the relay.

7. Check the continuity of the relay as shown.

Terminals B+ applied B+ not applied

30-87 Continuity No continuity

8. If not as specified, replace the main relay.

9. Turn ignition switch OFF.

10. Install the relay.

11. Replace the cover on the main fuse block.

Engine Control/Fuel System > Engine Control System > Fuel Pump Relay > Repair procedures

FUEL PUMP INSPECTION

Check Operation

The fuel system remains under pressure when the engine is not running. Release fuel system pressure before disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle components.

Listen for the fuel pump relay clicking as the ignition switch is turned ON.

Continuity Inspection

- Check continuity between relay terminals.

B+ : Battery positive voltage

Terminal 2-4 Terminal 5-(1 or 3)


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Apply B+ Yes

B+ not applied No

Engine Control/Fuel System > Engine Control System > Throttle Body > Repair procedures

Removal

Prior to removing the throttle body, check that the ignition switch is in the "OFF"position.

1. Drain the coolant.

2. Disconnect the connector for the throttle position sensor.

3. Loosen the clamp at the throttle body end of the air intake duct.

4. Remove the four breather hoses that join the intake duct.

5. Disconnect the MAF sensor electrical connector.

6. Loosen the clamp at the air cleaner assembly for the intake hose.

7. Remove the bolt holding the air intake hose bracket.

8. Remove the air intake hose assembly.

9. Remove the accelerator cable bracket bolts.

10. Disconnect the accelerator cable and move aside.

11. Disconnect the two coolant hoses from the throttle body.

12. Remove the two nuts and bolts holding the throttle body to the intake manifold.

13. Remove the throttle body.

14. Remove the throttle body gasket.

15. Clean the mating surfaces of the throttle body and the intake manifold.

Installation

1. Replace the throttle body gasket.

2. Connect the coolant lines and vacuum hoses to the throttle body.

3. Position the throttle body on the intake manifold.

4. Install and tighten the two nuts and bolts that hold the throttle body in place.

Tighten the nuts and bolts to 18 Ib-ft (25 N·m)

5. Connect the throttle position sensor electrical connector.

6. Connect the MAF sensor electrical connector.

7. Install the intake air hose assembly and tighten the hose clamps.

8. Connect the accelerator cable and install and tighten the two bolts for the accelerator cable bracket.

9. Verify that the throttle valve is fully closed and measure accelerator cable free play.

Free play should be 0.040-0.120 in (1.0 - 3.0 mm)

10. Install and tighten the two bolts for the air intake hose assembly.

11. Install the four hoses into the air duct.

12. Refill the radiator and check the coolant level.

Inspection

1. Check that the throttle plates do not bind or stick. Check for wear, deposits or coolant damage.

2. Check that the throttle valves move smoothly through their range of closed to fully opened.

3. Replace the throttle body with the throttle position sensor if necessary.

Engine Control/Fuel System > Engine Control System > Description and Operation

TROUBLESHOOTING WITH OBD-II DIAGNOSTIC TROUBLE CODES

RETRIEVING DIAGNOSTIC TROUBLE CODES

1. Connect the Kia Data Pro Scan Tool/Power Scan to the OBD-II DLC (Data Link Connector). The OBD-II DLC is located under the left side of the instrument panel, near the center console.

2. Start the engine.

3. Refer to the Kia Data Pro Scan Tool instruction manual and retrieve any DTCs (Diagnostic Trouble Codes).

4. Refer to Diagnostic Trouble Codes, page 21-22. Inspect and repair any applicable condition, as instructed.

5. When no further codes are presented, proceed to After Repair Procedure.

AFTER REPAIR PROCEDURE


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1. Cancel the memory of DTC’s by disconnecting the negative battery cable for at least twenty seconds. Reconnect the negative battery cable.

2. Locate the OBD-II DLC (Data Link Connector) and plug the Kia Data Pro Scan Tool/Power Scan into it.


4. Start and warm engine, by running it at 2,000 rpm for three minutes.

5. Verify that no DTC’s (diagnostic trouble codes) are recorded.

6. It DTC’s are recorded, refer to Diagnostic Trouble Codes, page 21-22.

Engine Control/Fuel System > Engine Control System > Troubleshooting

SYMPTOM DIAGNOSIS

USING THIS SECTION

Introduction

Most of the fuel and emission control system is electrically controlled, often making it difficult to diagnose problems in the system, especially intermittent problems. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer is often a good source of information on such problems, especially intermittent ones. Through talks with the customer, one can find out what the symptoms are and under what conditions they occur.

Work flow

Diagnostic Symptom Index

Symptom Diagnosis Charts

Description: Further describes the symptom. Confirm that the chart addresses the actual symptom before beginning troubleshooting.

Troubleshooting Hints: This describes the possible point of malfunction.

Step: This shows the order of troubleshooting. Proceed with troubleshooting as indicated.

Check: This describes an inspection to determine the malfunction of parts quickly.

Remedy: This recommends the appropriate action to take as a result (Yes/No) of the check.

DIAGNOSTIC SYMPTOM INDEX

No. TROUBLESHOOTING ITEM DESCRIPTION PAGE

1 Will not crank or cranks slowly Refer to Engine Electrical System Group 31

2

Cranks normally but will not start

No combustion Engine cranks at normal speed but shows no sign of tiring 21-104

3Partial combustion

Engine coldEngine cranks at normal speed but shows only partial combustion and will not continue to run 21-106

4Partial combustion

After warm-upEngine starts normally when cold, but will not start after running and hot soaked 21-108

5

Cranks normally but hard to start

Always Engine cranks at normal speed but requires excessive cranking time before starting 21-109

6 When engine is cold Same condition as No. 5 after running and cold; restarts normally after warm-up 21-110

7 After warm-up Same condition as No. 5 after running and hot starts normally when cold 21-111

8

Rough idle

(Low idle speed/engine stalls at idle)

Always Engine stalls or vibrates excessively at idle. 21-112

9 Before warm-up Engine stalls or vibrates excessively at idle during warm-up 21-113

10 After warm-up Engine runs normally at idle during warm-up but vibrates excessively or stalls after warm-up 21-114

11 When A/C ON Engine stalls or vibrates excessively at idle when A/C ON 21-115

12 Rough idle/engine stalls just after starting Engine stalls or vibrates excessively only just after starting (acceleration from idle) 21-116

13 High idle speed after warm-up Idle speed excessive after warm-up 21-117

14 Idle moves up and down/idle hunting Engine speeds up and down periodically at idle 21-118

15 Engine stalls on deceleration Engine unexpectedly stops running while decelerating or after deceleration 21-119

16 Engine stalls suddenly (intermittent) Engine intermittently stops running 21-120

17 Stumbles/hesitates on acceleration Flat spot occurs just after accelerator depressed or mild jerking occurs during acceleration 21-121

18 Surges while cruising Unexpected change in engine speed which is usually repetitive 21-122


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19 Lack of powerPerformance poor under load when throttle valve wide open

Maximum speed reduced21-123

20 Poor acceleration Performance poor while accelerating 21-124

21 Runs rough on deceleration/backfire Engine runs rough while decelerating and abnormal combustion occurs in exhaust system 21-127

22 Knocking Abnormal combustion accompanied by audible “pinging” noise 21-128

23 Fuel odor Gasoline odor in cabin 21-129

24 High oil consumption Oil consumption excessive 21-130

25 MIL always ON Kia Data Pro Scan Tool does not indicate Diagnostic Trouble Code but MIL always ON 21-131

26 MIL never ON Kia Data Pro Scan Tool indicates malfunction 21-131

27 A/C does not work Blower fan operates but magnetic clutch does not operate 21-131

Driveability Definitions

Stumble: Mild jerking during acceleration.

Hesitation: Delay in increase in engine speed occurring just after the accelerator pedal is depressed.

Surge: Continuous soft jerking during cruise.

Precautions for Symptom DiagnosisFuel System Pressure Release

THE FUEL SYSTEM REMAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING ANY FUEL LINE TO REDUCE THE CHANCE OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONENTS.

FUEL IS EXPLOSIVE. AN EMPTY FUEL TANK CAN STILL CONTAIN EXPLOSIVE GASES.

SUPPLY ADEQUATE VENTILATION TO THE WORK AREA. DO NOT SMOKE, AND KEEP SPARKS AND OPEN FLAMES AWAY.

TEFER TO GROUP 22, FUEL SYSTEM FOR FUEL SYSTEM PRESSURE RELEASE PROCEDURES.

SYMPTOM DIAGNOSIS CHARTS

2 Cranks normally, but will not start (no combustion)

Description

• Cranks normally, but no combustion

• Battery is OK

• Throttle valve closed while cranking

(Troubleshooting hint)

No fuel injection to engine because of fuel shortage or no ignition in all cylinders.

No spark

• Ignition control malfunction

• Malfunction of ignition system component

No fuel injection

• Malfunction of fuel pump

• Malfunction of injector

Low fuel pressure

Low engine compression pressure

Step Check Remedy

1 Check strong blue spark at each spark plug cord disconnected.Yes Go to step 5.

No Go to next step.

2 Check that malfunction indicator light is illuminated while ignition switch is ON. YesMalfunction indicator light is illuminated.

Check for causes. Refer to Troubleshooting with OBD-II Diagnostic Trouble Codes.

3

Check ignition system.

Check resistance of DLI coils.

Primary: Approx. 0.70Ω

Secondary: 12-13Ω

Check wiring harness between ECM and DLI coil.

Yes Go to next step.

No Replace ignition coils or repair wiring harness.

4

Check high tension cords.

Resistance: 16kΩ/m

Check for damage to high tension wire.


No Replace high tension wire.

5 Connect the data link connector terminals FUELPUMP and B+ with a jumper wire and check operational sound of fuel pump.Yes

Check that engine starts on this condition:

- Check fuel pump relay or wiring harness if engine starts.

- Go to step 7 if engine does not start.

No Go to next step.

6 Check that battery voltage is applied on G/Y wire of fuel pump connector when ignition switch is ON.Yes Check continuity of fuel pump (between G/Y and B).

No Check fuel pump relay.

7 Crank engine and check operational sound of injectorYes Go to step 10.

No Go to next step.

8 Check that battery voltage is applied on injector connector when ignition switch is ON.Yes Go to next step.

No Check wire between main relay and injector.

9 Check that the resistance of injector is 12Ω.Yes Go to next step.

No Replace injector.

10Connect the data link connector terminals FUEL PUMP and B+ with a jumper wire and check fuel line pressure while ignition switch is ON.

Fuel line pressure: 40-41 psi (285-259 kPa)


No

When pressure is low:

Plug fuel return hose and check fuel line pressure.

- Check fuel pressure regulator if pressure increases abruptly.

- Check clogging between fuel pump and fuel pressure regulator if pressure increases slowly.

- Check maximum pressure of fuel pump if not clogged.

When pressure is high:

Check clogging of fuel return hose.

- If normal: replace fuel pressure regulator.

- If not normal: repair or replace.

11 Check engine compression pressure. Yes Go to next step.


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Engine compression pressure: 163 psi-270 rpm No

Check engine condition:

- Wear of piston, piston ring and cylinder wall

- Defect of cylinder head gasket

- Deformation of cylinder head

- Improper valve clearance

- Valve stuck to guide

12

Check condition of all spark plugs.

• Spark plug gap: 0.032 inch (0.8mm)

• Excessive carbon deposit

• Contact with high tension cord


No Clean or replace.

13 Check crankshaft position sensor.Yes Go to next step.

No Check crankshaft position sensor and related wire harness.

14 Replace ECM and check for proper operation

3 Cranks normally, but won’t start (partial combustion)-When engine is cold

Description

• Cranks normally, but partial, not continuous, combustion occurs

• Battery is OK

• Fuel present in tank


Overrich air/fuel ratio

• Clogged air cleaner element

• Malfunction of mass air flow sensor

Overlean air/fuel ratio

• Incorrect fuel injection control (correction for engine coolant temperature)

• Low fuel line pressure

• Air leakage at intake system


Step Check Remedy

1 Check that malfunction indicator light is illuminated.Yes

Malfunction indicator light is illuminated.


No Go to next step.

2Disconnect spark plug.

Crank engine and check spark.


No Replace ignition coil or repair wiring harness.

3Connect the data link connecter terminals FUEL PUMP and B+ with a jumper wire and check fuel line pressure while ignition switch is ON.

Fuel line pressure: 40~41 psi (285-259 kPa)


No



- Check fuel pressure regulator if pressure increases abruptly

- Check clogging between fuel pump and fuel pressure regulator if pressure increases slowly

- Check maximum pressure of fuel pump if not clogged



- If normal: replace fuel pressure regulator

- If not normal: repair or replace

4 Does injector operate while cranking engine?Yes Go to next step.

No Check that battery voltage is applied on injector connector and check wire between main relay and injector.

5Check resistance of injector.

Resistance: 12Ω



6

Check condition of IAC valve.

Open circuit between IAC valve and ECM

Battery voltage is applied to B/W wire of IAC valve

IAC valve hose connection


No

Open circuit or incorrect voltage:

- Repair wiring harness

Incorrect IAC valve resistance:

- Replace IAC valve

7 Check terminal voltage of mass air flow sensor, throttle position sensor, ignition coils, engine coolant temperature sensor.Yes Go to next step.

No Check for causes.

8 Check contamination of sensor element inside mass air flow sensor.Yes Replace MAF sensor.

No Go to next step.

9 Check that engine starts when engine coolant temperature sensor connector is disconnected.Yes

Check engine coolant temperature sensor

- If normal: check wiring harness between engine coolant temperature sensor and ECM

- If not normal: replace engine coolant temperature sensor.

No Go to next step.

10 Check air leakage at intake system components.Yes Repair or replace.

No Go to next step.

11

Check engine compression pressure.

Engine compression pressure:

163 psi-270 rpm


No

Check engine condition:






12

Check condition of all spark plugs.

• Spark plug gap: 0.8mm

• Excessive carbon deposit

• Contact with high tension wire



13 Replace ECM and check for proper operation.

4 Cranks, normally, but won’t start (partial combustion)-After engine is warmed up

Description

• After engine is left hot after running, cranking speed is OK

• Battery is OK

• Engine starts normally when engine is cold



• Correction for coolant temperature

• Fuel leakage at injector

Vapor lock occurs

• Fuel pressure is not kept when engine stops

Step Check Remedy

1Warm up engine to normal operating temperature and stop engine. Connect the data link connector terminals FUEL PUMP and B+ with a jumper wire for 3 minutes while ignition switch is ON. Then check that

engine starts.

Yes Replace fuel with another brand.

No Go to step 3.

2 Remove vacuum hose from pressure regulator and check that engine starts.Yes Check fuel pressure regulator.

No Go to next step.

3 Connect the data link connecter terminals FUEL PUMP and B+ with a jumper wire and check fuel line pressure while ignition switch is ON. Yes Go to next step.


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Fuel line pressure: 40~41 psi (285-259 kPa) No










4Check that fuel pressure is kept while ignition switch is OFF on the same condition as step2.

Fuel line pressure: 19psi min. for 5 minutes

Yes Go to step 6.

No Go to next step.

5 Plug fuel pressure regulator outlet and check that fuel pressure is kept while ignition switch is OFFFuel line pressure: 21psi min. for 5 minutes

Yes Replace fuel pressure regulator.

No

Check fuel pump pressure is kept.


- If not normal: replace engine coolant temperature sensor

6 Check that engine starts when engine coolant temperature sensor connector is disconnected.Yes

Check engine coolant temperature sensor.


- If not normal: replace engine coolant temperature sensor.

No Go to next step.

7 Check that malfunction indicator light is illuminated.Yes



No Go to next step.


No Go to next step.


5 Cranks normally, but hard to start - Always

Description

• Cranks normally, but cranking time up to starting is excessively long

• Battery is OK

• Engine runs normal while engine is idling (Refer to “Rough Idling” if not in good idling condition)



• Incorrect fuel injection control (correction for engine coolant temperature)


• Air leakage at intake system


• Clogged air cleaner element


Spark plugs not in good condition

Step Check Remedy

1 Check that malfunction indicator light is illuminated while ignition switch is ON.Yes



No Go to next step.

2Check vacuum in intake manifold while engine is idling.

Vacuum: more than 17.7 in.Hg (450 mmHg)


No Check air leakage at intake system.

3 Check cleanness of air cleaner element.Yes Go to next step.

No Check air leakage at intake system.

4 Check if engine starts easily when throttle valve quarter open.Yes Check carbon deposit on throttle valve and go to step 6.

No Go to next step.

5Check fuel line pressure while engine is idling.

Fuel line pressure: 40~41 psi (285-295 kPa).


No





6 Check terminal voltage of mass air flow sensor, throttle position sensor, ignition coil, engine coolant temperature sensor.Yes Go to next step.


7 Connect fuel pump check connector by jumper wire while ignition switch is ON and check that engine starts while fuel pump operates.Yes

Check fuel pump relay.

- If normal, repair or replace wiring harness.

- If not normal, replace relay.

No Go to next step.

8 Check contamination of sensor inside mass air flow sensor.Yes Clean or replace.

No Go to next step.

9



163 psi-270 rpm


No

Check engine condition.






10

Check spark plug condition.

Spark plug gap: 032 in (0.8mm)

Excessive carbon deposit

Contact with high tension cord




6 Cranks normally, but hard to start - When engine is cold

Description

• Cranks normally, but cranking time up to starting is excessively long

• Battery is OK

• Restart is normal after engine warmed up

• Engine is normal while engine is idling (Refer to “Rough Idling” if not in good idling condition)




• Overlean air/fuel ratio

• Contaminated air cleaner element

• Malfunction of idle speed control


• Malfunction of injection control (Correction for engine coolant temperature)

EGR solenoid valve

• Solenoid valve stuck

EGR control valve

• EGR control valve stuck

Step Check Remedy

1 Check that malfunction indicator light is illuminated while ignition switch is ON. YesMalfunction indicator light is illuminated.



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No Go to next step.



3 Check if engine starts easily when throttle valve quarter open.Yes Check carbon deposit on throttle valve and go to step 6.

No Go to next step.


Vacuum: more then 17.7 in.Hg (450 mmHg)


No Check air leakage at intake air system component.


No Replace air cleaner element.

6Connect the data link connector terminals FUEL PUMP and B+ with a jumper wire and check fuel line pressure while ignition switch is ON.



No










7 Replace ECM and check for proper operation.Yes Replace the ECM.

No Replace fuel with another brand.

7 Cranks normally, but hard to start – After engine is warmed up

Description

• After engine is left hot after running, cranks normally, but cranking time up to starting is excessively long

• Battery is OK

• Starts normally when engine is cold

• Engine is normal while engine is idling (Refer to “Rough Idling” if not in good idling condition)



• Malfunction of fuel ignition control

• Fuel leakage from injector

Vapor lock


Step Check Remedy




No Go to next step.



3

After engine idling and turn ignition switch OFF.

Check that fuel line pressure is kept

Fuel line pressure: more than 22psi for 5 minutes


No

Plug outlet of fuel pressure regulator and turn ignition switch OFF. Then check that fuel line pressure is kept.

- If normal: replace fuel pressure regulator

- If not normal: check if fuel pump pressure kept.

If fuel pump is normal, check fuel leakage from injector.

4Warm up engine to normal operating temperature and stop engine. Connect the data link connector terminals FUEL PUMP and B+ with a jumper wire for 3 minutes while ignition switch is ON. Then check that

engine starts easily.

Yes Replace fuel with another brand.

No Go to next step.



8 Rough idling / Engine stops while idling - Always

Description • Engine starts normally, but engine stops or vibrates while idling.



• Air leakage

• Malfunction of fuel injection control


Clogging or malfunction of one or more injectors

Malfunction of mass air flow sensor

Malfunction of IAC valve

Malfunction of spark plug


Malfunction of throttle position sensor or related wiring harness

Step Check Remedy




No Go to next step.



3 Check operating sound of injector while engine idling.Yes Go to step 5.

No Go to next step.

4 Check that approx. battery voltage is applied on injector connector while ignition switch is ON.Yes Go to next step.

No Check the wiring harness between ECM and injector.

5Check the resistance of injector.

Resistance: 12Ω



6 Check that voltage of throttle position sensor terminal (Y/B wire) is 0.3-0.7v and does not vary.Yes Go to next step.

No Replace throttle position sensor or wiring harness.

7 Check if sensor element inside mass air flow sensor is contaminated.Yes Clean or replace.

No Go to next step.

8



163psi - 270 rpm


No







9 Rough idling / Engine stops while engine is idling - Engine cold

Description • Engine speed is slow, engine stops or vibrates while warming up engine.


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Insufficient intake air


• Clogged air cleaner

• Malfunction of IAC valve

Malfunction of fuel injection control.

• Malfunction of fuel injection control devices

(Correction for engine coolant temperature)

Step Check Remedy




No Go to next step.

2Check air leakage at intake system and vacuum of dynamic chamber while engine is idling.

Vacuum: 17.7in.Hg (450 mmHg)


No Check air leakage at intake system component.



4 Check terminal voltage of mass air flow sensor, throttle position, ignition coils, engine coolant temperature sensor.Yes Go to next step.


5

Check resistance of engine coolant temperature sensor.

• At -4°F (-20°C) resistance should be 14.6 to 17.8kΩ

• At 68°F (20°C) resistance should be 2.2 to 2.78kΩ

• At 176°F (80°C) resistance should be 0.29 to 0.358kΩ


No Replace the engine coolant temperature sensor.



10 Rough idling / Engine stops while engine is idling - After engine is warmed up

Description • Engine operation is normal while warming up engine, but engine stops or vibrates after warming up.


Malfunction of IAC


• Air leakage


Malfunction of ignition system



(correction for coolant temperature)


Step Check Remedy




No Go to next step.



3Check vacuum of intake manifold.

Vacuum: more than 17.7in.Hg (450 mmHg)


No Check for air leakage at intake system component.

4 Check cleanliness of air cleaner element.Yes Go to next step.

No Replace air cleaner.

5

Check fuel line pressure while engine is idling.

Fuel line pressure: 40~41psi (285-295 kPa)

(when disconnecting vacuum hose from pressure regulator)


No






6 Disconnect engine coolant temperature sensor connector and check that engine condition improves.Yes Replace the engine coolant temperature sensor.

No Go to next step.

7 Check operating sound of injector while engine is idling.Yes Go to step 10.

No Go to next step.

8Check resistance of injector

Resistance: 12Ω



9



163 psi-270 rpm


No Check the engine.


11 Rough idling / Engine stops while engine is idling - When A/C is in operation

Description• Engine stops or vibrates excessively when A/C is operating

• Idling condition is normal when A/C is turned OFF


Malfunction of IAC control system

Malfunction of A/C operational switch

Step Check Remedy




No Go to next step.

2 Check air conditioner cut relay is ON/OFF when air conditioner switch is ON/OFF.Yes Go to next step.

No Malfunction of air conditioner switch or air conditioner cut relay.

3 Is there continuity between pin No. 64 and of ECM?Yes Repair the wiring harness.

No Go to next step.


12 Abnormal idling / Engine stops immediately after starting

Description• Starting is normal, but engine vibrates excessively or stops immediately after starting (when accelerating from idling condition)

• Idling condition is normal on other conditions.


Malfunction of IAC system

Air leakage at intake

Malfunction of mass air flow sensor

Step Check Remedy


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No Go to next step.

2Is mass air flow sensor normal?

(Page 21-143).


No Repair mass air flow sensor or related wiring harness.

3 Check that voltage of throttle position sensor terminal (Y/B wire) is 0.3-0.7V and does not vary.Yes Go to next step.

No Replace throttle position sensor or wiring harness.

4Check for air leakage at intake system and vacuum of dynamic chamber while engine is idling.



No Check intake system and dynamic chamber.


13 High idle speed after engine warmed up

Description • Excessively high idle speed after engine warmed up


Excessive intake air flow

Throttle valve not closed completely

Malfunction of idle speed control

• IAC valve

• IAC valve connector disconnected

• Incorrect input signal from coolant temperature sensor

Step Check Remedy

1 Check that throttle valve is closed completely when accelerator pedal is released.Yes Go to next step.

No Check correct installation and free operation of throttle linkage. If not normal, clean or adjust linkage.




No Go to next step.

3 Disconnect engine coolant temperature senor connector and check that engine condition improves.Yes Replace engine coolant temperature sensor.

No Go to next step.

4 Plug PCV hose connected to the intake manifold and check engine speed decrease.Yes Check or replace the PCV valve.

No Go to next step.

5 Check that voltage of throttle position sensor terminal (Y/B wire) is 0.3-0.7V and does not vary.Yes Replace throttle position sensor or wiring harness.

No Go to next step.

6 Check ECM terminal voltage.Yes Go to next step.



14 Variation of idle speed / Idle hunting

Description • Periodic engine speed increase and decrease while engine is idling


Periodic engine speed increase and decrease while engine is idling

Air leakage


Fuel injection is irregular

Malfunction of ignition system

Step Check Remedy




No Go to next step.

2 Check that voltage of throttle position sensor terminal (Y/B wire) is 0.3-0.7V and does not vary.Yes Go to next step.

No Replace throttle position sensor wiring harness.

3 Check air cleaner element.Yes Go to next step.


4 Disconnect high tension wire and check equal engine speed decrease in all cylinders.Yes Go to next step.

No Go to step 7.

5 Check ECM terminal voltage.Yes Go to next step.


6Check mass air flow sensor.

(Page 21-129).

Yes Go to step 12.

No Replace the mass air flow sensor.

7 Check operating sound of injector while engine is idling.Yes Go to step 9.

No Go to next step.

8 Check that approx. battery voltage is applied on injector connector wire.Yes Go to next step.

No Check the wiring harness between ECM and injector.

9Check resistance of injector.

Resistance: 12Ω



10 Check spark plugs for proper operation.Yes Go to next step.


11



163 psi-270 rpm


No Check for cause.

12 Check for fuel leakage from injector.Yes Replace the injector.

No Go to next step.


15 Engine stalls on deceleration

Description• Engine stops unexpectedly during or after deceleration

• Idling condition is normal


Engine speed decreases abruptly when accelerator pedal is released, which can cause connectors to come loose.

Malfunction of idle air control

Malfunction of throttle position sensor system

Malfunction of fuel cut control

Step Check Remedy




No Go to next step.

2 Check throttle position sensor. IAC valve terminal voltage and related wiring harness. Yes Go to next step.


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No Repair the wiring harness or check unit part.

3 Check ECM terminal voltages for C211-2, C211-29, C211-59, C211-71 and C211-73. (Page 21-17).Yes Go to next step.

No Check for cause and repair.

4Check contact condition of the following connectors:

- Throttle position sensor, mass air flow sensor, ignition coils, injector, crankshaft position sensor, fuel pump relay, ECM.


No Repair or replace.


16 Engine stalls suddenly (Intermittent), sudden engine stop

Description• Engine stops suddenly and intermittently

• Engine is normal until engine stops



Malfunction of throttle position sensor system

Intermittently loosened contact of electrical wiring harness

Step Check Remedy




No Go to next step.

2Check contact condition of the following connectors:

- Throttle position sensor, mass air flow sensor, ignition coils, injector, crankshaft position sensor, fuel pump relay, ECM.

