Engine Controls - Self-Diagnostics - Tests: Diagnosis Kia Sephia II

DIAGNOSTIC TESTS

Note. For circuit identification, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

Note. After all repairs, clear codes. Verify repairs by driving vehicle with KIA Data Pro connected to OBD-II Data Link Connector (OBD-II DLC) and monitoring for pending codes.

Diagnostic Aids

Code will set if engine speed is more than 1320 RPM, coolant temperature is more than 140°F and calculated load value is more than 1.215 ms, or less than -2.722 ms, for at least 5 seconds. Monitor runs continuously. One trip fault.

Check for

1. Dirty air cleaner.
2. Oil cap or dipstick missing or improperly installed.
3. Air leak in intake system.
4. Contaminated, deteriorated or damaged MAF sensor.
5. Faulty MAF sensor or Throttle Position (TP) sensor.
6. Faulty wiring between Engine Control Module (ECM) and MAF sensor or TP sensor.

Engine Control Module (ECM) continuously monitors input from MAF sensor. ECM will set code if input is less than range of expected values for current engine operating conditions. Monitor runs continuously. One trip fault.

Check for

1. Open or short to ground in Red/White wire between MAF sensor and ECM.
2. Open in Red/Yellow wire between MAF sensor and EGI main relay.

Engine Control Module (ECM) continuously monitors input from MAF sensor. ECM will set code if input is more than range of expected values for current engine operating conditions. Monitor runs continuously. One trip fault.

Check for

1. Open in Red/Blue wire between MAF sensor and ECM.
2. Open in Black/Yellow wire between ground and MAF sensor.

Code will set if at least 180 seconds have passed since engine started, engine is idling and IAT sensor temperature input to Engine Control Module (ECM) is less than -40°F (-40°C) or more than 284°F (140°C). Conditions are continuously monitored. Monitor runs continuously. Two trip fault.

Check for

1. Open or short to power in Blue/Green wire between IAT sensor and ECM.
2. Open in Black/Green wire between IAT sensor and ECM.
3. Short to ground in Blue/Green wire between IAT sensor and ECM.
4. Short between IAT sensor wires.
5. IAT sensor malfunction.

Code will set if at least 180 seconds have passed since engine started, engine is idling and IAT sensor temperature input to Engine Control Module (ECM) is less than -40°F (-40°C). Monitor runs continuously. Two trip fault.

Check for

1. Open or short to power in Blue/Green wire between IAT sensor and Engine Control Module (ECM).
2. Open in Black/Green wire between IAT sensor and ECM.

Code will set if at least 180 seconds have passed since engine started, engine is idling and IAT sensor temperature input to Engine Control Module (ECM) is more than 284°F (140°C). Monitor runs continuously. Two trip fault.

Check for

1. Short to ground in Blue/Green wire between IAT sensor and ECM.
2. Short between IAT sensor wires.

DTC P0116 will set when difference between calculated temperature and measured temperature is more than 50°F (10°C). Monitor runs continuously. One trip fault.

DTC P0125 will set if elapsed time before engine feedback operation is initiated is too long. Feedback operation must be initiated within 120 seconds when engine coolant temperature at start up is 50°F, within 300 seconds when engine coolant temperature at start up is 47°F, and within 5100 seconds when engine coolant temperature at start up is 16°F. Monitor runs once per drive cycle. One trip fault.

Check for

1. ECT sensor malfunction.
2. Poor connections between ECT sensor and Engine Control Module (ECM).

Code will set if ECT sensor input to Engine Control Module (ECM) is less than -40°F (-40°C). Monitor runs continuously. One trip fault.

Check for

1. Open or short to power in Blue/Yellow wire between ECT sensor and ECM.

Code will set if ECT sensor input to Engine Control Module (ECM) is more than 284°F (140°C). Monitor runs continuously. One trip fault.

Check for

1. Short to ground in Blue/Yellow wire between ECT sensor and ECM.
2. Short between ECT sensor wires.

Code will set if engine speed is more than 720 RPM and throttle valve angle is less than 2.8 degrees. Monitor runs continuously. Two trip fault.

