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Engine Control System - Hev: Removal & Installation Kia Optima III

Testing & Diagnostics 13 illustrations ~954 words

Removal

Note. When replacing the ECM, the vehicle equipped with immobilizer must be performed the procedure as below. [In the case of installing used ECM] Perform "Neutral mode" procedure with GDS. (Refer to " IMMOBILIZER LAMP " in BE group) Insert the key and turn it to the IGN ON and OFF position. Then the ECM key register process is completed automatically. [In the case of installing new ECM] Insert the key and turn it to the IGN ON and OFF position. Then the ECM key register process is completed automatically.

Scheme 396

Scheme 396: Removal
Scheme 396: Removal

Scheme 397

Scheme 397
Scheme 397

Scheme 398

Scheme 398
Scheme 398
  1. Shut off the High Voltage circuit. (Refer to «HIGH VOLTAGE SHUTOFF PROCEDURE»(ref-535743-S29286320742013031200000) .
  2. Turn ignition switch OFF and disconnect the negative (-) battery cable.
  3. Disconnect the ECM Connector (A).
  4. Remove the air cleaner assembly (Refer to «REMOVAL AND INSTALLATION»(ref-535730-S16160591102013031200000) "Intake And Exhaust System" in EM group).
  5. Release the reservoir (A) after removing the bolts (B).
  6. Disconnect the power cable (A) from the HPCU. Pull the lever (B) in the direction of the arrow with the hook (C) pressed. Press the lever (D), and then pull the power cable connector.
  7. Remove the nut of the battery plus cable (A) in the engine room relay box.
  8. Disconnect the fixing clips (B) of the battery plus cable protector from the bracket.
  9. Pull the battery plus cable (A) toward the engine room to make space for the bracket bolt removal.
  10. Remove the ECM bracket assembly (A) after removing the installation bolt (B) and nut (C).

Scheme 399

Scheme 399
Scheme 399

Installation

Note. When replacing the ECM, the vehicle equipped with the smart key must be performed the procedure as below. [In the case of installing used ECM] Perform "Neutral mode" procedure with GDS. (Refer to " NEUTRALIZATION STATUS CHECK " in BE group) Turn the ignition ON and OFF position after completing "ECM neutral mode". Then the ECM key register process is completed automatically. [In the case of installing new ECM] Turn the ignition ON and OFF position after completing "ECM neutral mode". Then the ECM key register process is completed automatically.

Note. This ECM is a PCM type that includes a Transaxle Control Module (TCM). Therefore TCM must be performed TCM learning procedure after replacing or re-installing a TCM. (Refer to TCM LEARNING "Automatic transaxle Control System")

  1. Installation is reverse of removal. ECM installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) ECM bracket installation bolt/nut: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
  1. Installation is reverse of removal. Electronic throttle body Installation bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
  1. Installation is reverse of removal. Manifold absolute pressure sensor installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine coolant to the O-ring.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
  1. Installation is reverse of removal.
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine oil to the O-ring.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
  1. Installation is reverse of removal. Crankshaft position sensor installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) Crankshaft position sensor protector installation bolt (M6): 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) Crankshaft position sensor protector installation bolt (M8): 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
WARNINGDON'T remove the camshaft position sensor during engine running or right after engine stops, or a scald by the flowed out engine oil may occur.

Scheme 400

Scheme 400: [Bank 1 / Intake]
Scheme 400: [Bank 1 / Intake]
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Disconnect the camshaft position sensor connector (A).
  3. Remove the installation bolt (B), and then remove the sensor.

Scheme 401

Scheme 401: [Bank 1 / Exhaust]
Scheme 401: [Bank 1 / Exhaust]
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Disconnect the camshaft position sensor connector (A).
  3. Remove the hanger and the protector.
  4. Remove the installation bolt (B), and then remove the sensor.
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine oil to the O-ring.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
CAUTIONBe careful not to damage the sensor housing and the connector. Be careful not to damage the O-ring.
  1. Installation is reverse of removal. Camshaft position sensor installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
  1. Installation is reverse of removal. Knock sensor installation bolt: 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Disconnect the connector (A), and then remove the sensor (B). NOTE: Note that the SST (Part No.: 09392-2H100) is useful when removing the heated oxygen sensor.

Scheme 402

Scheme 402: [Bank 1 / Sensor 1]
Scheme 402: [Bank 1 / Sensor 1]

Scheme 403

Scheme 403
Scheme 403

Scheme 404

Scheme 404: [Bank 1 / Sensor 2]
Scheme 404: [Bank 1 / Sensor 2]

Scheme 405

Scheme 405
Scheme 405
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONDON'T use a cleaner, spray, or grease to sensing element and connector of the sensor because oil component in them may malfunction the sensor performance. Sensor and its wiring may be damaged in case of contacting with the exhaust system (Exhaust Manifold, Catalytic Converter, and so on).
  1. Installation is reverse of removal. Heated oxygen sensor installation: 39.2 ~ 49.1 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Remove the fuel tank. (Refer to Fuel Delivery System - "Fuel Tank")
  3. Remove the fuel tank pressure sensor (A) after releasing the hooks vertically.
CAUTIONNote that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONInsert the sensor in the installation hole and be careful not to damage when installation.
  1. Install in the reverse order of removal.
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine oil to the injector O-ring.
CAUTIONInspect the injector O-ring when installing.
  1. Installation is reverse of removal. Delivery pipe installation bolt: 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft) Delivery pipe installation nut (<--> Fuel feed tube): 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect before installing.
CAUTIONUse care to keep foreign material out of the valve.

Scheme 406

Scheme 406
Scheme 406
  1. Installation is reverse of removal. Purge control solenoid valve bracket installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
  2. Disconnect the CVVT oil control valve connector (A).
  3. Remove the installation bolt (B), and then remove the valve from the engine.

Scheme 407

Scheme 407: [Bank 1 / Intake]
Scheme 407: [Bank 1 / Intake]

Scheme 408

Scheme 408: [Bank 1 / Exhaust]
Scheme 408: [Bank 1 / Exhaust]
CAUTIONInstall the component with the specified torques. Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
CAUTIONApply the engine oil to the valve O-ring.
  1. Installation is reverse of removal. CVVT oil control valve installation bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  1. Install the component with the specified torques.
  2. Note that internal damage may occur when the component is dropped.

If the component has been dropped, inspect before installing.

  1. Installation is reverse of removal. NVLD installation bolt: 2.3 ~ 3.3 N.m (0.2 ~ 0.3 kgf.m, 1.7 ~ 2.5 lb-ft)
  1. Install the component with the specified torques.
  2. Note that internal damage may occur when the component is dropped.

If the component has been dropped, inspect before installing.

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