Yes Repair or replace.

No Go to next step.

3 Measure crankshaft position sensor and mass air flow sensor signals and check that normal signals are detected.Yes Go to next step.

No Check for cause and repair.

4 Check ECM terminal voltages for C211-16, C211-41, C211-43, C211-59, C211-71 and C211-73. (Page 21-17).Yes Go to next step.

No Check for causes and repair.


17 Stumble / Hesitation on acceleration

Description • Vehicle seems to stop for a time immediately after pressing accelerator or rattles a little during acceleration


Lean air/fuel ration on


• Air leakage


Step Check Remedy




No Go to next step.

2Check vacuum in intake manifold while engine idling.

Vacuum: more than 17.7 in-Hg (450 mmHg)


No Check air leakage at air intake system and repair.



4Check mass air flow sensor.

- Internal resistance, voltage, contamination of sensor element etc.



5 Check engine coolant temperature sensor.Yes Go to next step.

No Replace the engine coolant temperature sensor.

6

Check throttle position sensor.

Voltage between terminals:

Idling condition: 1V maximum

Throttle valve full open: about 4V


No Replace the throttle position sensor.

7 Disconnect injector connector one by one while engine is idling, and check equal engine speed decrease for each cylinder.Yes Go to next step.

No Check injector. Refer to Fuel System, Section 22.

8 Check correct installation and free operation of throttle linkage.Yes Go to next step.

No Adjust or replace joint or damaged linkage and adjust deflection of throttle cable.

9 Check fuel line pressure while engine is idling.


No


Plug fuel return hose and check fuel line pressure




10 Check air passage and vacuum hose installation.Yes Go to next step.

No Repair.

11 Check exhaust system clogging.Yes Repair or replace.

No Go to next step.


18 Repeated engine speed variation occurs at all times

Description •


Malfunction of throttle position system

Misfire

Loose contact of wiring harness

Lean air/fuel ration

Step Check Remedy




No Go to next step.

2 Check vacuum in intake manifold while engine idling.Yes Go to next step.

No Check air leakage at air intake system and repair.

3

Check throttle position sensor



Throttle valve full open: approx. 4V



4 Disconnect front heated oxygen sensor connector and check for proper operationYes Replace the front heated oxygen sensor.

No Go to next step.

5Check that vehicle speed sensor signal input to ECM is normal.

- ECM terminal No.42


No Replace the wiring harness or vehicle speed sensor.

6 Check ECM terminal voltages for C211-42, C211-59, C211-71 and C211-73 (page 21-17).Yes Go to next step.

No Check for causes and repair.


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7 Check correct installation and free operation of throttle linkage.Yes Go to next step.

No Adjust or replace joint or damaged linkage and adjust deflection of throttle body cable.

8 Check cleanliness of air cleaner element.Yes Replace air cleaner element (dry type).

No Go to next step.


Fuel line pressure: 40-41psi (285-259 kPa)


No


Plug fuel return hose and check fuel line pressure




10 Check exhaust system clogging.Yes Repair.

No Go to next step.


19 Lac of power

Description

• Lack of power at full throttle

• Lower maximum vehicle speed

• Idling speed is normal



• Throttle valve does not open fully

• Clogged intake air system

Lean air/fuel ratio

• Fuel line pressure decrease.

• Malfunction of fuel injection.

Malfunction of ignition


Step Check Remedy

1

Check the following items.

- Clutch slippage

- Brake dragging

- Lack of tire air pressure

- Improper tire size

Yes Go to next step if normal.

No Repair.

2 Is throttle valve open fully when depressing accelerator pedal fully?Yes Go to step 5.

No Go to next step.

3 Check EGR control valve operation while engine is idling.Yes Go to next step.

No Check the EGR solenoid valve.

4 Check correct installation of throttle cableYes Go to next step.

No Replace or replace throttle body.

5 Check correct operation of throttle body.Yes Go to next step.

No Repair or replace throttle body.




No Go to next step.

7 Check the camshaft position sensor.Yes Go to next step.

No Check camshaft position sensor and related wire harness.

8










No Repair intake system and dynamic chamber.

10 Disconnect injector connector one by one while engine is idling, and check equal engine speed decrease for each cylinder.Yes Go to next step.

No Check injector. Refer to Fuel System, section 22.



12

Keep engine idling and turn ignition switch OFF.

Check that fuel line pressure is kept.

Fuel line pressure: more than 21 psi for 5 minutes


No

Plug outlet of pressure regulator and turn ignition switch OFF. Then check that fuel line pressure is kept.

- If normal: replace pressure regulator.

- If not normal: check fuel pump pressure kept.

If fuel pump is normal, check fuel leakage from injector.

13Does fuel line pressure increase when accelerating abruptly?

Fuel line pressure: 40~41 psi (285-295 kPa)


No Check fuel line and fuel fitter clogging and repair if not normal.

14

Check mass air flow sensor.

- Internal resistance, contamination of sensor element, etc.

- Measure output voltage

• 1.5V when idling

• 5V when open fully


No Replace mass air flow sensor.

15


- Check resistance of DLI coil


Secondary: 12 - 13Ω

- Check wiring harness between DLI coil and ECM



16 Check high tension wires.Yes Go to next step.

No Replace high tension wires.

17 Check spark plug.Yes Go to next step.


18Check engine compression pressure.

Engine compression pressure: 163 psi - 270 rpm


No






- Vale guide stuck



20 Poor acceleration / Lack of power

Description

• Lack of power on acceleration

• Lack of power at full throttle

• Lower maximum vehicle speed

• Idling speed is normal


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Clutch slippage

• Clutch slippage

• Brake dragging

• Lack of tire air pressure

• Improper tire size

• Overload


• Throttle valve does not open fully

• Intake system clogging

Overlean air/fuel ratio

Malfunction of ignition


Step Check Remedy

1

Are the following factors OK?

- Clutch slippage

- Brake dragging

- Lack of tire air pressure

- Improper tire size

- Overload


No Repair.


No Go to next step.

3 Check correct installation of throttle cable.Yes Go to next step.

No Repair or replace throttle cable.

4 Check correct operation of throttle body.Yes Go to next step.


5 Check EGR valve operation while engine is idling.Yes Go to next step.

No Check the EGR solenoid valve.




No Go to next step.

7 Check camshaft position sensor and connector.Yes Go to next step.


8






No Replace throttle valve.




No Check air leakage at intake system and repair.

10 Disconnect injector connector one by one while engine is idling, Is there an equal engine speed decrease for each cylinder.Yes Go to next step.

No Check injector. Refer to Fuel System, section 22.



12

Check fuel line pressure while engine is idling.


(When disconnecting vacuum hose from pressure

regulator)


No





Check maximum pressure of fuel pump if not clogged.

13Does fuel line pressure increase when accelerating abruptly.

Fuel line pressure: approx. 42 psi


No Check fuel line and fuel fitter clogging and repair if not normal.

14


- Internal resistance, contamination of sensor element, etc.


• when idling: 1.5V

• when open fully: 5V



15


- Check resistance of DLI coil


Secondary: 12 - 13Ω

- Check wiring harness between DLI coil and ECM



16 Check high tension cords.Yes Go to next step.

No Replace high tension cord.

17

Check spark plug.

- Spark plug gap: 0.8mm

- Excessive carbon deposit

- Contact with high tension cord



18Check engine compression pressure.

Engine compression pressure: 163 psi - 270 rpm


No









21 Rough engine running on deceleration / Backfire

Description• Rough engine running on deceleration and backfire

• Transmission is normal



• Air cleaner element clogged

• Malfunction of fuel injection system

(fuel cut control)


• Malfunction of throttle position sensor

Step Check Remedy




No Go to next step.

2Check vacuum in intake manifold while engine idling.

Vacuum: more than 450 mmHg


No Check air leakage at air intake system


No Check cleanliness of air cleaner element.


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4 Check ECM terminal voltages for C211-14, C211-41, C211-59, C211-71 and C211-73. (Page 21-17).Yes Go to next step.

No Check for cause.

5Check fuel injection system.

(Section 22).


No Repair or replace fuel injection system.

6


- Internal resistance, voltage, contamination of sensor element, etc.


• when idling: 1.5V

• when open fully: 5V



7


- Voltage between terminals

• When idling: 0.3 ~ 0.7V

• When opening throttle valve fully: approx. 4V

- Check that idling voltage returns to specified value when releasing after pulling accelerator cable.



8 Check throttle body contamination.Yes Clean or replace.

No Go to next step.

9 Check fuel leakage from injector.Yes Clean or replace.

No Replace.


22 Knocking

Description • Abnormal combustion occurs, accompanied by audible “pinging” noise


Improper ignition timing

Carbon deposit in cylinder

Engine overheat

Overlean air/fuel ration

• Incorrect fuel injection

• Fuel line pressure decrease on acceleration

Step Check Remedy




No Go to next step.


No Go to next step.

3 Check correct installation of throttle cable.Yes Go to next step.

No Repair or replace throttle cable.

4 Check correct installation of throttle body.Yes Go to next step.


5



163psi - 270 rpm


No







6 Check camshaft position sensor.Yes Go to next step.



Fuel line pressure: 42 psi


No





Check maximum pressure of fuel pump if not clogged.

8 Check cooling system.Yes Go to next step.

No Repair or replace components.



23 Fuel odor

Description • Fuel odor in passenger compartment


Loose connection of fuel system or evaporative gas control system

Malfunction of evaporative gas control system

Step Check Remedy

1 Check damage or leakage of fuel system or evaporative gas control system.Yes Repair or replace.

No Go to next step.




No Go to next step.

3Warm up engine fully. After disconnecting vacuum hose from evaporative emissions canister to purge solenoid valve,

check that vacuum is applied to it.

Yes Go to step 6.

No Go to next step.

4 Check operational sound of purge solenoid valve is normal.Yes Check vacuum hose clogging.

No Go to next step.

5 Check that vacuum is applied to vacuum hose after applying battery voltage to purge solenoidYes Check ECM terminal voltage.

No Replace purge solenoid valve.


24 High oil consumption

Description • High oil consumption


Malfunction of PCV valve

Malfunction of engine (oil leakage)

Step Check Remedy

1 Check damage, removal, clogging or sticking of PCV hose, nipples of ventilation hoseYes Repair or replace.

No Go to next step.

2 Check that there is air pressure or oil in ventilation hose. Yes Go to next step.


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No Check engine condition.

- Oil leakage

- Wear of valve seal

- Wear of valve stem

- Wear of valve guide

3 Check vacuum is applied on PCV valve while engine is idling.Yes


- Wear of piston ring groove

- Malfunction of piston ring

- Wear of piston or cylinder

No Replace the PCV valve.

25 MIL light ON continuously

Description • Kia Data Pro Scan Tool does not display malfunction code, but MIL light on continuously


Short circuit of wiring harness

Malfunction of ECM

Step Check Remedy

1 Disconnect wire (L/W) from ECM and check that MIL remains illuminated.Yes Replace the ECM.

No Check short circuit from meter set to ECM.

26 MIL does not light

Description • Kia Data Pro Scan Tool displays malfunction code, but MIL does not illuminate


Bulb is blown

Open circuit

Malfunction of ECM

Step Check Remedy

1 Check bulb is OK.Yes Go to next step.

No Replace bulb.

2 Ground ECM wire (L/W) with a jumper wire and check that MIL illuminates.Yes Go to next step.

No Repair wiring harness from ECM to meter set.

3 Check that ECM connection is OK.Yes Replace ECM

No Repair or replace ECM connector.

27 Air conditioner does not operate

Description • Blower motor operates, but magnetic clutch not engaged


Short or open circuit of wiring harness

Malfunction of air conditioner relay, air conditioner switch, magnetic switch

Malfunction of ECM

Step Check Remedy

1 Check voltage of ECM terminal No. 64.Yes

Check voltage of ECM terminal No. 65.

- If normal, check air conditioner system.

- If not normal, replace the ECM.


Engine Control/Fuel System > Engine Control System > Repair procedures

Removal

1. Remove wire connector from sensor.

2. Loosen and remove fasteners, remove sensor.

Installation

1. Place sensor in position (note that the sensor is directional and must be installed with the connector facing to the rear).

2. Install nuts and tighten.


INSPECTION

1. With the component connector still connected, connect a voltmeter between terminal 3 (BLU/GRN) and ground.


3. Tap the chassis acceleration sensor bracket with a wrench.

4. Verify that a voltage spike (less than 1V) is output from the chassis acceleration sensor.

5. If no voltage spike is observed, replace the chassis acceleration sensor.

Engine Control/Fuel System > Fuel Delivery System > General Information

SYSTEM CHECKS

Fuel Pressure Hold Inspection

1. Disconnect the negative battery terminal.


1. Release fuel system pressure. Refer to? eleasing Fuel System Pressure?in this section.

2. Install a fuel pressure gauge to the pressure port located on the front of the fuel rail.


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3. Connect the negative battery terminal.

4. Connect the data link connector terminals FUEL PUMP and B+ with a jumper wire.

5. Turn the ignition switch on for 10 seconds to run the fuel pump.

6. Turn the ignition switch off and remove the jumper wire.

7. Check fuel pressure after 5 minutes.

Fuel pressure: More than 21psi (150 kPa)

8. If not as noted, do the following inspections:

A. Fuel pump hold pressure.

B. Pressure regulator hold pressure.

C. Injector fuel leakage.

Fuel Line Pressure Inspection1. Disconnect the negative battery cable.

2. Release fuel system pressure. Refer to ?eleasing Fuel System Pressure?in this section.

3. Install a fuel pressure gauge to the pressure port Iocated on the front of the fuel rail.

4. Connect the negative battery cable.


6. Turn the ignition switch on for 10 seconds.

7. Check fuel line pressure.

Fuel line pressure: 42 psi (292.5 kPa)


9. If not as noted, do the following inspections:

A. Fuel pump maximum pressure.

B. Fuel line clogging and restriction.

C. Fuel filter clogging and restriction.

D. Pressure regulator hold pressure.

Engine Control/Fuel System > Fuel Delivery System > Fuel Tank > Repair procedures

Removal

Fuel is explosive. An empty fuel tank can still contain explosive gases. Supply adequate ventilation to the work area. Do not smoke and keep sparks and open flames away. Purge fumes from the tank as soon as possible.

1. Disconnect the negative terminal from the battery.

2. Open the rear access door of the vehicle.

3. Release the catch for the rear seat and tilt it out of the way.

4. Pull back the square of carpet in the area behind the tilted seat which covers the fuel pump assembly access panel on the vehicle floor.

5. Disconnect the two halves of the fuel pump assembly electrical connector.

6. Remove the screw holding the ground wire lug to ground.

7. Remove the four screws attaching the access cover and remove the access cover, moving it out of the way.

8. Remove two fuel hose clamps from the two fuel hose assemblies connected to the fuel pump assembly.

9. Disconnect the two fuel hose assemblies from the fuel pump assembly.

10. Disconnect fuel tank pressure sensor electrical connector.

11. Working through the access port, remove the three fuel hose clamps from where the three fuel hoses are connected to the fuel tank.

12. Disconnect the three fuel hoses from the nozzles on the fuel tank.


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13. Loosen the inlet hose assembly joint clamp.

14. Remove filler pipe and inlet joint hose.

15. Raise the vehicle on a hydraulic lift to the normal undercarriage servicing level.

16. Using a lifting device, raise the lifting device to the bottom of the fuel tank in the vehicle. Center the lifting device on the fuel tank/shield assembly.

17. Remove five 15 mm bolts from the fuel tank/shield assembly.

18. Carefully pull the fuel tank/shield assembly away from the chassis of the vehicle and allow the assembly to rest on the lifting device.

19. Lower the lifting device and place the fuel tank/ shield assembly on a work bench area.

Cover the open ports on the fuel tank with plastic caps or other available covers to avoid fuel vapor contaminating the work area.

20. Separate the fuel tank from the shield by removing two attaching bolts. Lift the fuel tank away from the shield and store the shield.

Removal(FUEL TANK SENDER)

Fuel is explosive. When working on fuel system parts, make sure to supply adequate ventilation to the work area. Do not smoke, and keep sparks and open flames away.



3. Release the catch for the back seat and tilt it out of the way.





8. Remove the two fuel hose clamps from the two fuel hoses connected to the fuel pump assembly.

9. Disconnect the two fuel hoses from the fuel pump assembly.

Do not force fuel pump assembly parts. The fuel screen is delicate and can be damaged by improper removal from the fuel tank.


11. Remove eight retaining screws around the top surface of the fuel pump assembly.

12. While twisting very carefully and tilting the fuel pump assembly, pull gradually on the fuel pump assembly until it comes out of the top of the fuel tank assembly.

13. When the fuel pump assembly is completely taken out of the access area, wrap it in a shop towel carefully until it reaches the maintenance area.

14. Seal off the open fuel tank port with a cover or plug.

15. Remove retaining hardware that holds the fuel tank sender assembly to the fuel pump assembly.

Installation

Fuel is explosive. An empty fuel tank can still contain explosive gases. Supply adequate ventilation to the work area. Do not smoke and keep sparks and open flames away. Purge fumes from the tank as soon as possible.

1. Raise the vehicle on a hydraulic lift to the normal undercarriage servicing level.

2. Attach the shield to the fuel tank using two attaching bolts.

3. Ensure any protective caps are removed from the fuel tank ports.

4. Place the fuel tank on a lifting device and carefully raise the fuel tank assembly under the raised vehicle until the assembly is positioned at the point of installation.

5. Install five 15 mm bolts to fasten the fuel tank/shield assembly into place on the vehicle chassis.


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6. Lower the vehicle to ground level.

7. Install the inlet hose assembly joint clamp.

8. Connect two hoses to the fuel pump assembly.

9. Install two fuel hose clamps to the point where the fuel hoses are connected to the inlet ports on the fuel tank.

Push the ends eveaporative hose onto the fuel tank fitting at least 1.0 inch (25mm). Push the fuel filler hoses onto the fuel tank pipes and filler pipes at least 1.4 inch (35mm).

10. Connect fuel tank pressure sensor electrical connector.

11. Insert the grouding line and the fuel pump assembly electrical connector wiring through the access hole in the access panel.

12. Attach the four screws to attach the access cover to the top of the access area over the fuel pump assembly mounted in the fuel tank.

13. Attach the ground wire lug to chassis ground using the attaching screw.

14. Connect the two halves of the fuel pump assembly electrical connector.

15. Position the wiring into place using an adhesive strip and place the square of carpeting back over the access area on the vehicle flooring.

16. Release the catch for the rear seat and bring it back to the normal position.

17. Close the rear access door of the vehicle.

18. Connect the negative terminal to the battery.

Installation

Fuel is explosive. When working on fuel system parts, make sure to supply adequate ventilation to the work area. Do not smoke and keep sparks and open flames away.

1. Install the retaining hardware that holds the fuel sender assembly to the fuel pump assembly.

2. Remove any cap or protective cover from the port on the top of the fuel tank.

3. Holding the assembled fuel pump/fuel sender assembly, guide it into the access port on the top of the fuel tank as far as it will go.


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Do not force fuel pump assembly parts. The fuel screen is delicate, and can be damaged by improper installation to the fuel tank.

4. While twisting very carefully and tilting the fuel pump assembly, push gradually on the assembly until it goes in position in the fuel tank assembly.

5. Install eight screws around the top surface of the fuel pump assembly.

6. Connect the two fuel hoses assemblies to the fuel pump assembly.

7. Install the two fuel hose clamps to the two fuel hoses connected to the fuel pump assembly.


9. Insert the ground wire and the fuel pump electrical connector wires through the access hole in the access door and mount it over the access hole.

10. Install four screws to secure the access door to the vehicle flooring.

11. Install the ground wire lug to the floor with the attaching screw.


13. Attach adhesive tape to any loose wiring and cover the area of the installed access door with the square of carpeting.

14. Release the catch for the rear seat and put it in the normal position.



Engine Control/Fuel System > Fuel Delivery System > Fuel Pump > Repair procedures

Removal





4. Pull back the square of carpet in the area behind the tilted seat which covers the fuel pump assembly access panel on vehicle floor.




8. Remove the two fuel hose clamps from the two fuel hose assemblies connected to fuel pump assembly.

Do not use any excessive force on the fuel pump assembly. The parts are delicate, such as the fuel screen which might be damaged by incorrect removal from the fuel tank.



3. While twisting very carefully and tilting the fuel pump assembly, pull gradually until it comes out of the top of the fuel tank assembly.



Removal(Fuel pump filter)





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8. Remove the two fuel hose clamps from the two fuel hose assemblies connected to the fuel pump assembly.

Do not force fuel pump assembly parts. The fuel screen is delicate and can be damaged by improper removal from the fuel tank.




12. While twisting very carefully and tilting the fuel pump assembly, pull gradually on the assembly until it comes out of the top of the fuel tank.



15. Remove the circular retaining clip at the end of the fuel pump to allow the fuel filter (screen) to separate from the fuel pump assembly.

Removal









8. Remove the two fuel hose clamps from the two fuel hoses connected to the fuel pump assembly.


Do not use any excessive force on the fuel pump assembly. The parts are delicate, such as the fuel screen which might be damaged by incorrect removal from the fuel tank.



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12. While twisting very carefully and tilting the fuel pump assembly, pull gradually on the fuel pump assembly until it comes out of the top of the fuel tank assembly



15. Remove four retaining screws which hold the fuel pump plastic retaining bracket to the fuel pump assembly frame.

16. Take off the retaining clamp from the fuel hose and disconnect the fuel hose from the fuel pump.

17. Take off the fuel pump retaining plastic mounting bracket as necessary.

18. Remove fuel tank pressure sensor.

Installation


Do not force fuel/ pump assembly parts. The fuel/ screen is delicate and can be damaged by improper installation to the fuel tank


2. Holding the fuel pump assembly, guide it into the access port on the top of the fuel tank as far as it will go at that point.

3. While twisting very carefully, and tilting the fuel pump assembly, push gradually until the assembly seats in the fuel tank correctly.

4. Install eight retaining screws around the top of the installed fuel pump assembly.

5. Connect the two fuel hoses to the fuel pump assembly.

6. Install the two fuel hose clamps to the two fuel assemblies connected to the fuel pump assembly.

7. Insert the ground wire in the fuel pump assembly connector assembly through the access hole in the access cover.

8. Install the four retaining screws attaching the access cover to the flooring of the vehicle.

9. Attach the ground wire lug to the flooring of the vehicle with the attaching screw.


11. Place the adhesive tape over the loose wiring and put the square of carpeting back over the area of the access door behind the rear seat.

12. Release the catch for the rear seat and tilt it back into the normal position.



Installation


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2. Install the circular retaining clip at the end of the fuel pump to hold the fuel filter (screen) to the fuel pump assembly. The fuel pump assembly is now ready to install.


Do not force fuel pump assembly parts. The fuel screen is delicate and can be damaged by improper removal from the tank.

4. While twisting very carefully, and tilting the fuel pump assembly, push gradually until the assembly seats in the fuel tank correctly.

5. Install eight retaining screws around the top surface of the fuel pump assembly.




9. Insert the ground wire in the fuel pump assembly connector assembly through the access hole in the access cover.

10. Install the four retaining screws attaching the access cover to the flooring of the vehicle.

11. Attach the ground wire lug to the flooring of the vehicle with the attaching screw.


13. Place the adhesive tape over the loose wiring and put the square of carpeting back over the area of the access door behind the rear seat.

14. Release the catch for the rear seat and tilt it out of the way.



Installation


1. Install the plastic fuel pump mounting bracket onto the fuel pump and install the four mounting screws which hold the fuel pump to the assembly frame.

2. Connect the fuel hose to the fuel pump and install the retaining clamp to secure the hose to the fuel pump.




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Do not force fuel pump assembly parts. The fuel screen is delicate and can be damaged by improper installation to the fuel tank

5. While twisting very carefully and tilting the fuel pump assembly, push gradually on the assembly until it is in position in the fuel tank assembly.

6. Install eight screws around the top surface of the fuel pump assembly.



9. Install fuel tank pressure sensor.


11. Insert the ground wire and the fuel pump electrical connector wires through the access hole in the access door and mount it over the access hole.

12. Install four screws to secure the access door to the vehicle flooring.




16. Release the catch for the rear seat and put it to the normal position.



FUEL PUMP INSPECTION


Fuel Pump Operation


2. Remove the fuel filler cap.


4. Determine if the fuel pump is running by listening for the sound of it at the fuel filler inlet.

5. Install the fuel filler cap.

6. If no sound was heard, measure the voltage between the fuel pump connector wire (G/Y) to chassis ground.

Voltage: About 12V

7. If the voltage is normal, replace the fuel pump.

8. If you do not measure 12V, repair the related wire.

9. Disconnect the jumper wire.

Hold Pressure

Do this inspection if the pump operation inspection is not as specified.


2. Release fuel system pressure. Refer to "Releasing Fuel System Pressure"in this section.

3. Connect a fuel pressure gauge to the fuel filter and plug the outlet of the gauge as shown. (Install clamps as shown.)


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8. Observe the fuel pressure after 5 minutes.

Fuel pressure: More than 50 psi (340 kPa)

9. If not as noted, replace the fuel pump.

Fuel Pump Maximum Pressure1. Disconnect the negative battery terminal.

2. Release fuel system pressure. Refer to "Releasing Fuel System Pressure"in this section.

3. Connect a fuel pressure gauge to the fuel filter and plug the outlet of the gauge as shown. (Install clamps as shown.)



6. Turn the ignition switch on to run the fuel pump.

7. Measure the fuel pump maximum pressure.

Fuel pump maximum pressure: above 42.6 psi (294 kPa)


9. If this pressure is not measured, replace the fuel pump.

Engine Control/Fuel System > Fuel Delivery System > Fuel Filter > Repair procedures

Removal

Fuel is explosive. When working with fuel system parts, make sure to supply adequate ventilation to the work area. Do not smoke, and keep sparks and open flames away.

1. Depressurize the fuel system. See Releasing Fuel System Pressure in this section.

2. Disconnect the fuel pump connector.

3. Disconnect the fuel hoses from the fuel filter.

4. Remove the fuel filter and bracket.

Installation

When installing the fuel filter, push the fuel hoses fully onto the fuel filter.

1. Install the fuel filter and bracket.

Tighten the bolts to 95 Ib-ft (129 N·m).

2. Connect the fuel hoses to the fuel filter.

3. Connect the fuel pump connector.

Engine Control/Fuel System > Fuel Delivery System > Injector > Repair procedures

Removal

1. Depressurize the fuel system. See ?eleasing Fuel System Pressure?in this section.

2. Drain the cooling system.

3. Remove the two bolts for the air intake hose.

4. Loosen the clamp at the throttle body end of the air intake hose.

5. Remove the four breather hoses from the air intake hose.

6. Disconnect the mass air flow sensor electrical connector.

7. Loosen the air inlet hose at the air cleaner assembly.

8. Remove the air intake hose bracket bolt.

9. Remove the bolts from the mass air flow sensor bracket.


11. Remove the two accelerator bracket bolts.


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12. Disconnect the accelerator cable assembly.