Check for

1. Short to ground in Blue/Orange wire between TP sensor and Engine Control Module (ECM).
2. Open or short to ground in Blue/White wire between TP sensor and ECM.
3. Short to ground in Blue/White wire between ECM and Chassis Acceleration Sensor (CAS) or Fuel Tank Pressure Sensor (FTPS).
4. TP sensor, CAS or FTPS malfunction.

Code will set when engine speed is more than 720 RPM and throttle valve angle is more than 101.2 degrees. Monitor runs continuously. One trip fault.

Check for

1. Open or short to power in Blue/Orange wire between TP sensor and Engine Control Module (ECM).
2. Open in Black/Green wire between TP sensor and ECM.
3. TP sensor malfunction.

Diagnostic Trouble Code Diagnosis Charts

DIAGNOSTIC TROUBLE CODE DIAGNOSIS CHART

INSPECTION CHART

DIAGNOSTIC TROUBLE CODE DIAGNOSIS CHART

INSPECTION CHART

If less than 151 seconds have passed since front HO2S heating period started and rear HO2S voltage is more than 650 millivolts, code will set if front HO2S voltage is 40-60 millivolts. If less than 151 seconds have passed since front HO2S heating period started, engine coolant temperature at last engine shutoff was more than 175°F and engine coolant temperature on current drive cycle is less than 104°F, code will set if front HO2S voltage is -30-30 millivolts. Monitor runs continuously. Two trip fault.

Check for

1. Short in front HO2S circuit.
2. Bent, damaged or corroded front HO2S connector terminals.
3. Front HO2S malfunction.

If more than 151 seconds have passed since front HO2S heating period started, code will set if front HO2S voltage is less than -110 millivolts. If engine coolant temperature at last engine shut down was less than 104°F (40°C), and more than 151 seconds have passed since front HO2S heating period started, code will set if front HO2S voltage is 170-370 millivolts. Monitor runs continuously. Two trip fault.

Check for

1. Short to ground in front HO2S Green/Brown wire.
2. Front HO2S malfunction.

If more than 151 seconds have passed since front HO2S heating period started, code will set if front HO2S voltage is more than 1.54 volts. Monitor runs continuously. Two trip fault.

Check for

1. Short to power in Green/Brown wire between front HO2S and Engine Control Module (ECM).
2. Front HO2S malfunction.

If engine speed is 2000-3000 RPM, load value is 2.0-5.0 ms, calculated catalyst temperature is more than 846°F (452°C), and fuel system is in closed loop, code will set if front HO2S signal response period is more than 1.8 seconds (time period monitoring). If engine speed is 1480-3000 RPM, load value is outside of predetermined upper or lower limits, calculated catalyst temperature is more than 846°F (452°C) and fuel system is in closed loop, code will set if air/fuel compensation factor (calculated from rear HO2S) is outside of predetermined upper or lower limits (sensor aging monitoring). Monitor runs continuously. Two trip fault.

Check for

1. Front and rear HO2S connections reversed.
2. Fault in fuel delivery system.
3. Leak in intake system.
4. Leak in exhaust system.
5. Faulty Mass Airflow (MAF) sensor ground circuit.
6. HO2S malfunction.

If more than 151 seconds have passed since front Heated Oxygen Sensor (HO2S) heating period started, code will set if front HO2S voltage is 400-600 millivolts for more than 6 seconds. Monitor runs continuously. Two trip fault.

Check for

1. FRONT O2 fuse (10-amp) blown.
2. Open in Green/Brown wire or Green/Blue wire between front HO2S and ECM.
3. Front HO2S malfunction.

If more than 151 seconds have passed since front HO2S heating period started, code will set if front HO2S calculated resistance is more than 16.4 ohms or less than 6.1 ohms. Monitor runs continuously. Two trip fault.

Check for

1. FRONT O2 fuse (10-amp) blown.
2. Open or short to power in Green/Black wire between front HO2S and ECM.
3. Front HO2S malfunction.

