Engine Control System: Removal & Installation Kia Rio III

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 " 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 104

1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the ECM Connector (A).
3. Remove the battery (Refer to " «CHARGING SYSTEM»(ref-536081) " in EM group).
4. Remove the mounting bolts and nut, and then remove the ECM bracket assembly (A).

Scheme 105

Installation

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 " 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.

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: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

1. Installation is reverse of removal. Electronic throttle body 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 manifold absolute pressure sensor connector (A).
3. Remove the installation bolt (B), and then remove the sensor from the surge tank.

Scheme 106

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)

1. Installation is reverse of removal. Engine Coolant Temperature Sensor installation: 29.4 ~ 39.2 N.m (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft)

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Disconnect the crankshaft position sensor connector (A) and remove the sensor (B) after removing the installation bolt.

Scheme 107

1. Installation is reverse of removal. Crankshaft position sensor installation bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

1. Installation is reverse of removal. Camshaft position sensor installation bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Remove the intake manifold (Refer to " «INTAKE AND EXHAUST SYSTEM»(ref-536078) " in EM group).
3. Disconnect the injector connector (A).
4. Remove the installation bolt (B), and then remove the sensor from the cylinder block.

Scheme 108

1. Installation is reverse of removal. Knock sensor installation bolt: 18.6 ~ 24.5 N.m (1.9 ~ 2.5 kgf.m, 13.7 ~ 18.1 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 109

[Bank 1/Sensor 1]

Scheme 110

Scheme 111

[Bank 1/Sensor 2]

Scheme 112

Scheme 113

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. Release the residual pressure in fuel line (Refer to the " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(ref-536090-S29845153632013031400000) "). CAUTION: When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of "Release Residual Pressure in Fuel Line" work.
3. Remove the intake manifold (Refer to " «INTAKE AND EXHAUST SYSTEM»(ref-536078) " in EM group).
4. Disconnect the rail pressure sensor connector (A), and then remove the sensor (B) from the delivery pipe.

Scheme 114

1. Installation is reverse of removal. Rail Pressure Sensor Installation: 29.4 ~ 34.3 N.m (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)

1. Installation is reverse of removal.

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Release the residual pressure in fuel line (Refer to the " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(ref-536090-S29845153632013031400000) "). CAUTION: When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS after completion of " «RELEASE RESIDUAL PRESSURE IN FUEL LINE»(ref-536090-S29845153632013031400000) " work.
3. Remove the delivery pipe & injector assembly (Refer to " «DELIVERY PIPE»(ref-536090-S33337824992013031400000) " in this group).
4. Remove the connector (A) and the fixing clip (B), and then separate the injector from the delivery pipe.

Scheme 115

Scheme 116

Scheme 117

1. Installation is reverse of removal.

Replacement

The injector combustion seal should be replaced new one to prevent leakage after removing the injector.

Scheme 118

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Scheme 120

Scheme 121

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Scheme 124

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Scheme 128

Scheme 129

1. Remove the combustion seal (A) with a wire cutter. CAUTION: Grip the sealing ring carefully, pull it to form a small loop and then cut it. Be careful not to damage the surface of the valve sleeve with the wire cutter.
2. Before the assembly of the sealing ring the groove must be cleaned using a clean cloth. Any coking of the injector sealing surface must be carefully removed with a brass-wire brush. CAUTION: The surfaces of the new sealing ring must be clean and free of grease.
3. Place the combustion seal on the cone and pull downward on the seal as indicated in the photo. NOTE: Your fingers will work better for installing the Combustion Seal over the cone.
4. Pull the seal downward until it is near the bottom of the cone as shown in the photo.
5. Place the cone (with seal) on the end of the injector. Place the sizing tool (SST No.: 09353-2B000) over the cone. Make sure the tool flange is toward the seal as shown. Press down on the tool to work the seal over the injector and into the groove.
6. Because the seal will stretch as it goes over the end of the injector, it will be a bit oversized after installation. By letting the injector and seal set for a few minutes, the seal may reduce in size. Inspect the seal for damage before continuing.
7. Place the resizing tool (flange up) over the seal. Twist the tool slightly while pushing down over the seal. This should reduce the size of the seal. CAUTION: Be careful not to apply engine oil on the combustion seal ring.
8. Place injector into the head as shown.
9. Twist slightly while pressing the injector into position in the head. This should complete the resizing of the seal. Remove the injector and inspect the seal before completing the injector installation process.
10. If the injector comes with a protective steel washer held in place by a spring clip; both will have to be removed before installation.
11. Install the Washer Seal onto injector with the rubber side (stepped) toward the injector.
12. The stepped rubber side of the seal goes towards the injector.
13. The flat washer side of the seal goes towards the head.

Scheme 130

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Disconnect the purge control solenoid valve connector (A).
3. Disconnect the vapor hoses (B) from the purge control solenoid valve.
4. Remove the valve after removing the bolt (C).

Scheme 131

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.

[Bank 1/Intake]

Scheme 132

[Bank 1/Exhaust]

Scheme 133

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. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Disconnect the variable intake solenoid valve connector (A).
3. Disconnect the vacuum hoses (B) from the valve.
4. Remove the installation bolt, and then remove the valve (C) from the surge tank.

Scheme 134

1. Installation is reverse of removal.

1. Installation is reverse of removal.