13. Remove the vacuum hose from the vacuum pipe.

14. Disconnect the electrical connector from the throttle position sensor.


16. Remove the clamp and hose from the idle air control valve.

17. Remove the clamp and air hose from the air rail.

18. Remove the PCV hose from the dynamic chamber.

19. Remove the vacuum hose from the fuel pressure regulator.

20. Remove the vacuum hose from the EGR valve.

21. Remove the vacuum hose from the EGR duty solenoid.

22. Disconnect the EGR solenoid electrical connector.

23. Remove the clamp from the brake booster vacuum hose at the dynamic chamber.

24. Remove the cruise control vacuum line from the dynamic chamber.

25. Remove two bolts and the stay bracket from the dynamic chamber.

26. Disconnect the idle air control valve electrical connector.

27. Remove the bottom bolt from the idle air control valve bracket.

28. Remove the two top bolts from the manifold bracket.

29. Raise the vehicle on a lift.

30. Remove the two bottom bolts and the manifold bracket.

31. Lower the vehicle.

32. Remove the heater inlet hose at the elbow.

33. Remove the three nuts and bolts from the dynamic chamber assembly.

34. Remove the dynamic chamber assembly.

35. Disconnect the four electrical connectors from the fuel injectors.

36. Remove the fuel hose from the fuel pressure regulator.

37. Remove the fuel hose from the fuel rail.

38. Remove the four clamps and hoses from the air rail.

39. Remove the two bolts for the fuel rail.

40. Remove the four fuel injector clips.

41. Remove the fuel rail.

42. Remove the fuel injectors.

INJECTOR INSULATORS (Removal)


2. Drain the cooling system.

3. Remove the two bolts for the air intake hose.

4. Loosen the clamp at the throttle body end of the air intake hose.

5. Remove the four breather hoses from the air intake hose.


7. Loosen the air inlet hose at the air cleaner assembly.

8. Remove the air intake hose bracket bolt.

9. Remove the bolts for the mass air flow sensor bracket.


11. Remove the two accelerator bracket bolts.

12. Disconnect the throttle cable assembly.

13. Remove the vacuum hose from the vacuum pipe.

14. Disconnect the electrical connector from the throttle position sensor.



17. Remove the clamp and air hose from the air rail.

18. Remove the PCV hose from the dynamic chamber.

19. Remove the vacuum hose from the fuel pressure regulator.

20. Remove the clamp from the brake booster vacuum hose at the dynamic chamber.

21. Remove the cruise control vacuum line from the dynamic chamber.

22. Remove two bolts and the stay bracket from the dynamic chamber.

23. Disconnect the idle air control valve electrical connector.


25. Remove the two top bolts from the manifold bracket.


27. Remove the two bottom bolts and the manifold bracket.



30. Remove the three nuts and bolts from the dynamic chamber assembly.

31. Remove the dynamic chamber assembly.

32. Disconnect the four electrical connectors from the fuel injectors.


34. Remove the fuel hose from the fuel rail.

35. Remove the four clamps and hoses from the air rail.

36. Remove the two bolts for the fuel rail.

37. Remove the four fuel injector clips.


39. Remove the fuel injectors.

40. Remove two injector insulators.

41. Clean gasket surface area.

Installation

1. Clean the gasket mating surfaces.

2. Install four new injector seals into the fuel rail.

3. Install four new injector clips on the fuel injectors.

4. Install the fuel rail and injectors into the intake manifold.

5. Install the bolts for the fuel rail and tighten them.


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6. Install four clamps and air hose to the air rail.

7. Connect four electrical connectors to the fuel injectors.

8. Connect the fuel hose to the fuel rail.

9. Connect the fuel hose to the fuel pressure regulator.

10. Position the dynamic chamber gasket.

11. Install the dynamic chamber.

12. Install and tighten the three nuts and bolts for the dynamic chamber.

Tighten the dynamic chamber nuts and bolts to 16 Ib-ft (22 N·m)

13. Install the bottom bolt to the idle air control valve bracket.

14. Install the electrical connector for the idle air control valve.

15. Install the heater inlet hose at the inlet on the dynamic chamber.

16. Install two bolts and stay bracket to the dynamic chamber.

17. Install the cruise control hose to the inlet fitting on the dynamic chamber.

18. Install the brake vacuum booster hose to the fitting on the dynamic chamber.

19. Connect the EGR solenoid electrical connector.

20. Connect the vacuum hose on the EGR duty solenoid.

21. Connect the vacuum hose to the EGR valve.

22. Connect the vacuum hose to the pressure regulator.

23. Install the PCV hose to the dynamic chamber.

24. Install the clamp and air hose to the air rail.

25. Install the clamp and hose to the idle air control valve.

26. Install the top two bolts to the manifold bracket. Do not tighten the bolts.

27. Raise vehicle on a lift.

28. Install and tighten the bottom two bolts to the manifold bracket.


30. Tighten the top two bolts to the manifold bracket.

31. Connect the two coolant hoses to the throttle body.


33. Connect the vacuum hose to the vacuum pipe.

34. Install the air intake hose assembly.

35. Install and tighten the bolt for the air intake bracket.

36. Install the mass air flow sensor bracket bolts.

37. Connect the mass air flow sensor electrical connector.

38. Tighten the air intake hose clamp at the air cleaner.

39. Tighten the air intake hose clamp at the throttle body.

40. Connect the accelerator cable.

41. Install and tighten the accelerator bracket bolts.

42. Install and tighten the bolts for the intake hose assembly.

43. Install the four breather hoses to the air intake assembly.

44. Fill the cooling system.

45. Start the engine and check for leaks.

INJECTOR INSULATORS (Installation)


2. Install two injector insulators.

3. Install four new injector clips on the fuel injectors.

4. Install the fuel rail and injectors into the intake manifold.

5. Install the bolts for the fuel rail and tighten them.

6. Install four clamps and air hose to the air rail.

7. Connect four electrical connectors to fuel injectors.


9. Connect the fuel hose to the fuel pressure regulator.




Tighten the dynamic chamber nuts and bolts to 16 Ib-ft (22 N·m).

13. Install the bottom bolt for the idle air control valve bracket.

14. Connect the electrical connector for the idle air control valve.

15. Install the heater inlet hose at the inlet on the dynamic chamber.

16. Install the cruise control hose to the inlet fitting on the dynamic chamber.

17. Install the brake vacuum booster hose to the fitting on the dynamic chamber.

18. Connect the vacuum hose to the pressure regulator.

19. Install the PCV hose to the dynamic chamber.

20. Install the clamp and air hose to the air rail.

21. Install the hose to the idle air control valve.

22. Install the top two bolts for the manifold bracket. Do not tighten the bolts.

23. Raise vehicle on a lift.

24. Install and tighten the bottom two bolts for the manifold bracket.


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25. Tighten the top two bolts for the manifold bracket.

26. Connect the two coolant hoses for the throttle body.


28. Connect the vacuum hose to the vacuum pipe.


30. Install and tighten the bolt for the air intake bracket.

31. Install the mass air flow sensor bracket bolts.



34. Tighten the air intake hose clamp at the throttle body.


36. Install and tighten the accelerator bracket bolts.

37. Install and tighten the bolts for the intake hose assembly.

38. Install the four breather hoses to the air intake assembly.

39. Fill the cooling system.

40. Start the engine and check for leaks.

FUEL INJECTOR INSPECTION

Check Operation

1. Warm up the engine and let it idle.

2. Listen for the sound of each injector running by using a sound scope or a screwdriver.


Make sure the fuel injectors are firmly seated on the fuel rail to prevent movement and possible damage.

3. If no sound is heard, measure injector resistance.

4. If the injector is OK, check wiring to the injector and the voltages of the ECM terminals 16, 17, 34 and 35.

5. If removal of the injector system is needed, refer to ?n-Vehicle Service?in this section for the steps.

Fuel Leakage Test

1. Take out the injectors together with the fuel rail.

2. Secure the injectors to the fuel rail with wire.


4. Turn the ignition switch on.

5. Tilt the injectors about 60 degrees and verify that no fuel leaks from the injector nozzles.

6. If fuel leaks, replace the leaking injector. Refer to ?n-Vehicle Service?in this section.

7. Turn the ignition switch "OFF"and remove the jumper wire.

Volume Test

1. Take out the injectors together with the fuel rail.

2. Secure the injectors to the distributor pipe with wire.

3. Connect an injector tester to the battery and the injector.

4. Inspect the injector volume with a graduated container.

Injector volume: 130 cm2 (130 cc, 7.95)/min

5. If not as noted, replace the injectors. Refer to "On-Vehicle Service"in this section.

• Always use new injector O-rings when replacing injectors.

• Apply a small amount of clean engine oil to each of the O-rings before installing.


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Injector Resistance

1. Disconnect the injector harness.

2. Measure resistance of the injector

Resistance: 12 -16Ω @ 68°F (20°C)

3. If not noted, replace the injector. Refer to ?n-Vehicle Service?in this section for steps.

Inspection1. Remove the injectors with the fuel rail.

The operation in this section will result in fuel and fuel vapor being present in the atmosphere. See warning at beginning of fuel section.

2. Connect the fuel inlet and return line to the fuel distribution pipe.

3. Connect the data link connector with a jumper wire.

4. Turn the ignition switch on for 10 seconds.

5. Turn the ignition switch OFF and remove the jumper wire.

6. Fuel should not leak as the fuel rail is tilted to approximately a 60-degree angle.

7. If fuel leaks, replace the injector.

Engine Control/Fuel System > Fuel Delivery System > Fuel Pressure Regulator > Repair procedures

Removal


Fuel is explosive. When working with fuel system parts, make sure to supply adequate ventilation to the work area. Do not smoke, and keep sparks and open flames away.


2. Disconnect the fuel pump connector.

3. Disconnect the vacuum hose.

4. Disconnect the fuel return hose.

5. Remove the pressure regulator by removing the two mounting bolts.

Installation

1. Install a new O-ring on the regulator body.

2. Install the pressure regulator with two mounting bolts.

Tighten to 69-104 lb-in (7.8-11.7 N·m).

3. Install the fuel return hose.

4. Install the vacuum hose.

5. Connect the fuel pump electrical connector.

PRESSURE REGULATOR INSPECTION

Fuel Line Pressure



3. Connect a fuel pressure gauge to the pressure port located on the front of the fuel rail.


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5. Start the engine and run it at idle.

6. Inspect the fuel line pressure measurement.

Fuel line pressure: 34 psi (235 kPa)

7. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure.

Fuel line pressure: 42 psi (292.5 kPa)

Hold PressureDo this inspection if the fuel line pressure inspection is not as noted.


The fuel system remains under pressure when the engine is not running. Release fuel system pressure before disconnecting any fuel line to reduce the chance of personal injury or fire damage to the vehicle.


3. Connect a fuel pressure gauge to the pressure port located on the front of the fuel rail.





8. Pinch the fuel return hose at the regulator with pliers.

9. Observe the fuel pressure for 5 minutes.

Fuel pressure: More than 21 psi (147 kPa)

10. If not as noted, replace the pressure regulator. Refer to the pressure regulator replacement steps located in this manual.

Engine Control/Fuel System > Fuel Delivery System > Fuel Line > Repair procedures

Removal


It may be necessary to remove the transaxle assembly and other chassis brackets in order to gain access to the fuel lines. If this is necessary, refer to those sections for removal instructions.


2. Loosen the six retaining bracket screws and remove the two fuel lines from each bracket, one at a time, until the two fuel lines are free from the brackets.

3. Loosen the fittings at the ends of the fuel lines and carefully slide the lines through the undercarriage of the vehicle chassis until they can be fully taken away from the fixtures by taking off the fastening clips.

REMOVAL (INLET PIPE)


1. Release the fuel inlet filler door catch by actuating the door release handle at the right side of the driver seat on the vehicle floor. This releases the door and opens it.

2. Remove the filler cap from the inlet pipe assembly located on the vehicle rear right quarter.


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3. Remove three screws from the neck portion of the inlet pipe assembly.

4. Remove the nut from the attaching bracket for the neck portion of the inlet pipe assembly.

5. Raise the vehicle on a hydraulic lift to the level where access can be gained at the right rear wheel well.

6. Remove two bolts from the bracket attaching the assembly to the vehicle frame.

7. Remove the attaching bolt holding the inlet pipe assembly to the vapor separator assembly.

8. Loosen and take off the two clamps at the point where the inlet pipe assembly is attached to the hose-joint and to the fuel hose.

9. Remove the inlet pipe assembly and move it to the maintenance area.

Removal (VAPOR SEPARATOR-2DR ONLY)


1. Release the fuel inlet filler door catch by actuating the door release handle at the right side of the driver seat on the vehicle floor. This releases the door to open.

2. Remove the filler cap from the inlet pipe assembly.

3. Remove three screws from the neck portion of the inlet pipe assembly.

4. Remove the nut from the attaching bracket for the neck portion of the inlet pipe assembly.

5. Remove two bolts from the bracket attaching the inlet pipe assembly to the vehicle frame.

6. Remove the attaching bolt holding the vapor separator assembly to the inlet pipe assembly.

7. Remove the clamps retaining the hoses of the vapor separator assembly to the fuel tank.

8. Remove the vapor separator assembly and move it to the maintenance area.

Removal

1. Depressurize fuel system. See Releasing Fuel System Pressure in this section.

2. Drain the engine coolant.


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4. Remove two bolts holding the air intake hose assembly.

5. Loosen the clamp between the throttle body and the air intake duct.

6. Remove the four breather hoses connected to the air intake duct.


8. Remove the mass air flow sensor mounting bolts.

9. Loosen the clamp at the air cleaner assembly for the air intake hose.

10. Remove the bolt from the air intake hose bracket.

11. Remove the accelerator cable bracket bolts.

12. Disconnect the accelerator cable.

13. Remove the vacuum hose that goes from the intake manifold to the vacuum pipe.

14. Disconnect the electrical connectors for the throttle position sensor, idle air control valve.



17. Remove the clamp and hose.

18. Remove the clamp and hose on the air rail.

19. Remove the clamp and the brake booster vacuum hose from the dynamic chamber.

20. Remove the cruise control vacuum hose from the dynamic chamber.

21. Remove the two bolts and bracket from the dynamic chamber.


23. Remove the top two bolts from the manifold bracket.


25. Remove the bottom bolts from the manifold bracket.



28. Remove the vacuum hose at the vacuum pipe.

29. Remove the three nuts and bolts holding the dynamic chamber assembly.

30. Remove the dynamic chamber.


32. Remove the fuel inlet hose from the fuel rail.

33. Remove the two bolts from the fuel rail.

34. Remove the four injector fuel rail clips.


36. Remove two injector insulators.

37. Remove the fuel pulsation damper.

38. Remove the pressure regulator.


Installation

Fuel is explosive. When working on fuel system parts make sure to supply adequate ventilation to the work area. Do not smoke, and keep sparks and open flames away.

It may be necessary for the transaxle assembly and other chassis brackets to be removed in order to reinstall the fuel lines. If this is true, refer to the affected sections for removal and reinstallation instructions.

1. Reinsert the fuel lines carefully into each of the six retaining brackets along the undercarriage of the vehicle chassis until the fuel lines have been positioned into place.


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2. Tighten the six bracket retaining screws after the two fuel lines have been positioned into place.

3. Connect fuel lines/hoses to the fittings from which they were taken off.

4. Install clamps to fasten the fuel lines/hoses to the fittings.


Installation (Inlet pipe)


1. Raise the vehicle on a hydraulic lift to a level where access can be gained at the right rear wheel well area.

2. Install the inlet pipe assembly and the attaching bolt holding the inlet pipe assembly to the vapor separator assembly.

3. Connect the inlet pipe assembly/vapor separator assembly to the hose-joint and the fuel hose. Install the two clamps.

4. Install the attaching bolts to the bracket holding the inlet pipe assembly to the vehicle frame.

5. Install the nut to the attaching bracket for the neck portion of the inlet pipe assembly.

6. Lower the vehicle on the hydraulic lift to ground level. Install three screws to the neck portion of the inlet pipe assembly.

7. Install the filler cap to the threaded portion of the inlet pipe assembly.

8. Close the fuel inlet filler door by pushing it until the catch is secure.

Installation (Vapor separator-2dr only)

Fuel is explosive. When working on fuel system parts, make sure to supply adequate ventilation to the work place. Do not smoke, and keep sparks and open flames away.

1. Connect the hoses of the vapor separator assembly.

2. Install the hose retaining clamps on the hoses of the separator assembly as they are connected to the fuel tank.

3. Attach the bolt which holds the separator assembly to the inlet pipe assembly.

4. Install a nut to the attaching bracket for the neck portion of the inlet pipe assembly.

5. Install three screws to the neck portion of the inlet pipe assembly.

6. Install the filler cap to the threaded portion of the inlet pipe assembly.

7. Close the fuel inlet filler door by pushing it until the catch is secure.


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Installation

1. Install and tighten two bolts for the pressure regulator.

2. Install and tighten the pulsation damper.

3. Install two injector insulators.

4. Install the fuel rail to the injectors.

5. Install the four injector fuel rail clips.

6. Install the two bolts to the fuel rail and tighten.

7. Connect the fuel hose to the pressure regulator.v





12. Install the vacuum hose to the vacuum pipe.

13. Install the heater inlet hose at the elbow.

14. Install the bottom bolt to the idle air control valve bracket.

15. Connect the electrical connector to the idle air control valve.

16. Connect the hose for the idle air control valve.

17. Install the clamp and hose to the air rail.

18. Install the two top bolts with the manifold bracket. Do not tighten the bolts at this time.


20. Install and tighten the two bottom bolts on the manifold bracket.


22. Tighten the two top bolts on the manifold bracket.

23. Install the two bolts and brackets to the dynamic chamber.

24. Install the cruise control vacuum hose to the dynamic chamber.

25. Connect the two coolant hoses to the throttle body.

26. Connect the vacuum hose from the intake manifold to the vacuum pipe.


28. Connect the brake booster vacuum line to the dynamic chamber connector.


30. Install and tighten the one bolt for the air intake hose bracket.

31. Install the bolts for the mass air flow sensor bracket and tighten.



34. Tighten the air intake hose clamp at the throttle body


36. Install and tighten the two bolts for the accelerator cable bracket.

Deflection for accelerator cable should be 0 - 0.6 in (0 - 15 mm).

37. Install and tighten the two bolts for the air intake hose assembly.

38. Install the four breather hoses onto the air duct assembly.


40. Refill the cooling system.

41. Start the vehicle and check for leaks.


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Engine Control/Fuel System > Fuel Delivery System > Fuel Sensor > Repair procedures

Removal(FUEL TANK PRESSURE SENSOR)







7. Remove the four access cover and remove screws attaching the access cover moving it out of the way.

8. Disconnect the fuel tank pressure sensor connector. Should not remove until after the inspection.

Installation(Fuel Tank Pressure sensor)

1. Reinstall the fuel tank pressure sensor to the fuel tank sending unit.

2. Reinstall the retainer nut.

3. Reinstall the fuel tank pressure sensor connector.

4. Reattach the fuel tank pressure sensor ground wire to the fuel tank sending unit mounting plate with the previously removed screw.

5. Reinstall the fuel pump access cover.

6. Reinstall the four screws to secure the access door to the vehicle flooring.




10. Release the catch for the rear seat and put it in the normal position.



INSPECTION

1. Reinstall the fuel pump ground wire to the fuel pump access cover screw. Connect the negative terminal to the battery.

2. Vent the fuel tank by removing the fuel filler cap.

3. Turn the ignition switch to the ON position.

4. Using a voltmeter, measure voltage at all three fuel tank pressure sensor terminals in the fuel tank sending unit connector.

WHT/BLK -2.0-3.0 V (signal return voltage/base reading)

If signal voltage reads 5.0 volts, check the sensor ground wire.

GRN/YEL -0.0 V (sensor ground)

YEL/GRN - 5.0 V (reference voltage)

5. In the engine compartment, disconnect the hose at the evaporative emissions canister coming from the fuel tank.

6. Connect a hand-held vacuum pump to the hose.

7. Connect a voltmeter between the fuel tank ground and the WHT/BLK wire in the fuel tank sending unit connector.

8. With ignition switch in the ON position, verify that voltage goes down when vacuum is applied to the canister fuel tank hose, and that voltage goes up when pressure is applied.


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9. Disconnect the negative terminal from the battery. Disconnect the fuel tank pressure sensor connector, then remove the retainer nut, and remove the fuel tank pressure sensor from the tank.

10. Remove the screw attaching the fuel tank pressure sensor ground wire to the fuel tank sending unit mounting plate.

11. Measure fuel tank pressure sensor resistance.

GRN/YEL - WHT/BLK: 4.63 K ohms

GRN/YEL - YEL/GRN: 2.75 K ohms

YEL/GRN - WHT/BLK: 4.55 K ohms

12. If not within specification, replace the fuel tank pressure sensor.

Engine Control/Fuel System > Fuel Delivery System > Emergency Cut Solenoid > Repair procedures

Removal (CHECK AND CUT VALVE-2DR ONLY)



2. Remove the retaining clamps from the two hoses connected to the check valve.

3. Disconnect the two hoses from the check valve.

4. Remove the retaining screw that holds the check valve bracket to the frame.

Installation


1. Install the retaining screw that holds the check valve bracket to the frame.

2. Connect the two fuel hoses to the check valve.

3. Install the two retaining clamps to the two hoses connected to the check valve.


Engine Control/Fuel System > Fuel Delivery System > Components and Components Location

COMPONENTS


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COMPONENT (COUTINUE)

Engine Control/Fuel System > Troubleshooting > P0101

Diagnostic Trouble Code Diagnosis Charts

P0101 Mass air flow circuit range/performance problem

Threshold Value ~ Ratio of load value calculated by MAFS and TPS > 1.215 ms or < -2.625 ms.

Enable Conditions ~

• Engine speed >1320 RPM

• Coolant temperature > 140°F

Time Requirements ~ 5 seconds (continuous)

MIL Illumination ~ 1 driving cycle

Related Items

• Dirty air cleaner.

• Oil Cap or Dipstick missing or not installed correctly.

• Air leak in intake system.

• Contaminated, deteriorated or damaged MAFS.

• Faulty MAFS or Throttle Position Sensor (TPS).

• Poor connection(s) (or high resistance in wiring) between ECM and MAFS or TPS.

STEP INSPECTION Y/N ACTION

1Check air cleaner condition.

Is air cleaner clogged with dirt?

YES Replace air cleaner.

NO Go to step 2.

2Check oil cap and oil dipstick installation.

Are oil cap and dipstick installed correctly and is cap screwed on completely?

YES Go to step 3.

NO Repair as necessary.

3Check intake tube, breather hose and MAFS for any sources of air leaks.

Are there any cracks in intake tube, MAFS or breather hose and are all bands tight and correctly installed?

YES Go to step 4.



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4

Connect adapter cable # K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect harness connector C211 to adapter cable and adapter cable connector to ECM. Attach positive voltmeter lead to BOB terminal # 12 and negative lead to GND. Start engine and allow to warm up to operating temperature. In short spurts, spray aerosol carb cleaner in the following areas while looking for a long rise in voltage (a rise in voltage that is approximately as long as the spray of carb cleaner

indicates some of the carb cleaner was drawn into the intake chamber richening the fuel mixture verifying a leak)(Allow enough time between areas checked for carb spray to dissipate) ~

Do not spray carb cleaner on or near coils or plug wires. An arcing wire or coil could start a fire!

• Throttle body gasket

• Gasket between intake manifold and cylinder head.

• Gasket between intake manifold and surge tank

• Seals between intake manifold and fuel injectors

• Seal between surge tank and PCV pipe

Are any air leaks indicated?YES Repair as necessary.

NO Go to step 5.

5Check MAFS for contamination, deterioration, or damage.

Is MAFS contaminated, deteriorated or damaged?

YES Clean MAFS with aerosol brake cleaner and let air dry before reinstalling. Inspect air cleaner and housing for source of leak and repair as necessary. If damaged or deteriorated, replace.

NO Go to step 6.

6Check TPS.

Does TPS pass resistance checks?

YES Go to step 7.

NO Replace TPS.

7

Start engine and allow to warm up to operating temperature. With engine idling, measure voltage at BOB terminal #41 (approx. 1v). Open throttle slowly and verify voltage increases with airflow. Actual voltages will vary with altitude and

relative humidify but, at sea level and 50% relative humidity, voltage should be approximately:

• 0.9v to 1.1v @ idle

• 1.4v @ 1500 rpm

• 1.5v @ 2000 rpm

• 1.6v @ 2500 rpm

• 1.7v @ 3000 rpm

Is idle voltage within specifications and do voltage readings increase with rpm?

YES Go to step 8.

Go to step 8. If wiring and connections are all okay, replace MAFS.

8

Thoroughly check for loose, bent or corroded connectors at ECM, TPS and MAFS. With ignition off, disconnect ECM, TPS and MAFS. With ignition off, disconnect ECM, TPS and MAFS connectors. Measure resistance between TPS

and ECM on all three circuits (C144-1 to BOB #71, C144-2 to BOB #59 and C144-3 to BOB #73). Measure resistance between MAFS and ECM (C129-2 to BOB #14 and C129-4 to BOB #41). Measure resistance between MAFS and

GND (C129-1 and GND). Are resistance values all below 1 ohm?

YES Go to step 9.

Repair as necessary.

9

Redo resistance checks in step 8 while “wiggle testing” the harnesses in the following areas:

• For BOB pin 71 to C144-1 ~ S116 (@ or just forward of #1 injector branch), S192 (2-6 inches either side of bulkhead grommet) and C124.

• For BOB pin 59 to C144-2 ~ S193 (2-6 inches either side of bulkhead grommet) and C124.

• For BOB pin 73 to C144-3 ~ C124.

• For MAFS C129-1 and GND ~ S195 (@ base of C129 branch) and S194 (on G103 branch approximately 2-6 inches from base).

Does the measured resistance change while “wiggle testing” with any of the 4 tests?

YES Repair the connection @ C124 or solder the appropriate splice.

NO Go to step 10.

10 Clear codes and verify any repairs by driving vehicle with KIA Data Pro connected to OBD-II connector and monitoring for pending codes (refer to section 3 of the KIA Data Pro Generic OBD-II Program Card reference manual).

MAF SENSOR-1

Diagnostic Trouble codeNo. P0101 Mass or volume air cicuit range performance problem

[Related items] · Dirty air cleaner

· Air leak in take system

· Contaminated, deteriored or damaged MAFS

· Poor co nnection at ECM, MAFS, or TPS

If any codes relating to MAFS or TPS are present, do all repairs associated with them beford this trobleshooting procedure.

Step Inspection Action

1

Connect SCAN TOOL to data link connector or OBD-II check connector.

Turn ignition to ON and montitor other DTCs.

Is DTC P0102, P0103, P0121, P0122 or P0123 set?

Yes Do all repairs associated with those codes before proceeding this procedure.

No Go to step 2.

2

Using SCAN TOOL montitor MAFS voltage signals.

·0.9－1.1V @ idle

Is signal within specifications?

Yes Problem is intermittent or was repaired and engine control mobule memory was not cleared. Check terminal connections at ECM and MAFS.

No Go to stem 3

3Thoroughly check MAFS for loose, poor connection, bent, corrosion, contamination, deterioration or damage.

Is MAFS okey?