If more than 155 seconds have passed since front HO2S heating period started, engine speed is 1480-3000 RPM, calculated catalyst temperature is more than 738°F (392°C), and fuel system is in closed loop, code will set if rear HO2S voltage is -400-400 millivolts for more than 200 seconds. Monitor runs continuously. Two trip fault.

Check for

1. Short in Violet/White wire or Green/White wire between rear HO2S and ECM.
2. Loose, damaged or corroded rear HO2S connector or ECM connector terminals.
3. Rear HO2S malfunction.

If more than 155 seconds have passed since front HO2S heating period started, code will set if rear HO2S voltage is less than -150 millivolts. Monitor runs continuously. Two trip fault.

Check for

1. Short to ground in Green/White wire between rear HO2S and ECM.
2. Rear HO2S malfunction.

Code will set if rear HO2S voltage is more than 1.08 volts. Monitor runs continuously. Two trip fault.

Check for

1. Short to power in Green/White wire between rear HO2S and ECM.
2. Rear HO2S malfunction.

If calculated catalyst temperature is more than 846°F (452°C), code will set when air/fuel compensation factor (calculated from rear HO2S) is out of predetermined high and low parameters. Monitor runs continuously. Two trip fault.

Check for

1. Front and rear HO2S connections reversed.
2. Fuel delivery system malfunction.
3. Leak in intake system.
4. Leak in exhaust system.
5. Faulty Mass Airflow (MAF) sensor ground circuit.
6. Rear HO2S malfunction.

If more than 155 seconds have passed since rear HO2S heating period started, code will set if rear HO2S voltage is 420-520 millivolts for at least 640 seconds. Monitor runs continuously. Two trip fault.

Check for

1. REAR O2 fuse (10-amp) blown.
2. Open in Violet/White wire or Green/White wire between rear HO2S and ECM.
3. Rear HO2S malfunction.

If more than 155 seconds have passed since rear HO2S heating period started, code will set if rear HO2S calculated resistance is more than 16.4 ohms or less than 6.4 ohms. Monitor runs continuously. Two trip fault.

Check for

1. REAR O2 fuse (10-amp) blown.
2. Open or short to power in Green/Red wire between rear HO2S and ECM.
3. Rear HO2S malfunction.

If fuel system is in closed loop, code will set when long term fuel trim is more than 22 percent. Monitor runs continuously. Two trip fault.

Check for

1. Fuel delivery system malfunction.
2. Intake or exhaust system leak.
3. Mass Airflow (MAF) sensor malfunction.
4. Throttle Position (TP) sensor malfunction.

If fuel system is in closed loop, code will set when long term fuel trim is less than -23 percent. Monitor runs continuously. Two trip fault.

Check for

1. Ignition system malfunction.
2. Fuel delivery system malfunction.
3. Fuel injector malfunction.
4. Front Heated Oxygen Sensor (HO2S) malfunction.
5. Mass Airflow (MAF) sensor malfunction.
6. Throttle Position (TP) sensor malfunction.

Code enable criteria not available from manufacturer. Monitor runs continuously. One trip fault.

Check for

1. Open or short to ground in wire between fuel injector and Engine Control Module (ECM).
2. Open in wire between fuel injector and EGI main relay.
3. Fuel injector No. 1 malfunction.

Code enable criteria not available from manufacturer. Monitor runs continuously. One trip fault.

Check for

1. Short to power in Brown/Black wire between fuel injector and Engine Control Module (ECM).
2. Fuel injector No. 1 malfunction.

Code enable criteria not available from manufacturer. Monitor runs continuously. One trip fault.

Check for

1. Open or short to ground in wire between fuel injector and Engine Control Module (ECM).
2. Open in wire between fuel injector and EGI main relay.
3. Fuel injector No. 2 malfunction.

Code enable criteria not available from manufacturer. Monitor runs continuously. One trip fault.

Check for

1. Short to power in Brown/Green wire between fuel injector and Engine Control Module (ECM).
2. Fuel injector No. 2 malfunction.

Code enable criteria not available from manufacturer. Monitor runs continuously. One trip fault.

Check for

1. Open or short to ground in wire between fuel injector and Engine Control Module (ECM).
2. Open in wire between fuel injector and EGI main relay.
3. Fuel injector No. 3 malfunction.

Code enable criteria not available from manufacturer. Monitor runs continuously. One trip fault.

Check for

1. Short to power in Brown/Black wire between fuel injector and Engine Control Module (ECM).
2. Fuel injector No. 3 malfunction.

Code enable criteria not available from manufacturer. Monitor runs continuously. One trip fault.

Check for

1. Open or short to ground in wire between fuel injector and Engine Control Module (ECM).
2. Open in wire between fuel injector and EGI main relay.
3. Fuel injector No. 4 malfunction.

Code enable criteria not available from manufacturer. Monitor runs continuously. One trip fault.

Check for

1. Short to power in Brown/Yellow wire between fuel injector and Engine Control Module (ECM).
2. Fuel injector No. 4 malfunction.

Code will set if emissions relevant misfire rate exceeds 23 misfires (manual transaxle), or 25 misfires (automatic transaxle), per 1000 crankshaft revolutions. Code will set if catalyst damaging misfire every 200 crankshaft revolutions exceeds predetermined criteria based on load and RPM. Monitor runs continuously. Emissions relevant misfire is two trip fault. Catalyst damaging misfire is one trip fault and will cause Malfunction Indicator Light (MIL) to continuously blink.

Check for

1. Vacuum leak in air intake system.
2. Crankshaft Position (CKP) sensor circuit malfunction.
3. CKP sensor malfunction.
4. Ignition circuit malfunction.
5. Faulty ignition coil or plug wire.
6. Spark plug malfunction.
7. Low compression due to blown head gasket, leaking valve or piston ring.
8. Low or high fuel pressure.
9. Fuel injector circuit malfunction.
10. Faulty fuel injector.

If coolant temperature is more than 104°F (40°C), engine speed is more than 2200 and load value is more than 3.0 ms, code will set if knock sensor output is out of range of a predetermined engine RPM map. Monitor runs continuously. Two trip fault.

Check for

1. Open or short to ground in wire between knock sensor and Engine Control Module (ECM).
2. Knock sensor malfunction.

Code will set if engine is running and no CKP sensor signal is received by ECM. Monitor runs continuously. One trip fault. Malfunction Indicator Light (MIL) illuminates immediately.

Check for

1. Open or short in White/Green wire or White/Yellow wire between CKP sensor and Engine Control Module (ECM).
2. CKP sensor malfunction.

Code will set when engine speed is more than 2000 RPM and number of sensor ring teeth counted between reference mark gap does not equal actual number of teeth. Monitor runs continuously. One trip fault.

Check for

1. Open or short in White/Green wire or White/Yellow wire between CKP sensor and Engine Control Module (ECM).
2. CKP sensor malfunction.
3. Improper air gap between CKP sensor and target wheel.

Code will set when engine speed is more than 600 RPM and number of Camshaft Position (CMP) sensor signals during 2 crankshaft revolution is more than one. Monitor runs continuously. Two trip fault.

Check for

1. Open or short to ground in Blue/Red wire between CMP sensor and Engine Control Module (ECM).
2. CMP sensor malfunction.

Code will set when engine speed is more than 600 RPM and Engine Control Module (ECM) has not received signal from Camshaft Position (CMP) sensor for more than 200 crankshaft revolutions. Monitor runs continuously. Two trip fault.

Check for

1. Open or short to power in Blue/Red wire between CMP sensor and ECM.
2. Open in Black/Yellow wire between CMP sensor and ground.
3. Open in Red/Yellow wire between INJ fuse (10-amp) and CMP sensor.
4. Missing sensor pin on exhaust cam.
5. CMP sensor malfunction.

ECM evaluates catalytic converter storage capability by monitoring upstream Heated Oxygen Sensor (HO2S) and downstream HO2S performance, calculating a ratio based on the amplitude of the 2 signals and evaluating this information based on load and speed conditions. Code will set when ECM determines catalytic converter storage capability has degraded. Monitor runs continuously. Two trip fault.