Yes Go to step 4.

No Clean or repair as necessary.

4

Start engine and allow engine to idle untile engine reaches operating temperature.

Using SCAN TOOL, monitor TP voltage signals

·0.4－0.6V @ idle

·4.1－4.3V @ full open

Yes Go to step 5.

No Do all repairs associated with TPS before proeeding the next step.

5

Turn ignition switch to OFF and disconnect MAFS connector.

Turn ignition switch to ON and measure voltage of MAFS power circuit between MAFS harness connector and chassis ground.

·Specification : approximately 5V

Is voltage within specification?

Yes Go to step 6.

NoOpen circuit or short circuit to chassis ground between MAFS harness connector


6

Turn ignition to OFF and disconnect ECM connector.

Measure resistance of MAFS signal circuit between MAFS harness connector and ECM harness connector.

Measure resistance of MAFS ground circuit beltween MAFS harness connector and ECM harness connector.

·Specification : below 1Ω

Dose each resistance indicate continuity circuit?

Yes Go to step 7.

NoOpen circuit between MAFS harness connector and ECM connector.


7

ECM connector and MAFS contector is still disconnected.

Turn ignition to ON.

Measure voltage of MAFS signal circuit between MAFS harness connector and chassis ground.

Does voltage within specification?

Yes Go to step 8.

NoShort circuit to battery between MAFS harness connectors and ECM haeness connector.


8

ECM connector and MAFS connector is still disconnected.

Turn ignition to OFF.

Measure risistance between MAFS harness connector and chassis ground at MAFS signal circuit.

Specification : infinite

Does resistance indication open circuit?

YesTemporarily install a known good MAFS and check for proper operation.

If problem is corrected, replace MAFS

No Short circuit to chassis ground between MAFS harness connector and ECM harness connector.

9Check air cleaner for dirt, blockage, or damage.

IS air cleaner okey?

Yes Go to step 10.

No Repair or replace necessary.

10

Check entire air intake system for leaks of blockages such as

· Throttle body

· PCV valve

· Intake manifold

· Gasket between intake manifold and surge tank

· Seals between intake manifold and fuel injectors

· Seal between surge tank and PCV pipe

· ETC

Is entire air intake system okey?



No Repair or replace as necessary.

11 Return vehcicle to orginal condition. Clear all diagnostic trouble codes. Verify by driving vehcile with SCAN TOOL connected and monitor for pending codes.



P0102 / P0103 Mass air flow circuit low/high input

Threshold Value (P0102) ~

1.< pre-determined value of load/rpm ratio

2.< 15 kg/hr

(P0103) ~ >pre-determined value of load/rpm ratio

Enable Conditions (P0102) ~

1. For Threshold Value #1 ~ Engine speed >360 RPM

2. For Threshold Value #2 ~ Engine speed >360 RPM and Throttle Valve Opening >35°

(P0103) ~ Engine speed >360 RPM

Time Requirements ~ Continuous

MIL Illumination ~ One driving cycle

Related Items

• Open or short to ground between Mass Air Flow Sensor (MAFS)(C129-4) and Engine Control Module (ECM)(C211-41). (P0102)

• Open between MAFS (C129-3) and EGI Main Relay (terminal 3). (P0102)

• Open between MAFS (C129-2) and ECM (C211-14). (P0103)

• Open between MAFS (C129-1) and G103. (P0103)


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1

IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s).

For P0102: With engine idling, backprobe C129-3 at MAFS and measure voltage at C129-3 (B+).

Is battery voltage indicated?

YES Go to step 2.

NOTurn off ignition and disconnect C129 from MAFS and remove EGI main relay from Engine Compartment Fuse/Relay Box (ECFB)]. Measure resistance between terminal #3 (center terminal) and C129-3 (less than 1 ohm). If resistance

is less than 1 ohm and there is no corrosion present at terminals, replace EGI Main Relay. If resistance is greater than 1 ohm or terminals are corroded, repair as necessary.

2

For P0102: With ignition key off, disconnect C129 from MAFS and C211 from ECM.

Measure resistance between C129-4 and C211-41 (less than 1 ohm). Also check for short to GND on same circuit.

Is a short to GND or more than 1 ohm resistance indicated?

YES Locate source of high resistance open or short to GND. Repair as necessary.

NO Go to step 4.

3


Measure resistance between C129-2 and C211-14 (less than 1 ohm). Also measure resistance between C129-1 and GND (less than 1 ohm).

Is resistance on either circuit greater than 1 ohm?

YES Repair circuit(s) as necessary.

NO Go to step 4.


MAF SENSOR - 2

Diagnostic trouble code No. P0102 Mass or volume air flow circuit low input

〔Related items〕 · Open or short to ground between MAFS and ECM

· Open or short to ground between MAFS battery power and engine main relay

· Faulty MAFS


1


Start engine and monitor MAFS voltage signals.

· Specification : 0.9 - 1.1 V @ idle

Is signal within specification?

Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and MAFS.

No Go to step 2.

2


Turn ignition switch to ON.

Measure voltage of MAFS battery power circuit between MAFS harness connector and chassis ground.

· Specification : approximately 5V


Yes Go to step 3.

NoOpen circuit or short circuit to chassis ground between MAFS harness connector and main relay.


3



Measure voltage of MAFS battery power circuit between MAFS harness connector and chassis ground.



Yes Go to step 4.

NoOpen circuit or short circuit to chassis ground between MAFS harness connector and ECM connector.


4


Measure resistance of MAFS signal circuit between MAFS harness connector and ECM harness connector.

· Specification : below 1Ω

Does each resistance indicate continuity circuit?

Yes Go to step 5.

NoOpen circuit between MAFS harness connector and ECM harness connector.


5



Measure resistance between MAFS harness connector and chassis ground at MAFS signal circuit.

Measure resistance between MAFS signal circuit and MAFS ground circuit.

· Specification : infinite

Does each resistance indicate open circuit?

Yes

Temporarily install a known good MAFS and check for proper operation.


Short circuit to chassis ground between MAFS harness connector and ECM harness connector.

NoShort circuit between MAFS signal circuit and ground circuit.


6 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN TOOL connected and monitor for pending codes.



P0102 / P0103 Mass air flow circuit low/high input

Threshold Value (P0102) ~

1.< pre-determined value of load/rpm ratio

2.< 15 kg/hr

(P0103) ~ > pre-determined value of load/rpm ratio

Enable Conditions (P0102) ~

1. For Threshold Value #1 ~ Engine speed >360 RPM

2. For Threshold Value #2 ~ Engine speed >360 RPM and Throttle Valve Opening >35°

(P0103) ~ Engine speed >360 RPM


MIL Illumination ~ One driving cycle

Related Items

• Open or short to ground between Mass Air Flow Sensor (MAFS)(C129-4) and Engine Control Module (ECM)(C211-41). (P0102)

• Open between MAFS (C129-3) and EGI Main Relay (terminal 3). (P0102)

• Open between MAFS (C129-2) and ECM (C211-14). (P0103)

• Open between MAFS (C129-1) and G103. (P0103)


1


For P0102: With engine idling, backprobe C129-3 at MAFS and measure voltage at C129-3 (B+).

Is battery voltage indicated?

YES Go to step 2.

NOTurn off ignition and disconnect C129 from MAFS and remove EGI main relay from Engine Compartment Fuse/Relay Box (ECFB)]. Measure resistance between terminal #3 (center terminal) and C129-3 (less than 1 ohm). If resistance

is less than 1 ohm and there is no corrosion present at terminals, replace EGI Main Relay. If resistance is greater than 1 ohm or terminals are corroded, repair as necessary.

2


Measure resistance between C129-4 and C211-41 (less than 1 ohm). Also check for short to GND on same circuit.

Is a short to GND or more than 1 ohm resistance indicated?

YES Locate source of high resistance open or short to GND. Repair as necessary.

NO Go to step 4.

3


Measure resistance between C129-2 and C211-14 (less than 1 ohm). Also measure resistance between C129-1 and GND (less than 1 ohm).

Is resistance on either circuit greater than 1 ohm?

YES Repair circuit(s) as necessary.

NO Go to step 4.


MAF SENSOR - 3

Diagnostic trouble code No. P0103 Mass or volume air flow circuit high input

〔Related items〕 · Short to battery between MAFS signal and ECM

· Faulty MAFS


1


Start engine and monitor MAFS voltage signals.

· Specification : 0.9~1.1 V @ idle

Is signal within specification?

Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and MAFS.

No Go to step 2.

2


Measure resistance of MAFS ground circuit between MAFS harness connctor and ECM harness connector.



Yes Go to step 3.

NoOpen circuit between MAFS harness connector and ECM harness connector.


3



Measure voltage at MAFS signal circuit between MAFS harness connector and chassis ground.

· Specification : below 0.5V




NoShort circuit to battery between MAFS harness connector and ECM harness connector.




IAT SENSOR - 1

Diagnostic trouble code No. P0111 Intake air temperature sensor circuit range/performance malfunction

〔Related items〕 · Misplaced, loose or corroded terminal

· Poor connections between ECM and IATS

· Contaminated, deteriorated or damaged IATS

· Faulty IATS and/or ECTS

If any codes relating to ECTS, IATS circuits are present, do all repairs associated with those codes before proceeding with this troubleshooting procedure


47 de 74 03/03/2013 22:31


1



Is DTC P0110, P0115, or P0116 set?

Yes Do all repairs associated with those codes before proceeding this procedure

No Go to step 2.

2Thoroughly check IATS for loose, poor connection, bent, corrosion, contamination, deterioration, or damage.

Is IATS okay?

Yes Go to step 3.

No Clean or repair as necessary.

3

Start engine and allow engine to idle while engine reaches operating temperature.

Using SCAN TOOL and monitor IAT signals.

3.4~3.6V (2.27~2.64 KΩ) @ 20°C (68°F)

1.1~1.3V (0.30~0.33 KΩ) @ 20°C (176°F)


Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and IATS.

No Go to step 4.

4

Turn ignition to OFF and disconnect IATS connector.

Turn ignition to ON, measure voltage of IATS battery power circuit between IATS harness connector and chassis ground.

· Specifications: approximately B+

Is voltage witrhin specifications?

Yes Go to step 5.

No

Open circuit or short circuit to chassis

ground between IATS harness connector and ECM main relay.


5

Turn ignition switch to OFF and disconnect IATS connector and ECM connector.

Measure resistance of IAT signal circuit between IATS harness connector and ECM harness connector.

Measure resistance of IAT ground circuit between IAT harness connector and ecm harness connector.

· Specifications: below 1Ω


Yes Go to step 6.

NoOpen circuit between IATS harness connector and ECM harness connector.


6

Turn ignition to ON. ECM connector is still diconnected.

Measure voltage of IAT signal circuit between IATS harness connector and chassis ground,

· Specification: below 0.5V

Is voltage within specifications?

Yes Go to step 7.

No

Short circuit to battery between

ITS harness connector and ECM harness connector.


7

Ignition OFF, IATS connector and ECM connector is still disconnected.

Measure resistance between IATS signal circuit and IATS ground at circuit.

Measure resistance between IATS harness connector and chassis ground at IATS signal circuit.

· Specification: infinite

Does resistance indicate open circuit?

YesTemporarily install a know good IATS and check for proper operation.

If problem is corrected, replace IATS.

No

Short circuit between IATS signal circuit and ground circuit.

Short to chassis ground between IATS harness connector and ECM harness connector.


8 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAB TOOL connected and monitor for pending codes.



P0112 / P0113 Intake air temperature low/high input

Threshold Value ~

(P0112) ~ < -40°F

(P0113) ~ > 284°F

Enable Conditions ~

Time after engine start ~ >180 seconds

Engine speed ~ idling (after a minimum of 30 seconds after any fuel cut)


MIL Illumination ~ 2 driving cycles

Related Items

• Open or short to B+ between Intake Air Temperature (IAT) Sensor (C176-1) and ECM (C211-77) (P0112).

• Open between IAT (C176-2) and ECM (C211-71) (P0112).

• Short to GND between IAT Sensor (C176-1) and ECM (C211-77) (P0113).

• Short between IAT Sensor wires (P0113).


1

For vehicles with a P0112 displayed: With ignition off, disconnect C176 from IAT Sensor.

Turn ignition on and measure voltage at C176-1 (5v).

Is voltage at specification?

YES Go to step 2.

NO If voltage is greater than specification, locate short to battery. If voltage is less than specification, locate open in wiring between ECM and IAT. Repair as necessary.

2Turn ignition off and disconnect C211 from ECM. Measure resistance between C176-2 and C211-71 (less than 1 ohm).

Is resistance as specified?

YES Thoroughly check for loose, bent or corroded terminals between (C176-1 and C211-77) and (C176-2 and C211-71) then go to step 4.

NOLocate open between C176-2 and C211-71.


3For vehicles with a P0113 displayed: With ignition off, disconnect C176 form IAT and C211 from ECM. Measure resistance from C176-1 to GND (infinite resistance) and resistance between C176-1 and C176-2 (infinite resistance).


YES Go to step 4.

NO

Locate short to GND and repair as necessary.

Splice S192 is located 1 to 4” to either side of bulkhead grommet (follow wire from C211-71 to locate splice).

4 Clear codes and return vehicle to original condition. Verify any repairs by driving vehicle with KIA Data Pro connected to OBD-II connector and monitoring for pending codes (refer to section 3 of the KIA Data Pro Generic OBD-II Program Card reference manual).

IAT SENSOR - 2

Diagnostic trouble code

No. po112Intake air temperature circuit low inputt

〔Related items〕 · Open or short to battery between IATS signal and ECM

· Open between IATS ground and ECM

· Faulty IATS

step Inspection Action

1

Connect SCAN TOOL to data link connector or OBD-∥ check connector.

Turn ignition to ON and monitor other DTCs.

Is DTC P0102 ir P0103 set?


No Go to step 2.

2

Start engine and allow engine to idle until engine reaches operation temperature.

Using SCAN TOOL and monitor IAT signals.

· 3.4~3.6V (2.27~2.64 KΩ @ 20°C (68°F)

Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and IATS.

No Go to step 3.

3

Turn ignition to OFF and disconnect IATS connector.

Turn ignition to ON and measure voltage of IATS signal circuit between IATS harness connector and chassis ground.

· Specification: approximately 5V


Yes Go to step 4.

NoOpen circuit or short circuit to chassis ground between IATS harness connector and ECM harness connector.


4


Measure resistance of IATS ground circuit between IATS harness connector and ECM harness connector.

· Specification: below 1Ω


Yes Go to step 5.

NoOpen circuit between IATS harness connector and ECM harness connector.


5

Turn ignition to ON. ECM connector is still diconnected.

Measure voltage of IATS signal circuit between IATS harness connector and chassis ground.

· Specification: below 1Ω


YesTemporarily install a known good IATS and check for proper operation.

If problem is corrected, replace IATS.

NoShort circuit to battery between IATS harness connector and ECM harness connector.





P0112 / P0113 Intake air temperature low/high input

Threshold Value ~

(P0112) ~ < -40°F

(P0113) ~ > 284°F

Enable Conditions ~

Time after engine start ~ >180 seconds

Engine speed ~ idling (after a minimum of 30 seconds after any fuel cut)



Related Items

• Open or short to B+ between Intake Air Temperature (IAT) Sensor (C176-1) and ECM (C211-77) (P0112).

• Open between IAT (C176-2) and ECM (C211-71) (P0112).

• Short to GND between IAT Sensor (C176-1) and ECM (C211-77) (P0113).

• Short between IAT Sensor wires (P0113).



48 de 74 03/03/2013 22:31

1

For vehicles with a P0112 displayed: With ignition off, disconnect C176 from IAT Sensor.

Turn ignition on and measure voltage at C176-1 (5v).

Is voltage at specification?

YES Go to step 2.

NO If voltage is greater than specification, locate short to battery. If voltage is less than specification, locate open in wiring between ECM and IAT. Repair as necessary.



YES Thoroughly check for loose, bent or corroded terminals between (C176-1 and C211-77) and (C176-2 and C211-71) then go to step 4.

NOLocate open between C176-2 and C211-71.


3For vehicles with a P0113 displayed: With ignition off, disconnect C176 form IAT and C211 from ECM. Measure resistance from C176-1 to GND (infinite resistance) and resistance between C176-1 and C176-2 (infinite resistance).


YES Go to step 4.

NO

Locate short to GND and repair as necessary.

Splice S192 is located 1 to 4” to either side of bulkhead grommet (follow wire from C211-71 to locate splice).


IAT SENSOR - 3


No. P0113Intake air temperature circuit high input

〔Related items〕· Short to ground between IATS signal and ECM

· Faulty IATS

step inspection Action

1

Connect SCAN TOOL to data link connector or OBD-∥check connector.


Is DTC P0102 or P0103 set?

Yes Do all repairs associated with those codes before proceeding thes procedure.

No Go to spep 2.

2

Start engine and allow engine to idle until engine reaches operation temperature.

· 3.4~3.6V (2.27~2.64 KΩ @ 20°C (68°F)

· 1.1~1.3V (0.30~0.33 KΩ @ 80°C (176°F)


Yes Problem is intermittent or was repaired and engine control module memory was not cleared. check terminal connections at ECM and IATS.

No Go to spep 3.

3

Ignition OFF, IATS connector and ECM connector is still disconnected.

Measure resistance between IATS signal circuit and ECTS guound circuit.



YesTemporarily install a known good IATS and check for proper operation.

If problem is corrected, replace IATS

No

Short circuit between IATS signal circuit and ground circuit.

Short to chassis ground between IATS harness connector and ECM harness connector.





P0116 / P0125 Engine coolant temperature circuit range/performance problem / Insufficient coolant temperature for closed loop fuel control

Threshold Value ~

(P0116) ~ Difference between calculated temp and measured temp >50°F

(P0125) ~ Time to reach closed loop enable temp (from start up temp) ~

• 5100 seconds @ 17°F

• 300 seconds @ 46 to 48°F

• 120 seconds @ 50°F

Time Requirements ~

(P0116) ~ Continuous

(P0125) ~ Once per driving cycle


Related Items

• After engine start-up, the elapsed time before feedback operation is initiated is too long [Engine Coolant Temperature (ECT) sensor input is insufficient for closed loop operation].

• Poor connections between ECT and ECM.

• Faulty ECT.


1With ignition off, disconnect C145 from ECT and C211 from ECM. Measure resistance between C145-1 and C211-78 (less than 1 ohm).

Is resistance less than 1 ohm?

YES Go to step 2.

NO Locate source of high resistance between C145-1 and C211-78. Repair as necessary.

2

Remove ECT from engine. Measure resistance across terminals.

Are resistance measurements within specification?

-6°F = 16.2 k ohms +/- 10%

68°F = 2.45 k ohms +/- 10%

176°F = .322 k ohms +/- 10%

YES Thoroughly check for loose, bent or corroded terminals between ECT and ECM.

NO Replace ECT.

3 Clear codes and return vehicle to original condition. Verify any repairs by driving vehicle while monitoring ECT and Fuel Stat 1 in user data list with Kia Data Pro Scan Tool. Refer to chart “A” for amount of time in which Fuel Stat 1 should show closed loop operation after engine has been started. (Get start-up temperature by accessing user data with ignition key on and engine off before starting vehicle).

ECT SENSOR - 1


No. P0116Engine coolant temperature circuit range/performance problem


No. P0125Insufficient coolant temperature for closed loop fuel control

〔Related items〕 • After engine start-up, the elapsed time before feedback operation is initiated is too long

(engine coolant temperature sensor input is insufficient for closed loop operation)

• Poor connections between ECTS and ECM

• Misplaced, loose or corroded terminals

• Foreign materials fouled, contaminated, deteriorated ECTS

• Faulty ECTS

• Faulty thermostat

If any codes relating to ECTS are present, do all repairs associated with them before this troubleshooting procedure.

step inspection Action

1

Connect SCAN TOOL to data link connector or OBD-∥check connector


Is DTC P0117 or P0118 set?


No Go to step 2.

2

Start engine and allow engine to idle until engine reaches operating temperature.

Using SCAN TOOL and monitor ECT signals.

· 3.4~3.6V (2.27~2.64 KΩ @ 20°C (68°F)

Yes Problem is intermittent of was repaired and engine control module memory was not cleared. Check terminal connections at ECM and ECTS.

No Go to step 3.

3Check ECTS for contamination, deterioration or damage.

Is ECTS contaminated, deteriorated or damaged?

Yes Clean ECTS with cleaner before installing. If ECTS is damaged or deteriorated, replace.

No Go to step 4.

4

Thoroughly check for loose, bent or corroded connectors at ECM connector and ECTS connector.

With ignition OFF, disconnect ECM connector and ECTS connector.

Measure resistance of all two circuits between ECTS harness connector and ECM harness connector.

· Specifications : below 1Ω

Does each indicate continuity circuit?

Yes Go to step 5.

NoOpen circuit between ECTS harness connector and ECM harness connector.




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P0117 / P0118 Engine coolant temperature circuit low/high input

Threshold Value ~

(P0117) ~ < -40°F

(P0118) ~ > 284°F

Enable Conditions ~ N.A.



Related Items

• Short to battery voltage (B+) between Engine Coolant Temperature (ECT) Sensor (C145-1) and ECM (C211-78) (P0117).

• Open between ECT and ECM (P0117).

• Short to GND between ECT (C145-1) and ECM (C211-78) (P0118).

• Short between ECT wires (P0118).


1

IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s). For vehicles with a P0117 displayed: With ignition off, disconnect C145 from ECT. Turn ignition on and measure voltage at C145-1

(5v).

Is measured voltage approximately 5v?

YES Go to step 2.

NO If voltage is greater than specification, locate short to B+ between C145-1 and C211-78. If voltage is less than specification, locate open between C145-1 and C211-78. Repair as necessary.

2Turn off and disconnect C211 from ECM. Measure resistance between C145-2 and C211-71 (less than 1 ohm).



NO Locate open (or source of high resistance between C145-2 and C211-71. Repair as necessary.

3 For vehicles with a P0118 displayed: With ignition off, disconnect C145 from ECT and C211 from ECM. Measure resistance to GND at C145-1 and between C145-1 and C145-2 (infinite resistance).

Is resistance on both measurements infinite?


NO Locate short to GND between C145-1 and C211-78 or for short between wires. Repair as necessary.


ECT SENSOR - 2

Diagnostic trouble code No. P0117 Engine coolant temperature circuit low input

〔Related items〕 · Open or short to battery between ECTS signal and ECM

· Open between ECTS ground and ECM

· Faulty ECTS


1


Using SCAN TOOL and monitor ECT voltage signals.

· 3.4~3.6V (0.27~2.64 KΩ @ 20°C (68°F)

· 1.1~1.3V (0.30~0.33 KΩ @ 80°C (176°F)


Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and ECTS.

No Go to step 2.

2

Turn ignition to OFF and disconnect ECTS connector.

Turn ignition to ON and measure voltage of ECTS signal circuit between ECTS harness connector and chassis ground.



Yes Go to step 3.

NoOpen circuit or short circuit to chassis ground between ECTS harness connector and ECM harness connector.

Repair as necessary

3


Measure resistance of ECTS ground circuit between ECTS harness connector and ECM harness connector.



Yes Go to step 4.

NoOpen circuit between ECTS harness connector and ECM harness connector.


4


Measure voltage of ECTS signal circuit between ECTS harness connector and chassis ground.



YesTemporarily install a known good ECTS and check for proper operation.

If problem is corrected, replace ECTS

NoShort circuit to battery between ECTS harness connector and ECM harness connector.





P0117 / P0118 Engine coolant temperature circuit low/high input

Threshold Value ~

(P0117) ~ < -40°F

(P0118) ~ > 284°F

Enable Conditions ~ N.A.



Related Items

• Short to battery voltage (B+) between Engine Coolant Temperature (ECT) Sensor (C145-1) and ECM (C211-78) (P0117).

• Open between ECT and ECM (P0117).

• Short to GND between ECT (C145-1) and ECM (C211-78) (P0118).

• Short between ECT wires (P0118).


1

IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s). For vehicles with a P0117 displayed: With ignition off, disconnect C145 from ECT. Turn ignition on and measure voltage at C145-1

(5v).


YES Go to step 2.

NO If voltage is greater than specification, locate short to B+ between C145-1 and C211-78. If voltage is less than specification, locate open between C145-1 and C211-78. Repair as necessary.

2Turn off and disconnect C211 from ECM. Measure resistance between C145-2 and C211-71 (less than 1 ohm).



NO Locate open (or source of high resistance between C145-2 and C211-71. Repair as necessary.

3For vehicles with a P0118 displayed: With ignition off, disconnect C145 from ECT and C211 from ECM. Measure resistance to GND at C145-1 and between C145-1 and C145-2 (infinite resistance).

Is resistance on both measurements infinite?


NO Locate short to GND between C145-1 and C211-78 or for short between wires. Repair as necessary.


ECT SENSOR - 3

Diagnostic trouble code No. P0118 Engine coolant temperature circuit high input

〔Related items〕 · Short to ground between ECTS signal and ECM

· Faulty ECTS


1


Using SCAN TOOL and monitor ECT voltage signals.

· 3.4~3.6V (0.27~2.64 KΩ @ 20°C (68°F)

· 1.1~1.3V (0.30~0.33 KΩ @ 80°C (176 °F)


Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and ECTS.

No Go to step 2.

2

Ignition OFF, disconnect ECTS connector and ECM connector.

Measure resistance between ECTS signal circuit and ECTS ground circuit.

Measure resistance between ECTS harness connector and chassis ground at ECTS signal circuit.



YesTemporarily install a known good ECTS and check for proper operation.

If problem is corrected, replace ECTS

No

Short circuit between ECTS signal circuit and ground circuit.

Short to chassis ground between ECTS harness connector and ECM harness connector.

Repafir as necessary.

3 Return vehicle to original condition. Clear all dianostic trouble codes. Verify by driving vehicle with SCAN TOOL connected and monitor for pending codes.



P0122 Throttle position sensor circuit low input

Threshold Value ~ Throttle valve angle < 2.8°

Enable Conditions ~ Engine speed > 720 RPM



Related Items

• Short to GND between Throttle Position Sensor (TPS) C144-3 and (ECM) C211-73.

• Open or short to GND between (TPS) C144-2 and (ECM) C211-59.

• Short to GND between (ECM) C211-59 and Chassis Acceleration Sensor (CAS) or Fuel Tank Pressure Sensor (FTPS).

• Faulty TPS, CAS or FTPS.


1 With ignition off, disconnect C128 from TPS. Turn ignition on (engine off) and measure voltage at C128-2 (5v). YES Go to step 2.


50 de 74 03/03/2013 22:31

Is voltage approximately 5v? NO Go to step 4.

2With C128 still disconnected and ignition on (engine off) measure voltage at C128-3 (5.6v to 5.8v).

Is voltage approximately 5.6v to 5.8v?

YES Go to step 3.

NO Go to step 5.

3Check TPS.

Does TPS pass inspection?

YES Thoroughly check for loose, bent, misplaced or corroded connector terminals between TPS and ECM. Repair as necessary.

NO Replace TPS.

4

With ignition off, disconnect C254 from ECM. Check for short to GND at C254-59.

Is short to GND indicated?YES

While monitoring resistance from C254-59 to GND, disconnect CAS and FTPS one at a time. If short to GND is corrected by disconnecting either CAS or FTPS, replace faulty component. If short is still present after disconnecting CAS

and FTPS, check for short to GND between C254-59 and TPS, CAS and FTPS. Repair as necessary.

NO Thoroughly check for loose, bent, misplaced or corroded connector terminals between (TPS) C128-2 and (ECM) C254-59. Repair as necessary.

5With ignition off, disconnect C254 from ECM. Check for short to GND at C254-73.

Is short to GND indicated?

YES Locate short between (TPS) C128-3 and (ECM) C254-73. Repair as necessary.

NO Thoroughly check for loose, bent, misplaced or corroded connector terminals between (TPS) C128 and (ECM) C254. Repair as necessary.


TPS - 1

Diagnostic trouble code No. P0122 Throttle position sensor circuit low input

〔Related items〕 · Open or short to ground between TPS reference power and ECM

· Short to ground between TPS signal and ECM

· Faulty TPS


1


Using SCAN TOOL, monitor TP voltage signals.

· 0.4~0.6V @ idle

· 4.1~4.3V @ full open


Yes Problem is intermittent or was repaired and engine control control module memory was not cleared. Check terminal connections at ECM and TPS.

No Go to step 2.

2

Turn ignition to OFF and disconnect TPS connector.

Turn ignition to ON and measure voltage of TPS reference voltage between TPS hanress connector and chassis ground.



Yes Go to step 3.

NoOpen circuit or TPS harness connector and ECM harness connector.


3


Measure resistance of TPS signal circuit between TPS harness connector and ECM harness connector.



Yes Go to step 4.

NoOpen circuit between TPS harness connector and ECM harness connector.


4

Ignition OFF, TPS connector and ECM connector is still disconnected.

Measure resistance between TPS signal circuit and ground circuit.

Measure resistance between TPS harness connector and chassis ground at TPS signal circuit.



YesTemporarily install a known good TPS and check for proper operation.

If problem is corrected, replace TPS.

No

Short circuit between TPS signal circuit and ground circuit.

Short to chassis ground between TPS harness connector and ECM harness connector.





P0123 Throttle position sensor circuit high input

Threshold Value ~ Throttle valve angle < 101.2°

Enable Conditions ~ Engine speed >720 RPM



Related Items

• Open or short to battery between Throttle Position Sensor (TPS) C144-3 and (ECM) C211-73.

• Open between (TPS) C144-1 and (ECM) C211-71.

• Faulty TPS.


1IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s). With ignition off, disconnect C144 from TPS. Turn ignition on (engine off) and measure voltage at (TPS) C144-3 (5.6v to 5.8v).

Is voltage approximately 5.6v to 5.8v?

YES Go to step 2.

NOIf voltage is below specification, locate source of open or high resistance between (TPS) C144-3 and (ECM) C211-73. If voltage is above specification, check for short to battery between (TPS) C144-3 and (ECM) C211-73.


2With ignition off, disconnect C211 from ECM and measure resistance between (TPS) C144-1 and (ECM) C211-71 (<1 ohm).


YES Go to step 3.

NOWith ignition off, disconnect C211 from ECM and measure resistance between (TPS) C144-1 and (ECM) C211-71 (<1 ohm).


3Check TPS.

Does TPS pass inspection?

YES Thoroughly check for loose, bent, misplaced or corroded connector terminals at (TPS) C144 and (ECM) C211.

NO Replace TPS.


TPS - 2

Diagnostic trouble code No. P0123 Throttle position sensor circuit high input

〔Related items〕 · Open or short to battery between TPS signal and ECM

· Open between TPS ground and ECM

· Faulty TPS


1


Using SCAN TOOL, monitor TPS voltage signals.

· 0.4~0.6 V @ idle

· 4.1~4.3 @ full open


Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and TPS.

No Go to step 2.

2

Turn ignition to OFF and disconnect TPS connector and ECM connector.

Measure resistance of TPS ground circuit between TPS harness connector and ECM harness connector.



Yes Go to step 3.

NoOpen circuit between TPS harness connector and ECM harness connector.


3


Measure voltage of TPS signal circuit between TPS harness connector and chassis ground.



YesTemporarily install a known good TPS and check for proper operation.

If problem is corrected, replace TPS

NoShort circuit to battery between TPS harness connector and ECM harness connector.





P0116 / P0125 Engine coolant temperature circuit range/performance problem / Insufficient coolant temperature for closed loop fuel control

Threshold Value ~

(P0116) ~ Difference between calculated temp and measured temp >50°F

(P0125) ~ Time to reach closed loop enable temp (from start up temp) ~

• 5100 seconds @ 17°F

• 300 seconds @ 46 to 48°F

• 120 seconds @ 50°F

Time Requirements ~

(P0116) ~ Continuous

(P0125) ~ Once per driving cycle


Related Items

• After engine start-up, the elapsed time before feedback operation is initiated is too long [Engine Coolant Temperature (ECT) sensor input is insufficient for closed loop operation].

• Poor connections between ECT and ECM.

• Faulty ECT.


1With ignition off, disconnect C145 from ECT and C211 from ECM. Measure resistance between C145-1 and C211-78 (less than 1 ohm).


YES Go to step 2.

NO Locate source of high resistance between C145-1 and C211-78. Repair as necessary.


51 de 74 03/03/2013 22:31

2

Remove ECT from engine. Measure resistance across terminals.

Are resistance measurements within specification?

-6°F = 16.2 k ohms +/- 10%

68°F = 2.45 k ohms +/- 10%

176°F = .322 k ohms +/- 10%


NO Replace ECT.




P0130 Front O2 sensor circuit malfunction

Threshold Value ~

(Condition #1) ~ O2 sensor voltage: 0.04v to 0.06v

(Condition #2) ~ O2 sensor voltage: -0.03v to 0.03v

Enable Conditions ~

(Condition #1) ~

Time after O2 sensor heating period initiation: >151 seconds

Rear O2 sensor voltage: >0.65v

(Condition #2) ~


Engine coolant temperature at last ignition shut-off: >175°F

Engine coolant temperature: < 104°F

Time Requirements ~ Continuous (minimum 9 seconds duration)


Related Items

• Short in Front O2 sensor wiring between C211-11 and C211-12.

• Misplaced, bent, loose or corroded connector terminals.

• Faulty Front O2 sensor.


1

IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s). Disconnect C131 from Front O2 Sensor and C211 from ECM. With ignition key off, measure resistance between C131-2 and C131-4

(infinite resistance).

Is measured resistance infinite?

YES Go to step 2.

NO Locate short between Front O2 Sensor ground circuit and Front O2 Sensor input circuit.

2

Connect adapter cable #K99U-2106-G17 to BOB and adapter cable C211 to ECM.

Reconnect C131 to Front O2 Sensor. Start vehicle and allow it to warm up to operating temperature. With engine idling, monitor Front O2 Sensor voltage at BOB pin 12 and verify sensor is switching from rich to lean a minimum of 3

times in 10 seconds (voltage will vary between approx. 0.4v and 1.1v).

Is Front O2 Sensor switching properly?

YES Thoroughly check for misplaced, loose, bent or corroded terminals at Front O2 Sensor and at ECM.

NO Replace Front O2 Sensor.


HO2S - 1

Diagnostic trouble code No. P0130 HO2S circuit malfunction (bank 1, sensor 1)

〔Related items〕 · Open or short to battery between front HO2S and ECM

· Short to chassis ground between front HO2S and ECM

· Short between front HO2S wires

· Faulty front HO2S

· Poor connections between front HO2S and ECM

· Misplaced, bent, loose or corroded terminals


1



Are any other codes set?


No Go to step 2.

2

Warm up engine to normal operating temperature for more than 10 minutes.

Using SCAN TOOL, monitor HO2S signal waveform.

Does the HO2S signal switch lean to rich or rich to lean over 6 times for 10 seconds?

Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and HO2S.

No Go to step 3.

3

Turn ignition to OFF and disconnect ECm connector and HO2S connector.

Measure resistance of HO2S ground circuit between HO2S harness connector and ECM harness connector.

Measure resistance of HO2S signal circuit between HO2S harness connector and ECM harness connector.



Yes Go to step 4.

NoOpen circuit between HO2S harness connector and ECM harness connector.


4

Turn ignition to ON. ECM connector is still disconnected.

Measure voltage of HO2S signal circuit between HO2S harness connector and chassis ground.



Yes Go to step 5.

NoShort circuit to battery between HO2S harness connector and ECM harness connector.


5

Ignition OFF, HO2S connector and ECM connector is still disconnected.

Measure resistance between HO2S signal circuit and ground circuit.

Measure resistance between HO2S harness connector and chassis ground at HO2S signal circuit.



YesGo to step 6.

Short circuit between HO2S signal circuit and ground circuit.

NoShort to chassis ground between HO2S harness connector and ECM harness connector.


6Thoroughly check HO2S for contamination, deterioration or damage.

Is HO2S contaminated, deteriorated or damaged?

YesIf damaged or deteriorated, temporarily install a known good HO2S and check for proper operation.

If problem is corrected, replace HO2S.

NoVerify ECM and HO2S connectors are secure. If connectors are okay, temporarily install a known good HO2S and check for proper operation.

If problem is corrected, replace HO2S




P0131 Front O2 sensor circuit low voltage

Threshold Value ~

(Condition #1) ~ O2 sensor voltage: < -0.15v

(Condition #2) ~ O2 sensor voltage: 0.15v to 0.38v

Enable Conditions ~

(Condition #1) ~


(Condition #2) ~


Engine coolant temperature at last ignition shut-off: >140°F

Engine coolant temperature: < 104°F



Related Items

• Short to GND between C131-4 and C211-12

• Faulty Front O2 Sensor.


1

IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s). Disconnect C131 from Front O2 Sensor and C211 from ECM. With ignition key off, measure resistance to GND at C211-12 (infinite

resistance).


YES Go to step 2.

NO Locate source of short to GND between C131-4 and C211-12. Repair as necessary.

2Connect adapter cable #K99U-2106-G17 to BOB and adapter cable C211 to ECM.



52 de 74 03/03/2013 22:31

Reconnect C131 to Front O2 Sensor. Start vehicle and allow it to warm up to operating temperature. With engine idling, monitor Front O2 Sensor voltage at BOB pin 12 and verify sensor is switching from rich to lean a minimum of 3

times in 10 seconds (voltage will vary between approx 0.4v and 1.1v).

Is Front O2 Sensor switching properly?NO Replace Front O2 Sensor.


HO2S - 2

Diagnostic trouble code No. P0131 HO2S circuit low input (bank 1, sensor 1)

〔Related items〕 · Short to ground between front HO2S signal and ECM



1

Turn ignition to OFF and disconnect HO2S connector and ECM connector.





Yes Go to step 2.

No


Short to chassis ground between HO2S harness connector and ECM harness connector.


2

Connect HO2S connector and ECM connector.





No Go to step 3.










P0132 Front O2 sensor circuit high voltage

Threshold Value ~ O2 sensor voltage: >1.56v

Enable Conditions ~ Time after O2 sensor heating period initiation: >155 seconds



Related Items

• Short to battery (B+) between C131-4 and C211-12



1Disconnect C131 from Front O2 Sensor and C211 from ECM. With ignition key on, engine off, measure voltage at C211-12 (0v).

Is measured voltage 0v?

YES Go to step 2.

NOLocate source of short to B+ between C131-4 and C211-12.


2

Connect adapter cable #K99U-2106-G17 to BOB and adapter cable C211 to ECM. Reconnect C131 to Front O2 sensor. Start vehicle and allow it to warm up to operating temperature. With engine idling, monitor Front O2 Sensor

voltage at BOB pin 12 and verify sensor is switching from rich to lean a minimum of 3 times in 10 seconds (voltage will vary between approx. 0.4v and 1.1v).





HO2S - 2

Diagnostic trouble code No. P0132 HO2S circuit low input (bank 1, sensor 1)

〔Related items〕 · Open or short battery between front HO2S signal and ECM



1


Turn ignition to ON and measure voltage of HO2S signal circuit between HO2S harness connector chassis ground.



Yes Go to step 2.

NoShort circuit to battery between harness connector.


2



Does the HO2S signal switch lean to rich andr rich to lean over 6 times for 10 seconds?


No Go to step 3.










P0133 Front O2 sensor circuit slow response

Threshold Value ~

(Time period monitoring) ~ Sensor signal period: >1.2 seconds

(Sensor aging monitoring) ~ Air/Fuel compensation factor (atv)(calculated from rear O2 sensor): outside of pre-determined upper and lower limit values

Enable Conditions ~

(Time period monitoring) ~

• Engine speed: 2200 to 3000 RPM

• Load value: 2.0 ~ 4.0 ms

• Calculated catalyst temperature: >666°F

• Fuel system status: closed loop

(Sensor aging monitoring) ~

• Engine speed: 1280 ~ 4000 RPM

• Load value: outside of pre-determined upper and lower limit values

• Calculated catalyst temperature: >738°F

• Fuel system status: closed loop

Time Requirements ~

(Time period monitoring) ~ Continuous (for approximately 7 seconds)

(Sensor aging monitoring) ~ Continuous


Related Items

• Front and rear O2 sensor connections reversed.

• Faulty fuel delivery system.

• Leak in intake system.

• Leak in exhaust system.

• Faulty Mass Air Flow Sensor ground circuit.

• Faulty O2 Sensor.

If any misfire, Purge Solenoid Valve, Mass Air Flow Sensor or O2 Sensor heater codes are present, DO ALL REPAIRS associated with those codes before proceeding with this troubleshooting tree.


1IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s). Check front and rear O2 sensors for connections being reversed.

Are O2 sensor connections reversed?

YES Switch O2 sensor connections

NO Go to step 2.

2

WARNING! Refer to Service Manual for proper test procedures and precautions before doing any fuel pressure tests.Perform Fuel Pressure Test (34 to 38 PSI).

Perform Maximum Fuel pressure Tes (50 PSI minimum)

Perform Fuel Pressure Hold Test (21 PSI minimum after 5 minutes).

Are fuel pressure tests within specifications?

YES Go to step 3.


3Check for any split, disconnected or perforated vacuum hoses. Also, check PCV valve for proper operation and Purge Solenoid Valve (PSV) for proper installation and operation.

Are vacuum hoses, PCV and PSV okay?

YES Go to step 4.

NO Replace faulty vacuum hose(s), PCV or PSV.

4

Connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM.

Connect adapter cable C211 to ECM and vehicle C211 to adapter cable. Start vehicle and allow it to warm up to operating temperature. With engine idling, monitor Front O2 Sensor voltage at BOB pin 12 and verify sensor is switching

from rich to lean a minimum of 3 times in 10 seconds (voltage will vary between approximately 0.4v and 1.1v).


YES Go to step 5.

NO Perform checks in step 5. If no intake leaks are detected, replace O2 sensor.


53 de 74 03/03/2013 22:31

5

With engine still idling, in short spurts, spray aerosol carb cleaner in the following areas while looking for a long rise in voltage at BOB pin 12 (a rise in voltage that is approximately as long as the spray of carb cleaner indicates some of the carb cleaner was drawn into the intake chamber richening the fuel mixture verifying a leak). Allow enough time between areas checked for carb spray to dissipate.



• Gasket between intake manifold and cylinder head

• Gasket between intake manifold halves



NO Go to step 6.

6Check for exhaust leaks by having a helper hold a wadded rag against tailpipe and listen for exhaust leaks between main catalytic converter and cylinder head with vehicle idling.

Are any exhaust leaks detected?

YES Repair as necessary.

NO Go to step 7.

7

Turn ignition off and backprobe Mass Air Flow Sensor at C129-1. Attach voltmeter positive probe to C129-1 and negative probe to chassis GND. Start vehicle, let it idle at operating temperature and measure voltage drop between

C129-1 and GND (35 mv). Is voltage drop 35 mv or less?

YES Go to step 8.

NO

Solder splices S194 and S195. Locate and repair any other source of high resistance if voltage drop does not fall below 35 mv.

S194 is located on G103 branch approximately 2 to 4 inches from ECM; S195 is located at MAF Sensor / IAT Sensor split.


HO2S - 4

Diagnostic trouble code No. P0133 HO2S circuit slow responsive (bank 1, sensor 1)

〔Related items〕 · Abnormal combustion

· Improper fuel pressure

· Front and rear HO2S connections reversed

· Faulty fuel delivery system

· Leak in intake system

· Leak in exhaust system


If any misfire, purge solenoid valve, MAFS or HO2S heater codes are present, do all repairs associated with those before proceeding this troubleshooting procedure.


1Connect SCAN TOOL to data link connector or OBD-II check connector. Turn ignition to ON and monitor other DTCs.



No Go to step 2.

2Visually check for leak from exhaust system (especially between TWC converter and front exhaust pipe).

Are any leaks present?

Yes Repair intake system leaks as necessary.

No Go to step 3.

3Visually check for leak from intake system.

Are any vacuum leaks present?

Yes Repair exhaust system leaks as necessary.

No Go to step 4.

4

Start engine after installing fuel pressure gauge at service valve in fuel rail.

With engine running at operating temperature, is fuel pressure within specification?

· Fuel pressure at idle : 40~43 psi (276~296 kPa, 2.81~3.02 kg/cm²)

YesTemporarily install a known good HO2S and check for proper operation.


No1. If measured pressure is too high : Go to step 5

2. If measured pressure is too low : Go to step 6

5Disconnect return line hose from fuel filter. Blow through line towards tank.

Is return line restricted?

Yes Check for blockage in return line, clean or replace as necessary.

No Repair pressure regulator.

6Clamp a return line from fuel filter and check if pressure rises.

Does fuel pressure rise?

Yes Replace fuel delivery module.

No Check fuel filter at fuel pump. If it is OK, measure fuel pump maximum pressure and repair as necessary.




P0134 No activity detected in front O2 sensor circuit

Threshold Value ~ 0.4 ~ 0.6v


Time Requirements ~ Continuous (>5.12 seconds duration)


Related Items

• Front O2 Sen fuse blown or missing

• Open between Front O2 Sensor and ECM (C211 terminals 11 or 12).


If any misfire, Purge Solenoid Valve or O2 Sensor heater codes are present, DO ALL REPAIRS associated with those codes before proceeding with this troubleshooting tree.


1IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s).Verify Front O2 Sen fuse is installed and not blown.

Is fuse installed and not blown?

YES Go to step 2.

NO Replace fuse and repair any shorts as necessary.

2With ignition off, disconnect C131 from Front O2 Sensor and C211 from ECM. Check continuity between C131-2 to C211-11 and C131-4 to C211-12 (less than 1 ohm).

Is resistance on both circuits less than 1 ohm?

YES Go to step 3.

NO Locate source of open and repair as necessary.

3Turn ignition on and measure voltage at C131-1 (B+).

Is battery voltage available?

YES Go to step 4.

NO Locate source of open between Front O2 Sen fuse and C131-1.

4Drive vehicle while monitoring Front O2 Sensor input voltage with Kia Data Pro connected to OBD-II connector. Verify sensor is switching from rich to lean a minimum of 3 times in 10 seconds.

Is O2 sensor switching normally?

YES Thoroughly check for loose, bent, misplaced or corroded terminals. Repair as necessary.

NO Replace O2 sensor.


HO2S - 5

Diagnostic trouble code No. P0134 HO2S circuit no activity detected (bank 1, sensor 1)

〔Related items〕 · Open or shrot between front HO2S signal terminal and ECM

· Contaminated, deteriorated or aged front HO2S

· Misplaced, bent, loose or corroded connector terminals


If any misfire, purge solenoid valve or HO2S heater codes are present, do all repairs associated with those codes before proceeding this troubleshooting procedure


1


Turn ignition to ON and monitor any other DTC.



No Go to step 2.

2


Using SCAN TOOL monitor HO2S signal.

Does the HO2S signal switch lean to rich and rich to lean over 6 times for 10 seconds?


No Go to step 3.

3

Turn ignition to OFF and disconnect ECM connector and HO2S connector.

Measure resistance of HO2S ground circuit between HO2S harness connector and ECm harness connector.




Yes Go to step 4.



4 Turn ignition to ON. ECM connector is still disconnected. Yes Go to step 5.


54 de 74 03/03/2013 22:31



Is voltage within specifications?No

Short circuit to battery between HO2S harness connector and ECM harness connector.


5






Yes Go to step 6.

No








NoVerify ECM and HO2S connectors are secure. If OK, temporarily install a known good HO2S and check for proper operation.





No Go to step 8.




P0135 Front O2 sensor heater circuit malfunction

Threshold Value ~ Calculated resistance: >16.4N or < 6.1N




Related Items

• Blown or missing Front O2 Sen fuse.

• Short to B+ between Front O2 Sensor (C131-3) and ECM (C211-37).

• Open between Front O2 Sensor (C131-3) and ECM (C211-37).



1IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s).

Check for missing or blown Front O2 Sen fuse. Is fuse missing or blown?

YES Replace fuse and repair source of short between Front O2 Sen fuse and C131-1.

NO Go to step 2.

2Disconnect C131 from Front O2 Sensor and C211 from ECM. With ignition off, measure resistance between C131-3 and C211-37 (less than 1 ohm).


YES Go to step 3.

NO Repair open or source of high resistance as necessary.

3With connectors still disconnected, turn ignition on (engine off) and measure voltage at C211-37 (0v).

Is voltage 0v?

YES Go to step 4.

NO Locate and repair short to B+ between C131-3 and C211-37.

4At Front O2 Sensor, measure resistance between C131-1 and C131-3 (2 to 4 ohms).

Is resistance between 2 and 4 ohms?

YES Thoroughly check for loose, bent or corroded terminals in Front O2 Sensor heater circuit.



HO2S - 6

Diagnostic trouble code No. P0135 HO2S heater circuit malfunction (bank 1, sensor 1)

［Related items］ · Open or short to battery between front HO2S heater and ECM

· Short to chassis ground between front HO2S heater and ECM

· Open or short to ground between front HO2S heater and main reley.

· Incorrect front HO2S heater resistance

· Faulty front HO2S heater


1Visually inspect the HO2S circuit for exposed wiring, contamination, corrsion and proper installation.

Were any concerns found during the visuals inspection?

Yes Repair any concerns found in the visual inspection.

No Go to step 2.

2

Turn ignition switch to OFF and disconnect HO2S connector.

Start engine and allow an engine to idle until ECT reaches operating temperature.

Measure voltage of HO2S heater battery voltage between H2OS harness connector and chassis ground.

·Specification : approximately B+

Is measured voltage within specification?

Yes Go to step 3.

No Open circuit or short circuit ro chassis ground between main relay and HO2S harness connector.

3


Measure resistance of HO2S heater signal circuit between HO2S harness connector and ECM harness connector.


Yes Go to step 4.


Repair as mecessary.

4

Measure resistance between HO2S heater signal

· Approximately 6Ω at 20°C (68°F)

Is measured resistance within specification?

Yes Go to step 5.

NoTamporarily install a known good HO2S and check for proper operation.





P0136 Rear O2 sensor circuit malfunction

Threshold Value ~ O2 sensor voltage: -0.4v to 0.4v

Enable Conditions ~


Engine speed: 1280 to 4000 RPM

Calculated catalyst temperature: >738°F

Fuel system status: Closed loop

Time Requirements ~ Continuous (>40 seconds duration)


Related Items

• Short in Rear O2 sensor wiring between C211-10 and C211-39.

• Misplaced, bent, loose or corroded connector terminals.

• Faulty Rear O2 sensor.


1


Disconnect C199 from Rear O2 Sensor and C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and vehicle C211 to adapter cable.

With ignition key off, measure resistance between BOB pins 10 and 39 (infinite resistance).

Is measured resistance infinite ohms?

YES Go to step 2.

NO Locate source of short between Rear O2 Sensor ground circuit and Rear O2 Sensor input circuit.

2

Reconnect C199 to Rear O2 Sensor and connect adapter cable C211 to ECM. Start engine and allow to warm up to operating temperature. While monitoring Rear O2 sensor voltage at BOB pin 39, increase engine to between 2000

and 2500 rpm for 5 to 10 seconds and then release throttle back to idle. Rear O2 Sensor voltage should rise during sustained high rpm period and drop significantly when throttle is snapped shut. Repeat a couple of times to verify Rear

O2 Sensor operation.

Is Rear O2 Sensor switching properly?

YES Thoroughly check for misplaced, loose, bent or corroded terminals at Rear O2 Sensor and at ECM.

NO Replace Rear O2 Sensor.


HO2S-7


No. P0136HO2S circuit malfuntion (bank1, sensor 2)

［Related items］ · Open or short to chassis ground between rear HO2S and ECM

· Short to battery between rear HO2S and ECM

· Short to between rear HO2S wires

· Faulty rear HO2S



P0137 Rear O2 sensor circuit low voltage


55 de 74 03/03/2013 22:31

Threshold Value ~ O2 sensor voltage: < -0.15v




Related Items

• .

• Faulty Rear O2 Sensor.


1IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s).Disconnect C199 from Rear O2 Sensor and C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and vehicle C211 to

adapter cable. With ignition key off, measure resistance to GND at BOB pin 39 (infinite resistance).Is measured resistance infinite?

YES Go to step 2.

NO Locate source of short to GND between C199-4 and C211-39. Repair as necessary.

2





YES Thoroughly check for misplaced, loose, bent or corroded terminals at Rear O2 Sensor and at ECM.



HO2S - 8


No. P0137HO2S circuit low input (bank1, sensor2)

［Related items］ · Short to ground between rear HO2S signal and ECM

· Faulty rear HO2S


1



·Specification : infunite


Yes Go to step 2.

No




2

Connect HO2S connector and ECM connector.

Warm up engine to normal operaing temperature for more than 10 minutes.


Does the HO2S signal switch lean to rich or rich to lean over 6times for 10 seconds?


No Go to step 3


Is HO2S contaminated, deteriored, or damaged?

YesIf damaged or deteriored, temporarily install a known good HO2S and cjeck for prpper operation.


NoVerify ECM and HO2S connectors are secure. If connectors are okey, temporarily install a known good HO2S and check for proper operation.


4 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN TOOL connected and mounitor for pending codes.



P0138 Rear O2 sensor circuit high voltage

Threshold Value ~ Rear O2 sensor voltage: >1.08v

Enable Conditions ~ NA



Related Items

• Short to battery (B+) between C199-4 and C211-39.

• Faulty Front O2 sensor.


1


Disconnect C199 from Rear O2 Sensor and C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and vehicle C211 to adapter cable. With ignition key on, engine off, measure voltage at BOB pin 39 (0v).


YES Go to step 2.

NOLocate source of short to B+ between C199-4 and C211-39.


2





YES Thoroughly check for misplaced, loose, bent of corroded terminals at Rear O2 Sensor and at ECM.



HO2S - 9

Diagnostic trouble code No. P0138 HO2S circuit high input (bank 1, sensor 2)

〔Related items〕 · Open or short to battery between rear HO2S signal and ECM

· Faulty rear HO2S


1


Turn ignition to ON and measure voltage of HO2S signal circuit between HO2S harness connector and chassis ground.



Yes Go to step 2.



2





No Go to step 3.