Check for

1. Insufficient engine combustion.
2. Intake system or exhaust system air leak.
3. Improper fuel pressure.
4. Damaged Three Way Catalytic (TWC) converter.

Engine Control Module (ECM) will run EVAP System Leak Monitor when engine coolant temperature at start-up was 150°F (66°C) or less, at least 16.9 minutes have passed since engine started or long term fuel trim has stabilized and idle control system has passed diagnostic checks, intake air temperature is more than 10°F (-12°C), battery voltage is more than 10.9 volts, engine is idling, vehicle speed is zero MPH, fuel control system is in closed loop, and pressure within EVAP system is within predefined limits. ECM closes Canister Control Valve (CCV) and Purge Solenoid Valve (PSV), then monitors changes in EVAP system pressure. DTC P0440 or P0442 will set if pressure changes indicate system is malfunctioning or leak exists. If test conditions are met, monitor will run only once per drive cycle for about 30 seconds. If test conditions are not met, monitor will not run. Two trip fault.

Check for

1. Fuel filler cap loose or missing.
2. Fuel filler cap "O" ring missing or damaged.
3. Faulty or damaged fuel filler pipe.
4. Leaking, disconnected or plugged fuel vapor lines.
5. Fuel in lines due to faulty rollover valve or On-board Refueling Vapor Recovery (ORVR) valve.
6. Canister Close Valve (CCV) clogged, stuck open or closed.
7. Improperly installed EVAP canister Purge Solenoid Valve (PSV).
8. PSV stuck open or closed.
9. Fuel Tank Pressure Sensor (FTPS) malfunction.
10. Leaking EVAP canister or catch tank.