P0139 Rear O2 sensor circuit slow response

Threshold Value ~ Air/fuel compensation factor (atv)

(calculated from rear O2 sensor) out of pre-determined high and low parameters

Enable Conditions ~

atv: >0.8 seconds or< -0.8 seconds

Calculated catalyst temperature: >752°F



Related Items

• Front and rear O2 sensor connections reversed.




• Faulty Mass Air Flow Sensor ground circuit.

• Faulty O2 Sensor.

If any misfire, Purge Solenoid Valve, Mass Air Flow Sensor or O2 Sensor heater codes are present, DO ALL REPAIRS associated with those codes before proceeding with this troubleshooting tree.


1


Check front and rear O2 sensor for connections being reversed.

Are O2 sensor connections reversed?

YES Switch O2 sensor connections

NO Go to step 2.

2Perform Fuel Pressure Test (36 to 40 PSI). Perform Maximum Fuel Pressure Test (>50 PSI).



YES Go to step 3.




YES Go to step 4.



56 de 74 03/03/2013 22:31

4

Connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM.

Connect adapter cable C211 to ECM and vehicle C211 to adapter cable. Start engine and allow to warm up to operating temperature. While monitoring Rear O2 sensor voltage at BOB pin 39, increase engine to between 2000 and 2500

rpm for 5 to 10 seconds and then release throttle back to idle. Rear O2 Sensor voltage should rise during sustained high rpm period and drop significantly when throttle is snapped shut. Repeat a couple of times to verify Rear O2

Sensor operation.

Is O2 sensor switching properly?

YES Go to step 5.

NO Perform checks in step 5. If no intake leaks are detected, replace O2 sensor.

5

With engine still idling, in short spurts, spray aerosol carb cleaner in the following areas while looking for a long rise in voltage at BOB pin 12 (a rise in voltage that is approximately as long as the spray of carb cleaner indicates some of the carb cleaner was drawn into the intake chamber richening the fuel mixture verifying a leak). Allow enough time between areas checked for carb spray to dissipate.

Do not spray carb cleaner on or near coil or plug wires. An arcing wire or coil could start a fire!






NO Go to step 6.

6Check for exhaust leaks by having a helper hold a wadded rag against tailpipe and listen for exhaust leaks between main catalytic converter and cylinder head with vehicle idling.



NO Go to step 7.

7

Turn ignition off and backprobe Mass Air Flow Sensor at C129-1. Attach voltmeter positive probe to C129-1 and negative probe to chassis GND. Start vehicle, let it idle at operating temperature and measure voltage drop between

C129-1 and GND (35mv).

Is voltage drop 35 mv of less?

YES Go to step 8.

NO Locate source of high resistance and repair as necessary.


HO2S - 10

Diagnostic trouble code No. P0139 HO2S circuit slow responsive (bank 1, sensor 1)

〔Related items〕 · Abnormal combustion

· Improper fuel pressure

· Front and rear HO2S connections reversed

· Faulty fuel delivery system


· Leak in exhaust system


If any misfire, purge solenoid valve, MAFS or HO2S heater codes are present, do all repairs associated with those before proceeding this troubleshooting guide.



P0140 No activity detected in rear O2 sensor circuit

Threshold Value ~ Rear O2 sensor voltage: 0.42v to 0.52v




Related Items

• Rear O2 Sen fuse blown or missing.

• Open between Rear O2 Sensor and ECM (C211 terminals 10 or 39).


If any misfire, Purge Solenoid Valve or O2 Sensor heater codes are present, DO ALL REPAIRS associated with those codes before proceeding with this troubleshooting tree.


1


Verify Rear O2 Sen fuse is installed and not blown.

Is fuse installed and not blown?

YES Go to step 2.

NO Replace fuse and repair any short as necessary.

2

With ignition off, disconnect C199 from Rear O2 Sensor and C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and vehicle C211 to adapter cable. Check continuity between C199-2 to BOB pin 10 and C199-4 to BOB

pin 39 (less than 1 ohm).

Is resistance on both circuits less than 1 ohm?

YES Go to step 3.


3





YES Thoroughly check for loose, bent, or corroded terminals.

NO Replace O2 sensor.


HO2S - 11

Diagnostic trouble code No. P0140 HO2S circuit no activity detected (bank 1, sensor 2)

〔Related items〕 · Open or shrot between rear HO2S signal terminal and ECM

· Contaminated, deteriorated or aged rear HO2S

· Misplaced, bent, loose or corroded connector terminals

· Faulty rear HO2S

If any misfire, purge solenoid valve or HO2S heater codes are present, do all repairs associated with those codes before proceeding this trouble area.


1


Turn ignition to ON and monitor any other DTC.



No Go to step 2.

2


Using SCAN TOOL monitor HO2S signal.

Does the HO2S signal switch lean to rich and rich to lean over 6 times for 10 seconds?


No Go to step 3.

3






Yes Go to step 4.



4





Yes Go to step 5.



5






Yes Go to step 6.

No








NoVerify ECM and HO2S connectors are secure. If OK, temporarily install a known good HO2S and check for proper operation.





No Go to step 8.




57 de 74 03/03/2013 22:31


P0141 Rear O2 sensor heater circuit malfunction

Threshold Value ~ Calculated resistance: >16.4N or< 6.1N




Related Items

• Blown or missing Rear O2 Sen fuse.

• Short to B+ between Rear O2 Sensor (C199-3) and ECM (C211-30).

• Open between Rear O2 Sensor (C199-3) and ECM (C211-30).



1IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s).

Check for missing or blown Rear O2 Sen fuse. Is fuse missing or blown?

YES Replace fuse and repair source of short between Rear O2 Sen fuse and C199-1.

NO Go to step 2.

2Disconnect C199 from Rear O2 Sensor and C211 from ECM. With ignition off, measure resistance between C199-3 and C211-30 (less than 1 ohm).


YES Go to step 3.

NO Repair open or source of high resistance as necessary.

3With connectors still disconnected, turn ignition on (engine off) and measure voltage at C211-30 (0v).

Is voltage 0v?

YES Go to step 4.

NO Locate and repair short to B+ between C199-3 and C211-30.

4At Rear O2 Sensor, measure resistance between C199-1 and C199-3 (2 to 4 ohms).

Is resistance between 2 and 4 ohms?

YES Thoroughly check for loose, bent or corroded terminals in Rear O2 Sensor heater circuit.



HO2S - 12

Diagnostic trouble code No. P0141 HO2S heater circuit malfuntion (bank 1, sensor 2)

〔Related items〕 · Open or shrot to battery between rear HO2S heater and ECM

· Short to chassis ground between rear HO2S heater and ECM

· Open or short to ground between rear HO2S heater resistance

· Incorrect rear HO2S heater resistance

· Fauly rear HO2S heater resistance


1Visally inspect the HO2S circuit for exposed wiring, contamination, corrosion and proper installation.

Were any concrens found during the visual inspection?

Yes Repair any concerns found in the visual inspection.

No Go to step 2.

2

Turn ignition switch to OFF and disconnect HO2S connector.

Start engine and allow engine to idle.

Measure voltage of HO2S heater battery voltage between HO2S harness connector chassis ground

·Specification : approximately B＋


Yes Go to step 3.

No Open circuit or short circuit to chassis ground between main relay and HO2S harness connector.

3





Yes Go to step 4.



4

Measure resistance between HO2S heater signal and battery power terminal.

· Approximately 6Ω at 20°C (68°F)


Yes Go to step 5.

NoTemporarily install a known good HO2S and check for proper operation.





P0171 System too lean

Threshold Value ~ Long term fuel trim: >23%

Enable Conditions ~ Fuel system status: Closed loop



Related Items


• Clogged fuel injector(s).

• Faulty fuel injector(s).



• Faulty Mass Air Flow Sensor.

• Faulty Throttle Position Sensor.

If any codes relating to injectors, O2 Sensor, Coolant Temperature Sensor or Mass Air Flow Sensor are stored, do ALL REPAIRS associated with those codes before proceeding with this troubleshooting tree.


1


Check for any split, disconnected or perforated vacuum hoses.

Also, check PCV valve for proper operation and Purge Solenoid Valve (PSV) for proper installation and operation.


YES Go to step 2.


2

Perform Fuel Pressure Test (34 to 38 PSI).

Perform Maximum Fuel Pressure Test (50 PSI minimum).



YES Go to step 3.


3Perform Fuel Injector Inspection and Volume Test per Service Manual.

Are fuel injectors working okay and dispensing proper volume?

YES Go to step 4.


4

Connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect adapter cable C211 to ECM and vehicle C211 to adapter cable. Start engine and allow to warm up to operating temperature. With engine idling, monitor Front O2 Sensor voltage at BOB pin 12. In short spurts, spray aerosol carb cleaner in the following areas while looking for a long rise in voltage at Front O2 Sensor (a rise in voltage that is approximately as long as the spray of carb cleaner indicates

some of the carb cleaner was drawn into the intake chamber richening the fuel mixture verifying a leak). Allow enough time between areas checked for carb spray to dissipate.







NO Go to step 5.

5Check for exhaust leaks by having a helper hold a wadded rag against tailpipe and listen for exhaust leaks between main catalytic converter and cylinder head with vehicle running



NO Go to step 6.



YES Clean MAFS with aerosol brake cleaner and let air dry before reinstalling. Check air cleaner and housing for source of leak and repair as necessary. If damaged or deteriorated, replace.

NO Go to step 7.

7Check TPS.


YES Go to step 8.

NO Replace TPS.

8

Start engine and allow to idle at operating temperature. Measure voltage at BOB pin 41 (0.9v to 1v). Open throttle slowly and verify voltage increases with air flow. Actual voltages will vary with altitude and relative humidity but, at sea

level and 50% relative humidity, voltage should be approximately:

• 0.9 to 1v @ idle

• 1.4v @ 1500 rpm

• 1.5v @ 2000 rpm

• 1.6v @ 2500 rpm

• 1.7v @ 3000 rpm


YES Go to step 9.

NO Go to step 9. If wiring and connections are all okay, replace MAFS.

9 With ignition off, disconnect TPS and MAFS connectors. Measure resistance between TPS and ECM on all three circuits (C144-1 to BOB pin 71, C144-2 to BOB pin 59 and C144-3 to BOB pin 73). Measure resistance between MAFS YES Thoroughly check for loose, bent or corroded connectors at ECM, TPS and MAFS. Repair as necessary.


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and ECM (C129-2 to BOB pin 14 and C129-4 to BOB pin 41). Measure resistance between MAFS and GND (C129-1 and GND).

Are resistance values all below 1 ohm? NO Locate source of high resistance of open and repair as necessary.


FUEL SYSTEM (LEAN)

Diagnostic trouble code No. P0171 Fuel system too lean (bank 1)

〔Related items〕 · Faulty fuel delivery system

· Clogged fuel injetors

· Faulty fuel injectors


· Leak inexhaust system

· Faulty MAFS

· Faulty TPS

If any codes relating to injectors, HO2S or MAFS are stored, do all repairs associated with those codes before proceeding with this troubleshooting procedure


1


Turn ignition to ON and monitor DTCs.


Yes Do all repair associated with those codes before proceeding this procedure.

No Go to step 2.

2

Visually/physically inspect the following items :

· Throttle body gasket



· Seals between durge tank and PCV valves

· Crankcase ventilation valve and/or system for leaks

· Contaminated fuel

Are the above items okey?

Yes Go to step 3.


3

Visually/pysically inspect the following items :

· Air cleaner element for being restricted.

· MAFS for proper installation and foreign objectors

· Exhaust system for leaks?


Yes Go to step 4.


4Check vacuum hoses for splits proper connections to engine dynamic(especially PSV, ISC hose, throttle body, intake manifold, and brake booster).

Are connections OK?

Yes Go to step 5.


5 With engine idling disconnect hose between EVAP valve and canister. Check for vacuum at EVAP valve is vacuum available at purge valve when EVAP valve is not operating?Yes

EVAP canister purge valve or circuit failure.

Repair according to DTC P0443 repair procedure

No Go to step 6.

6

After installing fuel pressure gauge to service port on fuel reil, connect DLC F/P and B(B＋) with a jumper wire.

· Fuel pressure at idle : 40-43psi (276-296kPa, 2.81-3.02kg/cm²)

Is fuel line pressure correct with igniation switch ON?

Yes Go to step 7.

No

Low pressure :

Clamp return-line and check if pressure rises :

- If pressure rises : replace pressure regulator

- If pressure dose not rise : check the strainer at the fuel pump.

High pressure :

Disconnect return-line from filter side and blow through towards tank.

- If line is clear : replace fuel delivery module.

- If line blocked : check for blockage in return line and clear or replace as necessary.

If it is OK. check fuel.

7

Start engine and check for engine rpm decrese when disconnecting each injector connector in sequence.

Measure the decreasing engine rpm of all 4cylinders.

Is there any cylinder with no change in rpm or anly a small rpm change?

Yes Repair as necessary.

No Go to step 8.

8Remove spark plugs and inspect spark plug tips. Check for abnormal color compared to other cylinders.

Are any spark plugs with abnormal color compared to other cylinder?

Yes Check for engine mechanical failure failure. If it is OK, rplace spark plugs.

No Go to step 9.

9Check for ECM input signal from MAFS, HO2S, TPS and other input signals.

Are input signals within specification?

Yes Go to step 10.

No Replace all failed parts.

10 Return vehicle to orignal condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN TOOL connected and monitor for pending codes.



P0172 System too rich

Threshold Value ~ Long term fuel trim:< -23%

Enable Conditions ~ Fuel system status: Closed loop



Related Items

• Faulty ignition system.


• Faulty fuel injector(s).


• Faulty Mass Air Flow Sensor.

• Faulty Throttle Position Sensor.

If any codes relating to injectors, O2 Sensor, Coolant Temperature Sensor or Mass Air Flow Sensor are stored, do ALL REPAIRS associated with those codes before proceeding with this troubleshooting tree.


1


Refer to Service Manual (section 30) and check coils, plug wires and spark plugs.

Is ignition system functioning normally?

YES Go to step 2.


2

Perform Fuel Pressure Test (34 to 38 PSI).

Perform Maximum Fuel Pressure Test (50 PSI minimum).



YES Go to step 3.


3Perform Fuel Injector Inspection and Volume Test per Service Manual.

Are fuel injectors working okay and dispensing proper volume?

YES Go to step 4.


4

With ignition off, connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect adapter cable C211 to ECM and vehicle C211 to adapter cable. Start engine and allow to warm up to operating temperature.

With engine idling, monitor front O2 sensor voltage at BOB pin 12 and verify O2 sensor is switching from rich to lean a minimum of 2 times in 10 seconds.

Is Front O2 sensor switching normally?

YES Go to step 5.




YES Clean MAFS with aerosol brake cleaner and let air dry before reinstalling. Check air cleaner and housing for source of leak and repair as necessary. If damaged or deteriorated, replace.

NO Go to step 6.

6Check TPS.


YES Go to step 7.

NO Replace TPS.

7

Start engine and allow to warm up to operating temperature. With engine idling, measure voltage at BOB pin 41 (0.9v to 1v).

Open throttle slowly and verify voltage increases with air flow. Actual voltages will vary with altitude and relative humidity but, at sea level and 50% relative humidity, voltage should be approximately:

• 0.9 to 1v @ idle

• 1.2v @ 1500 rpm

• 1.4v @ 2000 rpm

• 1.5v to 1.6v @ 2500 rpm

• 1.7v @ 3000 rpm


YES Go to step 8.

NO Go to step 8. If wiring and connections are all okay, replace MAFS.

8

With ignition off, disconnect TPS and MAFS connectors. Measure resistance between TPS and ECM on all three circuits (C144-1 to BOB pin 71, C144-2 to BOB pin 59 and C144-3 to BOB pin 73). Measure resistance between MAFS

and ECM (C129-2 to BOB pin 14 and C129-4 to BOB pin 41). Measure resistance between MAFS and GND (C129-1 and GND).

Are resistance values all below 1 ohm?

YES Thoroughly check for loose, bent or corroded connectors at ECM, TPS and MAFS. Repair as necessary.

NO Locate source of high resistance or open and repair as necessary.



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FUEL SYSTEM (RICH)

Diagnostic trouble code No. P0172 Fuel system too rich (bank 1)

〔Related items〕 · Faulty ignition system

· EVAP canister purge valve malfunction


· Leak inexhaust system

· Faulty fuel

- Clogged fuel injectors

- Fuel pressure too high

- Fuel pressure regulator failure

· Faulty MAFS


· Faulty TPS

If any injectors, front HO2S, ECTS and MAFS codes before proceeding this troubleshooting procedure.


1




Yes Do all repair associated with those codes before proceeding this procedure

No Go to step 2.

2

Visually/physically inspect the following items :




· Seals between durge tank and PCV valves


· Contaminated fuel


Yes Go to step 3.


3

Visually/pysically inspect the following items :

· Air cleaner element for being restricted.

· MAFS for proper installation and foreign objectors

· Exhaust system for leaks?


Yes Go to step 4.


4Check vacuum hoses for splits proper connections to engine dynamic(especially PSV, ISC hose, throttle body, intake manifold, and brake booster).

Are connections OK?

Yes Go to step 5.

NoTemporarily install a known good HO2S and check for proper operation.


5 With engine idling disconnect hose between EVAP valve and canister. Check for vacuum at EVAP valve is vacuum available at purge valve when EVAP valve is not operating?Yes

EVAP cansiter puurge valve or circuit failure.

Repair according to DTC P0443 repair procedures

No Go to step 6.

6

After installing fuel pressure gauge to service port on fuel reil, connect DLC F/P and B(B＋) with a jumper wire.

· Fuel pressure at idle : 40-43psi (276-296kPa, 2.81-3.02kg/cm²)

Is fuel line pressure correct with igniation switch ON?

Yes Go to step 7.

No

Low pressure :

Clamp return-line and check if pressure rises :

- If pressure rises : replace pressure regulator

- If pressure dose not rise : check the strainer at the fuel pump.

High pressure :

Disconnect return-line from filter side and blow through towards tank.

- If linde is blocked : check for blockage in return line and clear or replace as necessary.

- If mine clear : replace fuel delivery module.

If it is OK. check fuel.

7

Start engine and check for engine rpm decrese when disconnecting each injector connector in sequence.

Measure the decreasing engine rpm of all 4cylinders.

Is there any cylinder with no change in rpm or anly a small rpm change?


No Go to step 8.

8Remove spark plugs and inspect spark plug tips. Check for abnormal color compared to other cylinders.

Are any spark plugs with abnormal color compared to other cylinder?

Yes Check for engine mechanical failure failure. If it is OK, rplace spark plugs.

No Go to step 9.

9Check for ECM input signal from MAFS, HO2S, TPS and other input signals.

Are input signals within specification?

Yes Go to step 10.

No Replace all failed parts.



INJECTOR

Diagnostic trouble code No. P0201 Cylinder 1 injector circuit malfuntion




〔Related items〕 · Open or short between main relay and injectors

· Open or short between ECM and injectors

· Short to battery between ECM and injcetors

· Faulty fuel injector


1

Turn ignition switch to OFF and disconnect injevtor connector.

Measure resistance between injector terminal 1 and terminal 2.

· 12-16Ω at 20°C (68°F)


Yes Go to step 2.

NoTemporarily install a known good injector and check for proper operation.

If problem is corrected, replace injector.

2

Turn ignition to OFF and disconnect injector connector.

Turn ignition to ON and measure voltage of injector battery power circuit between injector harness connector and chassis ground

· Specification : approximately B＋


Yes Go to step 3.

NoOpen circuit or short circuit to chassis ground between main relay and injector harness connector.


3

Disconnect ECM connector and injector connector.

Measure resistance between injector harness connector amd ECM harness connector.



Yes Go to step 4.

NoOpen circuit between injector harness connector and ECM harness connector.

Replace as necessary.

4

ECM connector and injector connector is still disconnected. Measure resistance between injector harness connector chassis ground at injector cignal circuit.


Does resistance indicate open circuit

YesTemporily install a known good injector and check for proper operation.

If problem is corrected, replace injector.

NoShort circuit to chassis ground between injector terminal 2 and ECM.





P0261, P0264, P0267 & P0270 (Cylinders 1 through 4 injector circuit low voltage)

Threshold Value ~ NA




Related Items

• Open between EGI Main Relay and Injector.

• Open or short to GND between Injector and ECM.

• Faulty Fuel Injector.


1With ignition off, disconnect connector from appropriate injector. Turn ignition on (engine off) and measure voltage at harness connector terminal #1 (B+).

Is battery voltage present?s

YES Go to step 2.

NOVerify voltage at EGI Main Relay (terminal #1) with ignition on. If voltage is not available at EGI Main Relay (vehicle will not run), replace EGI Main Relay and retest. If voltage is available at EGI Main Relay, check for B+ at C161-6. If

voltage is not available at C161-6 (and is available at EGI Main Relay), locate and solder splice S190. If voltage is available at C161-6, locate source of open between C161-6 and injector. Repair as necessary.


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2

Turn ignition off and disconnect C211 from ECM (leave injector connector disconnected). Connect adapter cable #K99U-2106-G17 to BOB and connect vehicle C211 to adapter cable. Measure resistance between injector connector

terminal #2 and appropriate BOB pin (refer to BOB overlay)(less than 1 ohm).


YES Go to step 3.


3With conditions the same as in step 2, measure resistance to GND at injector connector terminal #2 (infinite resistance).

Is resistance infinite?

YES Go to step 4.

NO Locate source of short to GND and repair as necessary.

4Measure resistance between Injector terminals 1 and 2 (12 to 16 ohms @ 68 degrees F).

Is resistance within specifications?

YES Thoroughly check for loose, bent or corroded terminals at all connectors in circuit.

NO Replace Injector.




P0262, P0265, P0268 & P0271 (Cylinders 1 through 4 injector circuit high voltage)





Related Items

• Short to Battery (B+) between injector and ECM.



1With ignition off, disconnect connectors from appropriate injector and ECM. Turn ignition on (engine off) and measure voltage at appropriate ECM terminal (0v).

Is 0 volts indicated?

YES Go to step 2.

NO Locate source of short to B+ and repair as necessary.



YES Wiggle test harnesses between injector and ECM while performing Step 1 again.










Related Items






Is battery voltage present?

YES Go to step 2.


voltage is not available at C161-6 (and is available at EGI Main Relay), locate and solder splice S190. If voltage is available at C161-6 and injector. Repair as necessary.

2




YES Go to step 3.




YES Go to step 4.














Related Items






YES Go to step 2.














Related Items







YES Go to step 2.



2




YES Go to step 3.




YES Go to step 4.














Related Items




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YES Go to step 2.














Related Items







YES Go to step 2.



2




YES Go to step 3.




YES Go to step 4.














Related Items






YES Go to step 2.









P0326 Knock sensor circuit range/performance

Threshold Value ~ Out of mV range of pre-determined engine RPM map.

Enable Conditions ~


• Coolant temperature >104°F

• Load value >3.0 ms



Related Items

• Open or short to GND between Knock Sensor and ECM terminal #70.

• Source of high resistance between Knock Sensor and ECM terminal #70.

• Faulty Knock Sensor.


1

IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s). With ignition off, disconnect C211 from ECM. Connect adapter cable # K99U-2106-G17 to BOB and connect vehicle C211 to adapter

cable. Leave adapter cable DISCONNECTED from ECM for all tests. Check continuity between BOB pins 70 and 71 (infinite resistance).


YES Go to step 2.

NO Go to step 3.

2Individually check continuity to GND between BOB pins 70 and 71 (infinite resistance).

Is resistance to GND infinite on both circuits?

YES Go to step 4.

NO Check for short to ground between knock sensor and ECM. Repair as necessary.

3Disconnect C196 from knock sensor. Check resistance between BOB pins 70 and 71 (infinite resistance).


YES Replace knock sensor and perform check in step 4 before proceeding to step 7.

NO Check harness for damage or other cause of short between knock sensor wiring. Repair as necessary.

4Disconnect C196 from knock sensor. Check resistance between BOB pin 70 and C196-1 (less than 1 ohm).


YES Go to step 5.


5

Remove knock sensor from vehicle and secure (across mounting boss) in a shop vise. Set up KIA Data Pro scan tool for use as an oscilloscope (make sure internal battery is fully charged). Attach negative probe to knock sensor pin #2

and positive probe to sensor pin #1. Set time (F1) to .5 seconds and voltage (F2) to 0.2v. Rap on vise with a ball peen hammer while monitoring oscilloscope screen (there should be a spike of less than 1 volt with each hammer strike).

Does knock sensor send a voltage spike with hammer strikes?

YES Go to step 6.

NO Replace knock sensor and perform verifications in step 7.

6

Remove foot plate on passenger side of vehicle. Carefully unwrap tape from junction connector C294 (taped to engine harness just in front of part number tag). Carefully inspect junction bar in connector for any signs of corrosion or

loose connections. Back-probe pins 5 & 6 and check their continuity to GND (less than 1 ohm).

Is continuity to GND on both circuits less than 1 ohm?

YESThoroughly check for loose, bent or corroded terminals.


NO

Locate source of high resistance and repair as necessary.

S194 is located on G103 pigtail (follow wire from C294-3 to splice).

7 Clear codes and return vehicle to original condition. Verify an repairs by driving vehicle with KIA Data Pro connected to OBD-II connector and monitoring for pending codes (refer to section 3 of the KIA Data Pro Generic OBD-II Program Card reference manual).

KNOCK SENSOR

Diagnostic trouble code No. P0326 Knock sensor circuit range/performance problem

Diagnostic trouble code No. P1386 Knock control zero test

〔Related items〕 · Open or short to GND between knock sensor and ECM

· Source of high resistance between knock sensor and ECM

· Faulty knock sensor Connect SCAN TOOL to data link connector or OBD-II check connector. Turn ignition to ON and monitor KS voltage signals.


1


Turn ignition to ON and monitor KS voltage signals.

· Specifications : 2.0-3.0V

Is signals within specifications?

Yes Problem is intermittent or was repaired and engine control module memory was not cleared. Check terminal connections at ECM and KS.

No Go to step 2.

2

Start and run engine.

Using SCAN TOOL monitor KS voltage signals from idle to 3000rpm.

Does voltage signals increase?

Yes Check any other DTCs. If any DTCs is present, do all repairs associated with those codes before proceeding next step.

No Go to step 3.

3Thoroughly check KS and ECM for loose, bemt, corroded, contaminated, deterioraded or damaged connectors.

Is any problem present?


No Go to step 4.


62 de 74 03/03/2013 22:31

4

Trun ignition to OFF and disconnect KS connector amd ECM connector.

Measures resistance of KS signals circuit between KS harness connector and ECM harness connector.

Measure resistance of KS ground circuit between KS harness connector and chassis ground.


Is each resistance within specification?

Yes Go to step 5.

NoOpen circuit between KS harness connector and ECN harness connector and/or chassis ground.


5


Measure voltage of KS signals circuit between KS harness connector and chassis ground.



Yes Go to step 6.

NoShort circuit to battery between KS harness connector and ECM harness connector.


6


Measure resistamce of KS harness connector and chassis ground at KS signal circuit.

Measure resistance between KS signal circuit and ground circuit.



Yes Temporarily install known good knock sensor and check for proper operation. If problem is corrected, replace knock sensor.

No

Short circuit to chassis ground between KS harness connector and ECM harness connector.

Short circuit between KS signal circuit and ground circuit.




CKP SENSOR-1

Diagnostic trouble code No. P0335 Crankshaft position sensor circuit circuit malfunction

Diagnostic trouble code No. P0336 Crankshaft position sensor circuit range/performance

〔Related items〕 · Open or short to chassis ground between CKPS and ECM

· Short to battery between CKPS and ECM

· Short between CKPS wires

· Out of allowable air gap

· Faulty target wheel tolerance

· Faulty CKPS


1Throughly check CKPS and ECM for loose, bent, corroded, contaminted, deteriored or damaged connector.



No Go to step 2.

2


Measure resistance of CKPS signal circuit between CKPS harness connector and ECM harness connector.

Measure resistance of CKPS ground circuit between CKPS harness connector and chassis ground.



Yes Co to step 3.

No

Open circuit between CKPS harness connector and ECM harness connector and/or chassis ground.

Open circuit between CKPS harness connector and chassis ground.


3


Measure resistance between CKPS harness connector and chassis ground.

· Specifications : infinte


Yes Go to step 4.

NoShort circuit to battery between CKPS harness connector and ECM harness connector.


4

Trun ignition to OFF.

Measures resistance between CKPS harness connector and chassis ground connector at CKPS signal circuit.

Measure resistance between CKPS signal circuit and CKPS ground circuit.

· Specifications : infinite


Yes Go to step 5.

No

Short circuit to chassis ground between CKPS harness connector and ECM harness connector.

Short circuit between CKPS signal circuit and CKPS ground circuit.


5Remove CKPS and calculate air gap between sensor and flywheel/torque converter (0.95-1.7mm<0.037-0.067 in>) measure distance from hosing to teeth on flywheel/torque converter (measurement "A") and

from mounting surface on sensor to sensor tip (measurement "B") subtract "B" from "A" = air gap. Is air gap within specifications?

Yes Temporarily install a known good correctly, and check CKPS for proper operation. If not, temporarily install a known good CKPS and check for proper operation. If problem is corredted, replace CKPS.

No Remove CKPS install CMPS correctly, and check for proper operation. If not, temporarily install a known good CKPS and check for proper operation. If problem is corredted, replace CKPS.




P0336 Crankshaft position sensor circuit range/performance

Threshold Value ~ # of sensor ring teeth counted (between reference mark gap) does not equal actual # of teeth

Enable Conditions ~ Engine speed: >600 RPM



Related Items

• Poor connection(s) at Crank Angle Sensor (CKP) or at ECM.

• Faulty or damaged Engine harness.

• Improper air gap between CKP and Target Wheel.

• Faulty CKP.


1


With ignition key off, disconnect C147 from CKP and C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and vehicle C211 to adapter cable. Measure resistance from C147-1 to BOB pin 16 and from C147-2 to BOB pin

43 (< 1 ohm).


YES Go to step 2.

NOLocate source of high resistance/open.


2

Reconnect C147 to CKP. Measure resistance between BOB pin 16 and BOB pin 43 (800 to 900 ohms at 68∞ F). Remove CKP Sensor from transmission and calculate air gap between sensor and flywheel/torque converter (0.037” to

0.067” - 0.95mm to 1.7mm) [measure distance from housing to teeth on flywheel/torque converter (measurement “A”) and from mounting surface on sensor to sensor tip (measurement “B”) - subtract “B” from “A” = air gap].

Are air gap and resistance measurements within specification?

YESInspect flywheel/torque converter sensor ring teeth (make sure all teeth are intact and ring is properly positioned. Thoroughly check for loose, bent or corroded terminals at CKP Sensor and ECM. Repair as necessary and proceed to

step 3.

NO Replace CKP Sensor or call tech line if air gap is out of specification.

3

Connect adapter cable C211 to ECM and reconnect C147 to CKP. Set up KIA Data Pro for use as a single channel oscilloscope (refer to KIA Data Pro Program Card Operators Manual section 4 for set up procedures). Make sure internal NI-CAD battery is fully charged or use adapter cable to power scan tool. Do not connect scan tool to OBD-II DLC for power source as this will affect waveform.

Adjust F1 to 2 ms, F2 to 5v, F3 to 0.00v, F5 to j, and F6 to n or a. Attach scan tool positive probe to BOB pin 16 and negative probe to BOB pin 43. Start vehicle, warm up to operating temperature and allow to idle. Compare waveform with sample in diagram “A” (your vehicle’s amplitude may vary from sample, but there should be a break [indicating gap for cylinder #1 identification] followed b steady pulses of similar duration and amplitude). If waveform is okay, try wiggle testing harness

between CKP and C211 while monitoring scan tool screen (repair harness in affected area if any anomalies arise). If waveform is erratic, substitute known good CKP and retest.



CMP SENSOR-2

Diagnostic trouble code No. P0342 Camshaft position sensor circuit low input

〔Related items〕 · Open or short to ground CMPS signal and ECM

· Open or short to ground between CMPS refer power and ECM

· Faulty CMPS

· Improper cam timing


63 de 74 03/03/2013 22:31

If vehicle lacks power or has low engine vacuum, check cam timing.


1Thoroughly check CMPS and ECM for loose, bent corroded, contaminted, deteriored or damaged connectors.

Is any problem present.


No Go to step 2.

2

Turn ignition to OFF and disconnect CMPS connector.

Turn ignition to ON and measure voltage of CAMP power circuit between CMPS harness connector and chassis ground.



Yes Go to step 3.

No Open circui or short circuit to chassis ground between CMPS harness connector and main relay.

3


Measure resistance of CMPS signal circuit between CMPS harness connector connector and ECM harness connector.



Yes Go to step 4.

NoOpen circuit between CMPS harness connector and ECM harness connector and/or chassis ground.


4

Trun ignition to OFF. ECM cornnect is still disconnect.

Measures resistance between CMPS harness connector and ECM harness connector at CMPS signal circuit.

Measyre resistance between CMPS signals circuit and ground circuit.

· Specifications : infinite


Yes Go to step 6.

No

Short circuit to chassis ground between CMPS harness connector and ECM harness connector.

Short circuit between CMPS signal circuit ground circuit.


5


Check for CMPS installation.

Is CMPS installed properly?

Yes Temporarily install a known good CMPS and check for proper operation. If problem is corredted, replace CMPS.

NoRemove CMPS, install CMPS correctly, and check CMPS for proper operation.

If not, temporarily install a known good CMPS and check for proper operation. If problem is correct, replace CMPS.




P0343 Camshaft position (phase) sensor high input

Threshold Value ~ No signal from camshaft position sensor for >200 crankshaft revolutions




Related Items

• Open or short to B+ between Cam Position (Phase) Sensor (CMP)(C118-2) and ECM (C211-44).

• Open between CMP Sensor (C118-3) and GND.

• Open between EGI Main Relay (pin #1) and CMP Sensor (C118-1).

• Missing sensor pin on exhaust cam.

• Faulty CMP Sensor.


1


With ignition off, disconnect C118 from CMP and C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and connect vehicle C211 to adapter cable (leave adapter cable disconnected from ECM). Measure resistance

between C118-2 and BOB pin 44 (less than 1 ohm).


YES Go to step 2.

NOLocate source of open or high resistance.


2Measure resistance between C118-3 and GND (< 1 ohm).

Is measured resistance less than 1 ohm?

YES Go to step 3.

NO Locate source of open or high resistance between C118-3 and GND. Repair as necessary.

3Torn ignition on (engine off) and measure voltage at BOB pin 44 (0v).


YES Go to step 4.

NO Locate source of short to B+ between CMP and C211-44. Repair as necessary.

4Turn ignition off and connect adapter cable C211 to ECM. Turn ignition on (engine off) and measure voltage at C118-1 (B+).

Is measured voltage B+?

YES Go to step 5.

NO Check for voltage at EGI Main Relay (pin 1). If voltage is low or absent, replace relay and retest. If B+ is present at relay but not at C118-1, locate source of open or high resistance and repair as necessary.

5

Turn ignition off, reconnect C118 to CMP and set up KIA Data Pro for use as a single channel oscilloscope (refer to KIA Data Pro Program Card Operators Manual section 4 for set up procedures). Make sure internal NI-CAD battery is

fully charged or use adapter cable to power scan tool. Do not connect scan tool to OBD-II DLC for power source as this may affect wave form. Connect positive lead to BOB pin 44 and negative lead to GND. Set scope time (F1) to

50ms and voltage (F2) to 5v. Start engine and allow to idle at operating temperature. Pattern should be similar to sample:

Is pattern similar to sample?

YES While still monitoring waveform, wiggle test harness between CMP Sensor and C211. If pattern becomes broken or is eliminated, repair or replace harness as necessary.

NO Remove CMP sensor mounting bracket and check exhaust cam for sensor pin. If pin is missing, replace exhaust cam. If pin is intact, replace CMP Sensor.


CMP SENSOR-3

Diagnostic trouble code No. P0342 Camshaft position sensor circuit low input

〔Related items〕 · Open or short to ground CMPS signal and ECM

· Open or short to ground between CMPS refer power and ECM

· Faulty CMPS

· Improper cam timing

If vehicle lacks power or has low engine vacuum, check cam timing.


1Thoroughly check CMPS and ECM for loose, bent corroded, contaminted, deteriored or damaged connectors.



No Go to step 2.

2


Turn ignition to ON and measure voltage of CAMP power circuit between CMPS harness connector and chassis ground.



Yes Go to step 3.

No Open circui or short circuit to chassis ground between CMPS harness connector and main relay.

3


Measure resistance of CMPS ground circuit between CMPS harness connector and chassis ground.



Yes Go to step 4.

NoOpen circuit between CMPS harness connector and ECM harness connector and/or chassis ground.


4

Trun ignition to ON. ECM cornnect is still disconnect.

Measures voltage of CMPS signal circuit between CMPS harness connector and chassis ground.

· Specifications : below 0.5V


Yes Temporarily install a known good CMPS and check for proper operation. If problem is corredted, replace CMPS.

NoShort circuit to power between CMPS harness connector and ECM harness connector.




VEHICLE SPEED SENSOR

Diagnostic trouble code No. P501 Vehicle speed sensor circuit malfunction

[Related items]

· Open or short between ECM and instrument cluster

· Open or short between VSS and instrument cluster

· Faulty VSS


1 Does speedometer operate normally? Yes Go to step 2.


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No Check VSS power, signal and ground circuits. Repair as necessary.

2

Turn ignition to OFF and disconnect ECM connector and instrument cluster.

Measure resistance of vehicle speed signal circuit between instrument cluster and ECM harness connector.


Does resistance indicate continuity circuit?

Yes Go to step 3.

No Open circuit between ECM harness connector and instrument cluster.Repair as necessary.

3


Measure voltage of vehicle speed signal circuit between instrument cluster and chassis ground.


Yes Go to step 4.

NoShort circuit to battery between ECM harness connector and instrumentcluster.


4

Measure resistance between instrument cluster and chassis ground at vehicle speed signal circuit



YesThoroughly check for poor connection, misplaced, corroded terminalsat ECM connector.


NoShort circuit to chassis ground between ECM harness connector and battery.


5· Temporarily install a known good ECM and check for proper operation. If problem is corrected replace ECM.

· Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN TOOL connected and monitor for pending codes.



P0506 Idle control system RPM lower than expected

Threshold Value ~

(Desired RPM) - (Engine RPM) & 100 RPM and Idle Air Control (IAC) Valve integrator value:< -5.2 kg/h or Fuel cut-off counter: >3

Enable Conditions ~

Engine speed: idling

Vehicle speed: 0 MPH

Engine coolant temperature: >176 degrees F

Time Requirements ~ Continuous (12 seconds duration)


Related Items

• High resistance between EGI Main Relay and IAC Valve.

• High resistance between IAC Valve and ECM.

• Faulty IAC Valve.

If any TPS, MAFS, Fuel injector or IAC Valve circuit codes (or pending codes) are present, do ALL REPAIRS associated with them before proceeding with this troubleshooting tree.


1With ignition off, disconnect C146 from IAC Valve. Turn ignition on and measure voltage at C146-2 (B+).


YES Go to step 2.

NO Locate source of high resistance between EGI Main Relay and C146-2. Repair as necessary.

2Turn ignition off and measure IAC Valve winding resistance between terminals 1 ~ 2 and 2 ~ 3 (approximately 14 ~ 18 ohms at 68 degree F).

Are resistance readings with specification?

YES Go to step 3.

NO Replace IAC Valve.

3Disconnect C211 from ECM. Measure resistance between C146-1 and C211-2. Also measure resistance between C146-3 and C211-29 (less than 1 ohm).

Are resistance values for both circuits less than 1 ohm?

YES Go to step 4.

NO Locate source of high resistance on affected circuit(s). Repair as necessary.

4

Remove IAC Valve from Throttle body and check for excessive carbon deposits and sticking per following check:

Connect IAC Valve terminal #2 to 12v power source. One-at-a-time, momentarily ground pins 1 and 3 while visually verifying valve closes when pin #1 is grounded and valve opens when pin #3 is grounded. Repeat numerous times to

ensure valve reliability. Is IAC Valve moving freely and not carbon fouled?

While IAC Valve is removed, inspect Throttle Body for obstructions in idle circuit ports. Repair or replace as necessary.

YES Thoroughly check for loose, bent or corroded terminals. Repair as necessary.



IDLE CONTROL SYSTEM

Diagnostic trouble code No. P0506 Idle control system rpm lower than expected

[Related items]

· Open or short between main relay and IACV

· Open or short between ECM and IACV

· Intake system is plugged

· Carbon fouled throttle plate

· Faulty IACV

If any codes relating to TPS, MAFS, fuel injector or IACV present, do all repairs associated with them before proceeding with this troubleshooting guide


1



Are any other codes also set?


No Go to step 2.

2Check accelerator cable free play [0.040~0.120 in (1.0~3.0 mm)].

Is accelerator cable free play within specification?

Yes Go to step 3.

No Adjust cable

3



· 0.4~0.6V @ idle



Yes Go to step 4.

No Do all repairs associated with TPS before proceeding the next step.

4

Turn ignition to OFF and disconnect IACV connector. With ignition ON,measure voltage of IACV battery voltage between IACV harness connector andchassis ground.



Yes Go to step 5.

NoOpen circuit or short circuit to chassis ground between IACV harnessconnector and main relay.


5


Measure resistance of IACV opening coil and closing coil.

· Opening coil: 16.5~18.5Ω at 20°C (68°F)

· Closing coil: 14.5~16.5Ωat 20°C(68°F)


Yes Go to step 6.

NoTemporarily install a known good IACV and check for proper operation.

If problem is corrected replace IACV.

6

Remove IACV from throttle body and check for excessive carbon deposits and sticking per following check.

Connect IACV battery terminal to 12V power. One at a time, momentarily ground IACV opening coil signal terminal and closing coil terminal while visuallyverifying valve closes when the closing coil terminal is

grounded and valve opens when opening coil signal terminal is grounded.

Repeat numerous times to ensure valve reliability.

Is IACV moving freely and is not carbon fouled?

NOTE:

While IACV is removed, inspect throttle body for obstructions in idle circuit ports. Repair or replace as necessary.

Yes Thoroughly check for loose, bent or corroded terminals at all connectorsin circuit.



7

Turn ignition to OFF and disconnect ECM connector. Measure resistance of IACV opening coil signal circuit between IACV harness connector and ECM harness connector.

Measure resistance of IACV closing coil signal circuit between IACV harness connector and ECM harness connector.



Go to step 8.

NoOpen circuit between IACV harness connector and ECM harness connector.


8

ECM connector and IACV connector is still disconnected.Measure resistance between IACV harness connector and chassis ground at IACV opening coil circuit.Measure resistance between IACV harness

connector and chassis ground at IACV closing coil circuit.

· Specifications: infinite


Yes Go to step 9.

NoShort circuit to chassis ground between IACV harness connector and ECMharness connector.


9 Remove intake hose and inspect throttle plate for excessive carbon deposits. Is throttle plate being held open with excessive carbon deposits?Yes Clean throttle body.

No Go to step 10.

10 Return vehicle to original condition. Clear all diagnostic trouble codes.Verify by driving vehicle with SCAN TOOL connected and monitor for pending codes.



P0507 Idle control system RPM higher than expected

Threshold Value ~

(Engine RPM) - (Desired RPM) >200 RPM and Idle Air Control (IAC) Valve integrator value: >5.0 kg/h

Enable Conditions ~

Engine speed: idling

Vehicle speed: 0 MPH

Engine coolant temperature: >176 degrees F

Related Items

• Improperly adjusted Accelerator Cable.

• Air leak in intake system between head and Throttle Plate.

• Faulty PCV Valve.

• Carbon fouled Throttle Plate.


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Time Requirements ~ Continuous (7 seconds duration)


• Poor connection(s) in TPS circuit or faulty TPS.

• High resistance between IAC Valve and ECM.

• Faulty IAC Valve.

If any TPS, MAFS or IAC Valve circuit codes (or pending codes) are present, do ALL REPAIRS associated with them before proceeding with this troubleshooting tree.


1Check Accelerator Cable free play [0.040~0.120 in. (1.0~3.0 mm)].

Is Accelerator Cable free play within specification?

YES Go to step 2.

NO Adjust cable.



YES Go to step 3.

NO Replace faulty vacuum hose(s), PCV or PSV

3Remove Intake Hose and inspect Throttle Plate for excessive carbon deposits.

Is Throttle Plate being held open with excessive carbon deposits?

YES Clean Throttle Body with O2 Sensor safe carb cleaner.

NO Go to step 4.

4

With ignition off, connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect adapter cable C211 to ECM and vehicle C211 to adapter cable. Turn ignition on (engine off) and measure TPS output voltage

at BOB pin 73 with Throttle Plate closed (0.4~0.6v).

Is TPS output voltage within specification?

YES Go to step 5.

NO Inspect TPS per DTC P0123 Troubleshooting Tree. Repair as necessary.

5Turn ignition off, disconnect C146 from IAC Valve and measure IAC Valve winding resistance between terminals 1~2 and 2~3 (approximately 14~18 ohms at 68 degrees F).

Are resistance readings with specification?

YES Go to step 6.


6

Remove IAC Valve from Throttle body and check for excessive carbon deposits and sticking per following check:

Connect IAC Valve terminal #2 to 12v power source. One-at-a-time, momentarily ground pins 1 and 3 while visually verifying valve closes when pin #1 is grounded and valve opens when pin #3 is grounded. Repeat numerous times to

ensure valve reliability. Is IAC Valve moving freely and not carbon fouled?

While IAC Valve is removed, inspect Throttle Body for obstructions in idle circuit ports. Repair or replace as necessary.

YES Go to step 7.

NO Replace valve.

7With ignition off, disconnect adapter cable C211 from ECM. Measure resistance between C146-1 and BOB pin 2. Also measure resistance between C146-3 and BOB pin 29 (less than 1 ohm).

Are resistance values for both circuits less than 1 ohm?

YES Go to step 8. If no leaks are found in step 8, thoroughly check for loose, bent or corroded terminals.


8

Reconnect adapter cable C211 to ECM and all removed connectors to their component. Connect positive voltmeter probe to BOB pin 12 and negative probe to GND. Start engine and allow to warm up to operating temperature. In short spurts, spray aerosol carb cleaner in the following areas while looking for a long rise in voltage at BOB pin 12 (a rise in voltage that is approximately as long as the spray of carb cleaner indicates some of the carb cleaner was drawn into the intake chamber

richening the fuel mixture verifying a leak). Allow enough time between areas checked for carb spray to dissipate.




• Gasket between intake manifold and surge tank



IDLE CONTROL SYSTEM

Diagnostic trouble code No. P0507 Idle control system rpm higher than expected

[Related items] · Short to ground between IACV and ECM

· Air leak in intake system

· Improperly adjusted accelerator cable

· Faulty IACV

· Faulty TPS

· Faulty PCV/PSV

If any codes relating to TPS, PSV, MAFS, fuel injector or IACV are present, do all repairs associated with them before proceeding with this troubleshooting guide


1



Are any other codes also set?


No Go to step 2.

2Check accelerator cable free play [0.040~0.120 in (1.0~3.0 mm)].

Is accelerator cable free play within specification?

Yes Go to step 3.

No Adjust cable

3



· 0.4~0.6V @ idle



Yes Go to step 4.

No Do all repairs associated with TPS before proceeding the next step.

4

Turn ignition to OFF and disconnect IACV connector. With ignition ON,measure voltage of IACV battery voltage between IACV harness connector andchassis ground.



Yes Go to step 5.

NoOpen circuit or short circuit to chassis ground between IACV harnessconnector and main relay.


5


Measure resistance of IACV opening coil and closing coil.

· Opening coil: 16.5~18.5Ω at 20°C (68°F)

· Closing coil: 14.5~16.5Ωat 20°C(68°F)


Yes Go to step 6.



6

Remove IACV from throttle body and check for excessive carbon deposits and sticking per following check.

Connect IACV battery terminal to 12V power. One at a time, momentarily ground IACV opening coil signal terminal and closing coil terminal while visuallyverifying valve closes when the closing coil terminal is

grounded and valve opens when opening coil signal terminal is grounded.

Repeat numerous times to ensure valve reliability.

Is IACV moving freely and is not carbon fouled?

NOTE:

While IACV is removed, inspect throttle body for obstructions in idle circuit ports. Repair or replace as necessary.

Yes Thoroughly check for loose, bent or corroded terminals at all connectorsin circuit.



7

Turn ignition to OFF and disconnect ECM connector. Measure resistance of IACV opening coil signal circuit between IACV harness connector and ECM harness connector.




Yes Go to step 7.



8

ECM connector and IACV connector is still disconnected. Measure resistance between IACV harness connector and chassis ground at IACV opening coil circuit. Measure resistance between IACV harness

connector and chassis ground at IACV closing coil circuit.



Yes Go to step 9.

NoShort circuit to chassis ground between IACV harness connector and ECMharness connector.


9 Check for any split, disconnected or perforated vacuum hoses. Also, check PCV valve for proper operation and purge solenoid valve for proper installationand operation.Are vacuum hoses, PCV and PSV okay?Yes Go to step 10.

No Replace faulty vacuum hoses, PCV or PSV

10

Visually/physically inspect the following items:



· Gasket between intake manifold and cylinder head


· Seals between surge tank and PCV valves


Are the above items okay?

Yes Go to step 11.


11 With engine idling disconnect hose between EVAP valve and canister.Check for vacuum at EVAP valve Is vacuum available at purge valve when EVAPvalve is not operating?Yes EVAP canister purge valve or circuit failure.Repair according to DTC P0443 repair procedures.

No Go to step 12.




P0601 & P0604 ECM checksum and RAM error


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Threshold Value ~

P0601 ~ Checksum error

P0604 ~ RAM error

Enable Conditions ~ At power up

Time Requirements ~ Once per driving cycle


Related Items

• Open or blown fuse (ECU fuse in Passenger Compartment Fuse Box - PCFB of Fuel Inj fuse in Engine Compartment Fuse/Relay Box - ECFRB) in ECM back up power supply circuit.

• Faulty ECM.


1Check Fuel Inj fuse in ECFRB and ECU fuse in PCFB.

Is either fuse blown?

YES Locate source of short and repair as necessary.

NO Go to step 2.

2With ignition off, connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect adapter cable C211 to ECM and vehicle C211 to adapter cable. Measure voltage at BOB pin 26 (B+).


YES Monitor voltage at BOB pin 26 while test driving. If voltage stays constant and pending code returns, replace ECM. If voltage fluctuates, check circuit Thoroughly for loose, bent or corroded terminals and repair as necessary.

NO Locate open or source of high resistance between ECM B+ fuse and C211-26. Repair as necessary.


BATTERY

Diagnostic trouble code No. P0601 ECM random check sum error

Diagnostic trouble code No.P0604 ECM random access memory error

[Related items] · Too many codes stored memory is full. Repair individual codes and recheck.

· Internal fault. There is no inspection of service possible for this diagnostic trouble code.

· Temporarily install a known good ECM and check for proper operation.If problem is corrected, replace ECM.

· Return vehicle to original condition. Clear all diagnostic trouble codes.Verify by driving vehicle with SCAN TOOL connected and monitor for pending codes.



P0601 & P0604 ECM checksum and RAM error

Threshold Value ~

P0601 ~ Checksum error

P0604 ~ RAM error

Enable Conditions ~ At power up

Time Requirements ~ Once per driving cycle


Related Items

• Open or blown fuse (ECU fuse in Passenger Compartment Fuse Box - PCFB of Fuel Inj fuse in Engine Compartment Fuse/Relay Box - ECFRB) in ECM back up power supply circuit.

• Faulty ECM.


1Check Fuel Inj fuse in ECFRB and ECU fuse in PCFB.

Is either fuse blown?

YES Locate source of short and repair as necessary.

NO Go to step 2.

2With ignition off, connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect adapter cable C211 to ECM and vehicle C211 to adapter cable. Measure voltage at BOB pin 26 (B+).


YES Monitor voltage at BOB pin 26 while test driving. If voltage stays constant and pending code returns, replace ECM. If voltage fluctuates, check circuit Thoroughly for loose, bent or corroded terminals and repair as necessary.

NO Locate open or source of high resistance between ECM B+ fuse and C211-26. Repair as necessary.



MIL CLRCUIT

Diagnostic trouble code No. P1307 MIL circuit malfunction

[Related items] · Open or short to chassis ground between MIL and ECM

· Faulty MIL


1


Turn ignition to ON and measure voltage at ECM MIL control terminal.



YesPoor terminal contact due to oxidation, bent or misplaced terminal at ECM.


No Go to step 2.

2Check for MIL in instrument cluster.

Does MIL operate correctly?

YesOpen circuit or short circuit to chassis ground between ECM harnessconnector and MIL.


No Replace MIL.




P1115 Water temperature signal malfunction

Threshold Value ~ Circuit continuity: No voltage




Related Items

• Short to GND or B+ between ECM and TCM on ECT line.

• Open between ECM and TCM on ECT line.


1

With ignition off, connect adapter cable #K99U-2103-G17 to BOB, disconnect C211 from ECM and C229 from TCM.

Connect vehicle C229 to adapter cable (leave adapter cable C229 disconnected from TCM).

Measure resistance between BOB-33 and C211-68 (< 1 ohm).


YES Go to step 2.


2Measure resistance between BOB-33 and GND (infinite resistance).


YES Go to step 3.


3Turn ignition on and measure voltage at BOB-33 (0v).


YES Thoroughly check for loose, bent or corroded terminals between ECM and TCM.





P1121 TPS circuit from ECM to TCM malfunction

Threshold Value ~ Circuit continuity ~

Open: No signal

Shorted: TPS = < 5% or >94%




Related Items

• Short to GND or B+ between ECM and TCM.

• Open Between ECM and TCM.

If Throttle Position Sensor (TPS) codes or pending code(s) P0122 or P0123 are stored, do ALL repairs associated with them before proceeding with this troubleshooting tree. A malfunction in the TPS circuit or faulty TPS can set a P1121 code.