DIAGNOSTIC TROUBLE CODE DIAGNOSIS CHART

INSPECTION CHART STEP INSPECTION Y/N ACTION 1 Verify PSV is installed with arrow pointing towards intake manifold. Is PSV installed properly? YES Go to step 2. NO Test PSV per step 2 and reverse installation. 2 Turn ignition off, disconnect C254 from ECM and install adapter cable K99U-2106-G17 to BOB. Connect adapter cable C254 to ECM and harness C254 to adapter cable. Disconnect hoses from PSV (do not disconnect connector). Per diagram "A", draw a vacuum at nipple "B" with a mityvac (do not exceed 20" of vacuum) and verify PSV holds vacuum. Turn ignition on and jumper a wire from BOB pin 36 to GND (should hear a faint from PSV). Vacuum should bleed off. Repeat this procedure 4 or 5 times to ensure PSV reliability. Is PSV working properly? YES Go to step 3. NO Replace PSV. 3 Turn ignition off. Blow air through hose disconnected from PSV leading to catch tank (do not exceed 5psi with air supply). Air should escape through air filter attached to LDP (see Fig. ). Does air escape from filter as described? YES Go to step 5. NO Go to step 4. 4 Air should escape through air filter attached to LDP (see Fig. ). Remove hose between LDP and Canister. Blow air through hose disconnected from PSV again. Air should escape from hose disconnected from LDP. Did air escape from hose as described? YES Verify LDP filter is not obstructed and go to step 5. NO Locate source of obstruction between PSV and LDP. Repair as necessary. 5 Reconnect hose to LDP (if removed in step 4). Turn ignition on (engine off) and jumper BOB pin 20 to ground momentarily while again blowing air through hose removed from PSV. With BOB pin 20 grounded, no air should escape from LDP filter. With BOB pin 20 ground removed, air should escape from LDP filter. Repeat this operation 4-5 times to ensure LDP Valve reliability. Did LDP Valve operate as described? YES Carefully check all hoses for signs of pinching and wiring between LDP and ECM for signs of shorting. Repair as necessary. NO Replace LDP. 6 Clear codes and return vehicle to original condition. Verify any repairs by driving vehicle per following Readiness Drive Cycle. Make sure ECT is below 150 degrees F before starting drive cycle. After completing test, check for any pending codes (refer to section 3 or the KIA Data Pro Generic OBD-II Program Card reference manual). 7 Return vehicle to original condition (but leave BOB connected). Per diagram "D", insert "T" in evap hose between PSV and Catch Tank. Make sure fuel fillercap is installed and tight. Attach a jumper wire from chassis ground to BOB terminal 18 (CCV ground control). Attach ground lead of digital voltmeter to chassis ground lead of digital voltmeter to chassis ground and positive lead to BOB terminal 76 (FTPS output voltage). Turn ignition on (engine off) and, using pressure port on Mityvac or similar tool, apply pressure to system through "T" until FTPS output voltage is approximately 4v. Clamp off hose to Mityvac and monitor FTPS output voltage for 1 minute. After 1 minute, FTPS output voltage should not drop more than 0.1v. Did voltage drop more than 0.1v? NOTE: If voltage does not increase as described, check: Remove small hose from "T" in hose between canister and ORVR valve (see diagram " Fig. ") and verify release of pressure. If release of pressure is verified, replace FTPS. If no release of pressure is noticed, proceed to check #2. Plugged vapor lines between PSV and fuel tank (refer to diagram " Fig. "). Fuel in canister due to stuck closed CCV (refer to step 6) or faulty rollover/ORVR valve. If ORVR valve is stuck closed, refueling will be very difficult if not impossible. Repair as necessary. YES Remove clamp from hose to Mityvac, pressurize system to a maximum of 2 psi and clamp off system again. With system sealed and pressurized, check for leaks with a R134-A leak detector (be sure to check hose at rollover valve, gasket at Tank Unit, catch tank and canister). Repair as necessary and then redo step 7. NO Go to step 8. 8 Remove jumper wire to GND from BOB pin 18. Voltage at BOB pin 76 should drop (within approximately 15 seconds) to base voltage measured in step 4. Did voltage drop as described? YES Go to step 9. NO Recheck evap lines, catch tank, CCV and canister for obstructions. Repair as necessary and redo steps 7&8. 9 Repeat steps 7 and 8. However, instead of removing ground jumper from BOB terminal 18, attach a jumper wire from chassis ground to BOB terminal 36 (PSV ground control) and monitor FTPS output voltage at BOB terminal 76. Again, output voltage should drop but somewhat slower as PSV has a small controlling orifice in it (voltage should drop to base voltage within approximately 30 seconds). Did voltage drop as described? YES Go to step 10. NO Recheck PSV operation and canister/catch tank for obstructions. Repair as necessary and redo step 9. 10 Clear codes and return vehicle to original condition. Verify any repairs by driving vehicle per following Readiness Drive Cycle. Make sure ECT is below 150 degrees F before starting drive cycle. After completing test, check for any pending codes (refer to section 3 of the KIA Data Pro Generic OBD-II Program Card reference manual)

Scheme 18

Scheme 19

Scheme 20

Code will set if Engine Control Module (ECM) detects Purge Solenoid Valve (PSV) circuit voltage out of parameters. Monitor runs continuously. Two trip fault.

Check for

1. Open in wire between INJ fuse (10-amp) and PSV.
2. PSV malfunction.
3. Open in wire between PSV and ECM.
4. Short to power or short to ground in wire between PSV and ECM.

Code will set if Engine Control Module (ECM) detects Canister Close Valve (CCV) circuit voltage is out of parameters. Monitor runs continuously. Two trip fault. CCV is located at center rear of engine compartment.

Check for

1. Open in wire between INJ fuse (10-amp) and CCV.
2. CCV malfunction.
3. Open in wire between CCV and ECM.
4. Short to ground or short to power in wire between CCV and ECM.

Monitor runs once per drive cycle when engine is idling and engine coolant temperature at start-up was 95°F (35°C) or less. Code will set if Engine Control Module (ECM) determines fuel tank pressure exceeds predetermined limit. Two trip fault.

Check for

1. Open or short to power in Light Green/Yellow wire between Fuel Tank Pressure Sensor (FTPS) and Engine Control Module (ECM).
2. High resistance or open in Black/Green wire between ECM and FTPS.
3. FTPS malfunction.
4. Canister Close Valve (CCV) stuck closed.
5. Blocked vapor hose between EVAP canister and CCV.

Code will set when Engine Control Module (ECM) determines fuel tank pressure is less than predetermined limit. Monitor runs continuously. Two trip fault.

Check for

1. Short to ground in Blue/White wire or Light Green/Yellow wire between Fuel Tank Pressure Sensor (FTPS) and Engine Control Module (ECM).
2. Open in Blue/White wire between FTPS and ECM.
3. FTPS malfunction.

Code will set when Engine Control Module (ECM) determines fuel tank pressure is less than predetermined limit. Monitor runs continuously. Two trip fault.

Check for

1. Open or short to power in Light Green/Yellow wire between Fuel Tank Pressure Sensor (FTPS) and Engine Control Module (ECM).
2. Short to power in Blue/White wire between FTPS and ECM.
3. Open in Black/Green wire between FTPS and ECM.
4. FTPS malfunction.

DIAGNOSTIC TROUBLE CODE DIAGNOSIS CHART

INSPECTION CHART STEP INSPECTION Y/N ACTION 1 Check fuel filler cap for being tightly installed, has o-ring seal installed and is in good condition. Verify cap releases pressure/vacuum at specified values (approximately 2 psi pressure and approximately 1.5 inches of mercury vacuum). Are cap, o-ring and release pressures okay? YES Go to step 2. NO Replace center filler cap. 2 Check fuel fleftpipe for cracks, pinholes, damage and o-ring seat for deformation. Is fuel filler pipe okay? YES Go to step 3. NO Replace fuel filler pipe. 3 Per diagram "A", thoroughly check all fuel vapor hoses and hose clamps between: Canister and rollover/ORVR valve. Canister and LDP. Canister and PSV. 4-way Distribution Manifold and fuel filler pipe. PSV and intake manifold. (Continued on next page) (At this point, verify arrow on PSV is pointing towards intake manifold. If it is not, reverse installation.) Are vapor hoses and clamps okay? YES Go to step 4. NO Replace ALL cracked/damaged hoses or loose clamps. 4 Turn ignition off, disconnect C254 from ECM and install adapter cable K99U-2106-G17 to BOB. Connect adapter cable C254 to ECM and harness C254 to adapter cable. Disconnect hose leading from PSV to intake manifold at PSV. Per diagram "B", draw a vacuum at nipple "B" with a mityvac (do not exceed 20" of vacuum) and verify PSV holds vacuum. Turn ignition on and jumper a wire from BOB pin 36 to GND (should hear a faint from PSV). Vacuum should bleed off. Repeat this procedure 4 or 5 times to ensure PSV reliability. Is PSV working properly? YES Go to step 5. NO Replace PSV and then go to step 5. 5 Return PSV hose to original condition. Disconnect C154 from PSV and prepare multimeter for current draw using 300 milliamp scale. Attach negative probe to chassis ground and positive probe to BOB pin 20. Turn ignition on (engine off) and record LDP current draw (allow 5-10 seconds for current to stabilize). Minimum 17mA, maximum 36mA. Jumper BOB pin 18 to chassis ground and observe current draw of LDP. Within 5 minutes, current draw should be greater than or equal to reference draw recorded in step 5a. Was LDP current draw in step 5b greater or equal to current draw in step 5a? YES Go to step 6. NO Using appropriate evaporative emissions leak testing equipment, (or redo step 5 using an R-134A sniffer or exhaust gas analyzer) locate source of leak and repair as necessary. 6 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)