1

With ignition off, disconnect C211 from ECM and C229 from TCM. Connect adapter cable #K99U-2103-G17 to BOB and vehicle C229 to adapter cable (leave adapter cable C229 disconnected from TCM). Measure resistance between

BOB-20 and C211-38 (less than 1 ohm).


YES Go to step 2.

NO Locate source of resistance and repair as necessary.

2Measure resistance to GND at BOB-20 (infinite resistance).


YES Go to step 3.

NO Locate source of short to ground and repair as necessary.

3 Turn ignition on (engine off) and measure voltage at BOB-20 (0v). YES Thoroughly check for loose, bent or corroded terminals between C254-38 and C221-38.


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Is voltage 0v? NO Locate source of short to battery voltage and repair as necessary.




Diagnostic trouble code No. P1307 Chassis acceleration sensor signal malfunction

[Related items] · Open or short to chassis ground between CAS signal and ECM

· Short to battery between CAS signal and ECM

· Open or short to chassis ground between CAS reference voltage and ECM

· Short to battery between CAS reference voltage and ECM

· Faulty CAS


1



Is DTC P0501 set?


No Go to step 2.

2Thoroughly check CAS and ECM for loose, bent, corroded, contaminated, deteriorated or damaged connectors.



No Go to step 3.

3


Using SCAN TOOL, monitor CAS voltage signals.

· Specifications: approximately 2.5V

Is voltage within the specifications?

Yes Problem is intermittent or was repaired and engine control module memory was not cleared.

No Go to step 4.

4

Turn ignition to OFF and disconnect CAS connector.

With ignition ON, measure voltage of CAS reference voltage between CAS harness connector and chassis ground.

· Specifications: approximately 5V


Yes Go to step 5.

NoOpen circuit or short circuit to chassis ground between CAS harness connector and ECM connector.


5


Measure resistance of CAS signal circuit between CAS harness connector and ECM harness connector.

Measure resistance of CAS ground circuit between CAS harness connector and ECM harness connector.



Yes Go to step 6.

NoOpen circuit between CAS harness connector and ECM harness connector.


6

Turn ignition to ON. ECM connector is still disconnected.Measure voltage of CAS signal circuit between CAS harness connector and chassis ground.

· Specifications: below 0.5V


Yes Go to step 7.

NoShort circuit to battery between CAS harness connector and ECM harness connector.


7


Measures resistance between CAS harness connector and ECM harness connector at CAS signal circuit.

Measure resistance between CAS signal circuit and ground circuit.



YesTemporarily install a known good CAS and check for proper operation.

If problem is corrected, replace CAS.

No

Short circuit to chassis ground between CAS harness connector and ECM harness connector.

Short circuit between CAS signal circuit and ground circuit.





P1307, P01308 & P01309 Chassis acceleration sensor signal malfunction, low input and high input

Threshold Value ~

P1307 ~ Sensor signal amplitude: >0.34 gravity

P1308 ~ Sensor signal mean value:< -2.49 gravity

P1309 ~ Sensor signal mean value: >2.49 gravity

Enable Conditions ~

P1307 ~ Time after vehicle has come to stop: >15 seconds



Related Items

• Open between Chassis Acceleration Sensor (CAS) and ECM.

• Short to B+ or GND between CAS and ECM.

• Faulty CAS.

If a P0501 and/or P1500 code (or pending code) is present, do ALL repairs relating to that code before proceeding with this troubleshooting tree.


1

With ignition off, disconnect C197 from CAS and C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and connect vehicle C211 to adapter cable (leave adapter cable C211 disconnected from ECM). Measure resistance

between C197-3 and BOB-80 (less than 1 ohm).


YES Go to step 2.




YES Go to step 3.


3Measure resistance between BOB-71 and C197-2 (< 1 ohm).


YES Go to step 4.


4Turn ignition on (engine off) and measure voltage at BOB-80 (0v).

Is voltage as specified?

YES Go to step 5.


5Turn ignition off and connect adapter cable C211 to ECM. Turn ignition on (engine off) and measure voltage at C197-1 (5v).


YES Go to step 6.

NO Locate source of open, high resistance or short to B+ between C197-1 and C211-59. Repair as necessary.

6

Turn ignition off, remove CAS from vehicle and reconnect C197 to CAS. Turn ignition on (engine off) and verify approximately 2.5v at BOB-80 (with CAS not moving). While monitoring voltage at BOB-80, have helper violently shake CAS

up and down in hand (with mounting base held parallel to floor). Voltage should quickly vary between approximately 0.1v and 5v (amount of variation will depend on change of acceleration in vertical plane).

Is CAS voltage as specified?

YES Thoroughly check for loose, bent or corroded terminals between CAS and ECM. If pending P1307 reappears during test drive, check Vehicle Speed Sensor wiring per schematic in P0501 troubleshooting tree.

NO Replace CAS.



Diagnostic trouble code No. P1308 Chassis acceleration sensor signal low input

[Related items]

· Short to chassis ground between CAS signal and ECM

· Open or short to chassis ground between CAS reference voltage and ECM

· Faulty CAS


1






No Go to step 2.

2

Turn ignition to OFF and disconnect IACV connector.

With ignition ON, measure voltage of IACV reference voltage between IACV harness connector and chassis ground.



Yes Go to step 3.

NoOpen circuit or short circuit to chassis ground between ACS harness connector and ECM connector.


3



Measure resistance of CAS ground circuit between CAS harness connector and chassis ground.



Yes Go to step 4.

NoOpen circuit between CAS harness connector and ECM harness connectorand/or chassis ground.


4

Tun ignition to OFF.

Measures resistance between CAS harness connector and ECM harness connector at CAS signal circuit.

Measure resistance between CAS signal circuit and ground circuit.





No

Short circuit to chassis ground between CAS harness connector and ECM harness connector.

Short circuit between CAS signal circuit and ground circuit.





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P1307, P01308 & P01309 Chassis acceleration sensor signal malfunction, low input and high input

Threshold Value ~

P1307 ~ Sensor signal amplitude: >0.34 gravity

P1308 ~ Sensor signal mean value:< -2.49 gravity

P1309 ~ Sensor signal mean value: >2.49 gravity

Enable Conditions ~

P1307 ~ Time after vehicle has come to stop: >15 seconds



Related Items

• Open between Chassis Acceleration Sensor (CAS) and ECM.

• Short to B+ or GND between CAS and ECM.

• Faulty CAS.

If a P0501 and/or P1500 code (or pending code) is present, do ALL repairs relating to that code before proceeding with this troubleshooting tree.


1

With ignition off, disconnect C197 from CAS and C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and connect vehicle C211 to adapter cable (leave adapter cable C211 disconnected from ECM). Measure resistance

between C197-3 and BOB-80 (less than 1 ohm).


YES Go to step 2.




YES Go to step 3.


3Measure resistance between BOB-71 and C197-2 (< 1 ohm).


YES Go to step 4.


4Turn ignition on (engine off) and measure voltage at BOB-80 (0v).


YES Go to step 5.


5Turn ignition off and connect adapter cable C211 to ECM. Turn ignition on (engine off) and measure voltage at C197-1 (5v).


YES Go to step 6.

NO Locate source of open, high resistance or short to B+ between C197-1 and C211-59. Repair as necessary.

6

Turn ignition off, remove CAS from vehicle and reconnect C197 to CAS. Turn ignition on (engine off) and verify approximately 2.5v at BOB-80 (with CAS not moving). While monitoring voltage at BOB-80, have helper violently shake CAS

up and down in hand (with mounting base held parallel to floor). Voltage should quickly vary between approximately 0.1v and 5v (amount of variation will depend on change of acceleration in vertical plane).

Is CAS voltage as specified?

YES Thoroughly check for loose, bent or corroded terminals between CAS and ECM. If pending P1307 reappears during test drive, check Vehicle Speed Sensor wiring per schematic in P0501 troubleshooting tree.

NO Replace CAS.



Diagnostic trouble code No. P1309 Chassis acceleration sensor signal low input

[Related items]

· Open between CAS signal and ECM

· Short to battery between CAS signal and ECM

· Open between CAS ground and ECM

· Faulty CAS


1






No Go to step 2.

2

Turn ignition to OFF and disconnect IACV connector.

With ignition ON, measure voltage of IACV reference voltage between IACV harness connector and chassis ground.



Yes Go to step 3.

NoOpen circuit or short circuit to chassis ground between ACS harness connector and ECM connector.


3



Measure resistance of CAS ground circuit between CAS harness connector and chassis ground.



Yes Go to step 4.

NoOpen circuit between CAS harness connector and ECM harness connectorand/or chassis ground.


4


Measure voltage of CAS signal circuit between CAS harness connectorand chassis ground.





NoShort circuit to battery between CAS harness connector and ECM harness connector.





P1386 Knock sensor control zero test

Threshold Value ~ >293 mv

Enable Conditions ~ @ engine start or:


• Coolant temperature >104°F

Load value >3.0 ms


MIL Illumination ~ Two driving cycles

Related Items

• Open or short to GND between Knock Sensor and ECM terminal #70 or 71.

• Defective Knock Sensor.


1

IMPORTANT! Record all freeze frame data before disconnecting any connectors or clearing code(s). With ignition off, disconnect C211 from ECM. Connect adapter cable #K99U-2106-G17 to BOB and connect vehicle C211 to adapter

cable. Leave adapter cable DISCONNECTED from ECM for all tests. Check continuity between BOB pins 70 and 71 (infinite resistance).


YES Go to step 2.

NO Go to step 3.

2Individually check continuity to GND between BOB pins 70 and 71 (infinite resistance).

Is resistance to GND infinite on both circuits?

YES Thoroughly check for loose, bent or corroded terminals. If all wiring checks okay, replace knock sensor.

NO Check for short to ground between knock sensor and ECM. Repair as necessary.

3Disconnect C196 from knock sensor. Check resistance between BOB pins 70 and 71 (infinite resistance).


YES Replace knock sensor.

NO Check harness for damage or other cause of short between knock sensor wiring. Repair as necessary.




P1458 A/C compressor control signal malfunction

Threshold Value ~ Voltage detected at ECM terminal 64 but no voltage detected at ECM terminal 65.

Enable Conditions ~ Engine speed: >22.85 RPM



Related Items

• Open between ECM (C211-64) and S242 with A/C switch on.

• Short to GND between A/C thermostat (C285-3) & ECM (C211-65) with A/C switch off.


1

With ignition off, connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect vehicle C211 to adapter cable and adapter cable C211 to ECM. Turn ignition on (engine off), blower switch on (#1 position),

A/C switch on and measure voltage at BOB-64 (< 0.5v).

Is measured voltage less than 0.5v?

YES Go to step 2.

NO Locate source of high resistance or open between S242 and C211-64. Repair as necessary.

2Turn A/C switch off and measure voltage at BOB-65 (5v).


YES Thoroughly check for loose, bent or corroded terminals (or pinched/shorted harness) between A/C relay (C283-5) and ECM (C211-64 & 65).

NO Locate source of short to GND between A/C thermostat (C285-3) and C211-65. Repair as necessary.


A/C COMPRESSOR


No. P1458A/C compressor active signal malfuntion


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［Related items］ · Open or short between A/C switch and ECM

· Open or short to battery between A/C relay and ECM

· Open or short to ground between A/C relay and battery voltage

· Faulty A/C relay and A/C switch


1

Turn ignition to ON and set A/C switch to OFF.

Measure voltage at ECM terminal 64.

Specification : spproximately 5V


Yes Go to step 2.

NoOpen circuit or short circuit chassis ground between A/C switch harness connector and ECM harness terminal 64.


2

Set blower switch to position 1 and A/C switch to ON.

Measure voltage at ECM terminal 65.

·Specification : below 0.5V


Yes Go to step 3.

NoShort circuit to battery between A/C DPS and ECM harness terminal 65.

Replace as necessary.

3

Ignition OFF disconnect A/C relay connector and A/C switch connector.

Measure resistance between A/C relay harness connector and A/C switch harness connector.



Yes Go to step 4.

NoOpen circuit or between A/C relay harness connector and A/C switch harness connector


4

Measure resistance between A/C relay coil terminal and chassis ground.

·Specification : infinits

Does resistance indication open circuit?

Yes Go to step 5.

NoShort to chassis ground between A/C relay harness connector and A/C switch harness connector.


5 Are A/C switch, blower switch, and AC relay okay?Yes Check A/C system

No Repair or replace as necessry.

6 Return vehicle to original condition. Clear all diagnostic trouble codes. Verify by driving vehicle with SCAN TOOL connected and mounitor for pending codes.



P1500 Vehicle speed sensor range/performance malfunction

Threshold Value ~ No signal

Enable Conditions ~

Output speed signal: >775 RPM

L4 switch: Off



Related Items

• Open between Meter Fuse and Vehicle Speed Sensor (VSS).

• Open between VSS and GND.

• Open between VSS and ECM.

• Short to B+ or GND between VSS and ECM.

• Faulty VSS.

• Faulty Speedometer.


1Verify Meter Fuse is not blown. If it is, locate source of short and repair as necessary. With ignition off, disconnect C137 from VSS. Turn ignition on (engine off) and measure voltage at C137-3 (B+).


YES Go to step 2.

NOLocate source of open between Meter Fuse and VSS.


2Turn ignition off and measure resistance to GND at C137-2(< 1 ohm).

Is measured resistance below 1 ohm?

YES Go to step 3.

NO Locate source of high resistance or open between G203 and VSS. Repair as necessary

3

Reconnect C137 to VSS. Locate C207 and C205 (under ECM cover) and back-probe C205-13 (auto) or C205-5 (manual) and C207-11. Set up KIA Data Pro for use as an oscilloscope with dual signals (refer to section 4 of Data Pro Program Card Operators Manual for detailed information on dual channel oscilloscope operation). Attach red lead to back probe at C205-13 (auto) or C205-5 (manual) and black lead to back probe at C207-11. Adjust TIME (F1) to 50ms; adjust both A and B

VOLTAGES (F2) to 5v; adjust LEVEL (F3) to 5v; adjust A GND (F4) to 1st grid from bottom and B GND (F4) to 3rd grid from top (see sample waveforms below). Raise vehicle on lift with tires at least 6 inches off of the floor. Start vehicle and shift into 2nd gear. Let vehicle idle and verify speed is approximately 5 mph.

Top waveform is VSS input into speedometer and bottom waveform is VSS output from speedometer. At 5 mph the waveforms should be similar to the samples in diagram “A”.

Diagram “B” illustrates a vehicle with one or more of the following on the output side of the speedometer ~

1. a short to B+ (step 4) 2) a short to GND or an open (step 5) 3) a faulty speedometer If this is the case, go to step indicated in parenthesis.

Diagram “C” illustrates a vehicle with one or more of the following on the input side of the speedometer ~

1. a short to B+ (step 7) 2) a short to GND or an open (step 8) 3) a faulty VSS If this is the case, go to step indicated in parentheses.

4

Turn ignition off and remove back-probes from C207 and C205. Remove instrument cluster and disconnect C211 from ECM, C229 from TCM, C125 from Cruise Control Unit (CCU) and C164 from ABSControl Unit (ABSCU). Turn ignition

on and measure voltage at C205-13 (auto) or C205-5 (manual) (0v).


YES Inspect Printed Circuit Board (PCB) for signs of shorting between C250 and speedometer (replace if necessary). If PCB is okay, replace speedometer and redo step 3.

NOLocate source of short to B+ on output side of speedometer circuit.

Repair as necessary and redo step 3.


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5

Turn ignition off and remove back-probes from C207 and C205. Remove instrument cluster and disconnect C229 from TCM and C125 from Cruise Control Unit (CCU). Measure resistance between C205-13 (auto) or C205-5 (manual)

and GND (infinite resistance).


YES Go to step 6.

NOLocate source of short to GND on output side of speedometer circuit.


6Measure resistance between C250-3 and C211-42 (< 1 ohm).


YES Inspect Printed Circuit Board (PCB) for signs of opens between C250 and speedometer (replace if necessary). If PCB is okay, replace speedometer and redo step 3.

NOLocate source of open or high resistance between C250-3 and C229-15.


7Turn ignition off and remove back-probes from C207 and C205. Remove instrument cluster and disconnect C250 from cluster and C137 from VSS. Turn ignition on and measure voltage at C207-11 (0v).


YES Replace VSS and redo step 3.

NOLocate source of short to B+ between C250-2 and VSS.


8Turn ignition off and remove back-probes from C207 and C205. Remove instrument cluster and disconnect C250 from cluster and C137 from VSS. Measure resistance between C207-11 and GND (infinite resistance).


YES Go to step 9.

NOLocate source of short to GND between C250-2 and VSS.


9Measure resistance between C230-8 and VSS (< 1 ohm).


YES Replace VSS and redo step 3.

NOLocate source of open or high resistance between C250-2 and VSS.





P1505 & P1506 Idle air control valve opening coil signal low/high

Threshold Value ~ Voltage ~

P1505 ~ Low

P1506 ~ High




Related Items

• Open or high resistance between Idle Air Control Valve (IAC) and ECM.

• Short to B+ or GND between IAC and ECM.

• Faulty IAC.


1

With ignition off, disconnect C146 from IAC.

Turn ignition on and measure voltage at C146-2 (B+).


YES Go to step 2.

NO Locate source of open between EGI Main Relay and IAC. Repair as necessary.



YES Go step 3A or 3B.

NO Locate source of open or high resistance and repair as necessary.

3A

For vehicles with P1505:

Measure resistance to GND at C211-29 (infinite resistance).


YES Go to step 4.


3B


Turn ignition on (engine off) and measure voltage at C211-29 (0v).


YES Go to step 4.


4Turn ignition off and measure resistance at IAC valve between terminals 1~2 and 2~3 (11~13 ohms at 68 degrees F).



NO Replace IAC.

5 Clear codes and return vehicle to original condition. Verify any repairs by driving vehicle with KIA Data Pro connected OBD-II connector and monitoring for pending codes (refer to section 3 of the KIA Data Pro Generic OBD-II Program Card reference manual).

IDLE AIR CONTROL VALVE


No. P1505Idle air control valve opening coil signal low input

[Related items]· Open or short to chassis ground between IACV and ECM

· Faulty IACV


1

Turn ignition to OFF and disconnect IACV connector.With ignition ON, measure voltage of IACV battery voltage between IACV harness connector and chassis ground.



Yes Go to step 2.

NoOpen circuit or short circuit to chassis ground between IACV harness connector and main relay.


2


Measure resistance of IACV opening coil.

· Opening coil: 16.5~18.5Ω @ 20°C(68°F)

Is resistance within specification?

Yes Thoroughly check for loose, bent or corroded terminals at all connectors in circuit.



3

IACV connector and ECM connector are still disconnected.

Measure resistance of IACV opening coil signal circuit between IACV harness connector and ECM harness connector.



Yes Go to step 4.

NoOpen circuit between CAS harness connector and ECM harness connector.


4

ECM connector and IACV connector are still disconnected.

Measure resistance between IACV harness connector and chassis ground at IACV opening coil circuit.



Yes Go to step 5.

NoShort circuit to chassis ground between IACV harness connector and ECM harness connector.





P1505 & P1506 Idle air control valve opening coil signal low/high


P1505 ~ Low

P1506 ~ High




Related Items



• Faulty IAC.


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1




YES Go to step 2.

NO Locate source of open between EGI Main Relay and IAC. Repair as necessary.





3A




YES Go to step 4.


3B




YES Go to step 4.





NO Replace IAC.




No. P1506Idle air control valve opening coil signal high

[Related items]· Short to battery between IACV and ECM

· Faulty IACV


1

Turn ignition to OFF and disconnect IACV connector and ECM connector.

With ignition ON, measure voltage of IACV opening coil circuit between IACV harness connector and chassis ground.



Yes Go to step 2.

NoShort circuit to battery between IACV harness connector and ECM harnessconnector.


2


Measure resistance of IACV opening coil.

· Opening coil: 16.5~18.5Ω @ 20°C (68°F)



No Temporarily install a known good IACV and check for proper operation.If problem is corrected replace IACV.




P1507 & P1508 Idle air control valve closing coil signal low/high


P1507 ~ Low

P1508 ~ High




Related Items



• Faulty IAC.


1




YES Go to step 2.

NO Locate source of open between injector fuse and IAC. Repair as necessary.





3A




YES Go to step 4.


3B




YES Go to step 4.





NO Replace IAC.




No. P1507Idle air control valve closing coil signal low

[Related items]· Open or short to chassis ground between IACV and ECM

· Faulty IACV


1

Turn ignition to OFF and disconnect IACV connector.With ignition ON, measure voltage of IACV battery voltage between IACVharness connector and chassis ground.

· Specifications : approximately B+


Yes Go to step 2.

NoOpen circuit or short circuit to chassis ground between IACV harness connector and main relay.


2


Measure resistance of IACV closing coil.

· Opening coil: 14.5~16.5Ω@ 20°C (68°F)





3





Yes Go to step 4.



4

ECM connector and IACV connector are still disconnected.Measure resistance between IACV harness connector and chassis ground at IACV closing coil circuit.



Yes Go to step 5.

NoShort circuit to chassis ground between IACV harness connector and ECM harness connector.





P1507 & P1508 Idle air control valve closing coil signal low/high


P1507 ~ Low

P1508 ~ High




Related Items



• Faulty IAC.


1




YES Go to step 2.

NO Locate source of open between injector fuse and IAC. Repair as necessary.






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3A




YES Go to step 4.


3B




YES Go to step 4.





NO Replace IAC.




No. P1508Idle air control valve closing coil signal high

[Related items]· Short to battery between IACV and ECM

· Faulty IACV


1

Turn ignition to OFF and disconnect IACV connector and ECM connector.

With ignition ON, measure voltage of IACV closing coil circuit between IACV harness connector and chassis ground.



Yes Go to step 2.

NoShort circuit to battery between IACV harness connector and ECM harness connector.


2


Measure resistance of IACV closing coil.

· Opening coil: 14.5~16.5Ω@ 20°C (68°F)








P1586 AT / MT codification

Threshold Value ~

• AT coding signal is on (no voltage present at C211-72) but drive position switch is off (no voltage present at C211-86) and enabling conditions are met

• AT coding signal is off (voltage present at C211-72) but drive position switch is on (voltage present at C211-86) and enabling conditions are met

Enable Conditions ~

Engine speed: >2200 RPM

Load value: >3.0 ms



Related Items ~

Auto Trans ~

• Open between C211-72 and GND.

• Short between C211-86 and GND.

Manual Trans ~

• Open between C211-86 and GND.

• Short between C211-72 and GND (there should not be a wire installed at C211-72).


1


With ignition off, connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect vehicle C211 to adapter cable but leave adapter cable C211 disconnected from ECM. Measure resistance to GND at BOB pin

72 (< 1N).

Is resistance measured less than 1 ohm?

YES Go to step 2.

NO Locate source of open/high resistance between C211-72 and GND. Repair as necessary.

2Connect adapter cable C211 to ECM and turn ignition key on (engine off). Measure voltage at BOB pin 86 with gear selector in D (approximately 9~11v w/cruise control, 5vwo/cruise control).

Is measured voltage between 8~10v?

YES Thoroughly check for loose, bent or corroded connectors. “Wiggle test” appropriate harnesses while redoing tests. Repair as necessary if any intermittent shorts/opens appear.

NO

Disconnect C136 from range switch. If voltage at BOB pin 86 falls into specs, replace range switch and retest. If voltage at BOB pin 86 stays at approximately 0v, locate source of short to GND in C211-86 circuit between ECM, CCU,

ignition switch and C136-6.



1


With ignition off, connect adapter cable #K99U-2106-G17 to BOB and disconnect C211 from ECM. Connect vehicle C211 to adapter cable but leave adapter cable C211 disconnected from ECM. Measure resistance to GND at BOB pin

72 (infinite ohms).

Is resistance measured infinite?

YES Go to step 2.

NO Check Engine Harness part # to ensure proper harness is in vehicle. If part # checks okay, cut wire at C211-72.

2Measure resistance to GND at BOB pin 86 (< 1N).


YES Thoroughly check for loose, bent or corroded connectors. “Wiggle test” appropriate harnesses while redoing tests. Repair as necessary if any intermittent shorts/opens appear.

NO Locate source of open/high resistance between C211-86 and G103.

3A Clear codes and return vehicle to original condition. Verify any repairs by driving vehicle with KIA Data Pro connected to OBD-II connector and monitoring for pending codes (refer to section 3 of the KIA Data Pro Generic OBD-II Program Card reference manual).

AT／／／／MT ENCODING


No. P1586AT／／／／MT encoding malfunction

[Related items]

· Poor connection to chassis ground at ECM

· Open or short circuit between ECM AT/MT and chassis ground

· Normal condition: AT-chassis ground, MT-open


1 Does vehicle have manual transmission?Yes Go to step 2.

No Go to step 3.

2


Measure resistance between ECM AT/MT encoding terminal and chassis ground.




NoShort circuit to chassis ground at ECM AT/MT encoding terminal.


3

Turn ignition to OFF and disconnect ECM connector.Measure resistance between ECM AT/MT encoding terminal and chassis ground.


Does resistance indicate continuity?


NoOpen circuit between ECM AT/MT encoding terminal and chassis ground.





P1611 & P1614 MIL request circuit - low/high voltage

Threshold Value ~

P1614 ~ Voltage high for 1 second after ECM detects “ignition on”

Enable Conditions ~

P1611 ~ Time after “ignition on”: >2.3 seconds

P1614 ~ At power up

Time Requirements ~

P1611 ~ Continuous

P1614 ~ Once per driving cycle


Related Items

• Open between ECM and TCM on mil request line.

• Short to B+ or GND between ECM and TCM on mil request line.


1A

For vehicles with a P1611:

With ignition off, disconnect C229 from TCM and C211 from ECM. Measure resistance between C229-14 and GND (infinite resistance).


YES Go to step 3.


1B

For vehicles with a P1614:

With ignition off, disconnect C229 from TCM and C211 from ECM. Measure resistance between C229-14 and C211-61 (less than 1 ohm).


YES Go to step 2.

NO Locate source of open or high resistance a repair as necessary.

2Turn ignition on and measure voltage at C211-61 (0v).


YES Go to step 3.



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3

Turn ignition off, connect adapter cable #K99U-2106-G17 to BOB and vehicle C211 to adapter cable. Connect vehicle C229 to TCM and adapter cable C211 to ECM. Have voltmeter on and (while monitoring voltmeter) turn ignition on.

Voltage may momentarily spike to 4~8v when ignition is first turned on, but will immediately drop to below 1 volt.

Approximately 2.3 seconds after key is turned on the voltage will jump to approximately B+ and remain there.

Is MIL circuit voltage operating as described?

YES Thoroughly check for loose, bent or corroded terminal between ECM and TCM. Repair as necessary.

NO If voltage is below 1v and all wiring checks okay, try known good ECM and retest. If voltage is a constant 12v and all wiring checks okay, try a known good TCM and retest.




P1624 MIL request signal from TCM to ECM

Related Items

This is only a request from TCM to ECM to turn the MIL on. The fault code is stored in the TCM. The Freeze Frame Data is stored in the ECM under the P1624 request code. Be sure to retrieve freeze frame data before clearing code P1624 from ECM.


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