Scheme 21

Scheme 22

Scheme 23

DIAGNOSTIC TROUBLE CODE DIAGNOSIS CHART

INSPECTION CHART STEP INSPECTION Y/N ACTION With ignition off, connect adapter cable #K99U-2106-G17 to BOB and disconnect C254 from ECM. Connect vehicle C254 to adapter cable, but leave adapter cable disconnected from ECM. Prepare Data Pro Scan Tool for use as a single channel oscilloscope and set parameters to the following values: Time - Two seconds Voltage - 1 volt Level - Equal to ground Ground - Next to bottom row (see sample 1) F5 - Arrow up F6 - a Connect positive probe to BOB pin 82 and negative probe to BOB pin 34. Start vehicle and test drive while monitoring oscilloscope. Be sure to include bumpy road conditions and abrupt starts and stops to test reliability in all driving conditions. Depending on fuel level, voltage will be between approximately 0.25v to 4.5v and will vary as fuel sloshes around in the tank. At no time should voltage go above or below limits indicated in the sample. The time criteria for voltage out of range before a pending or hard code will be set is five seconds (a short spike out of range will not set the code but needs to be investigated as it is an indicator of a possible wiring or component malfunction). 1 Did the voltage in the above test remain within the upper and lower limits? YES May be an intermittent condition ~ "Wiggle Test" all connections between C254-82 and G300 while monitoring oscilloscope. If vehicle has been in for this condition before, inspect FGSU per step 7. NO If voltage is approximately 5.4v to 5.8v, there is an open in the circuit between C229-4 and G300 (go to step 2). If voltage is below 0.25v there is a short to ground between C254-82 and C304-1, an open between C229-4 and C254-82, a faulty Fuel Gauge Sending Unit or faulty Fuel Gauge/Printed Circuit Board (go to step 4). 2 Turn ignition off, disconnect adapter cable C254 from ECM, C229 from instrument cluster and C304 from Tank Unit. Measure resistance between BOB pin 82 and C304-1 (less than 1 ohm). Is measured resistance less than 1 ohm? YES Go to step 3. NO Locate source of open or high resistance between C254-82 and C304-1. Repair as necessary. 3 Measure resistance between C304-3 and GND < 1 ohm). Is measured resistance less than 1 ohm? YES Go to step 7. NO Locate source of open or high resistance between C304-3 and G300. Repair as necessary. 4 Turn ignition off, disconnect adapter cable C254 from ECM, C229 from instrument cluster and C304 from Tank Unit. Measure resistance between BOB pin 82 and GND (infinite resistance). Is measured resistance infinite? YES Go to step 5. NO Locate source of short to GND and repair as necessary. 5 Measure resistance between BOB pin 82 and C229-4 (less than one ohm). Is measured resistance less than one ohm. YES Go to step 7. NO Locate source of open or high resistance between C254-82 and C229-4 and repair as necessary. 6 Remove Tank Unit from fuel tank and measure resistance between C304-1 and C304-3 per following: Sending unit float at full ~ 4-9 ohms. Sending unit float at empty ~ 92-97 ohms. Also check for opens with float in all positions between empty and full. Is sending unit resistance measurements within specifications? YES Inspect Instrument Cluster Printed Circuit Board for damage or burned out tracks (replace if damaged). If Circuit Board is okay, replace Fuel Gauge and retest. NO Inspect wiring in Tank Unit. If wiring is okay, replace sending unit and retest. If sending unit wiring is faulty, repair as necessary and retest. 7 Remove tank Unit from fuel tank and measure resistance between C304-1 and C304-3 per following: Sending unit float at full ~ 4-9 ohms. Sending unit float at empty ~ 92-97 ohms. Also check for opens with float in all positions between empty and full. Is sending unit resistance measurements within specifications? YES Thoroughly check for loose, bent or corroded terminals between C254-82 and G300. Inspect wiring in Tank Unit. NO Inspect wiring in Tank Unit. If wiring is okay, replace sending unit and retest. If sending unit wiring is faulty, repair as necessary and retest. 8 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)

Scheme 24

Code will set when Engine Control Module (ECM) determines fuel tank level thermistor is malfunctioning. Monitor runs continuously. Two trip fault.

Check for

1. Open or short to ground between ECM and Low Fuel Thermistor (LFT) circuit. See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
2. Open in LFT circuit.
3. Faulty LFT.

Code will set when engine speed is more than 2000 RPM and Engine Control Module (ECM) does not detect VSS signal for more than 2.2 milliseconds. Monitor runs continuously. Two trip fault.

Check for

1. Open in Yellow wire between METER fuse (10-amp) and VSS.
2. Open in Black wire between VSS and ground.
3. Open in Green/Orange wire or Orange/Black wire between VSS and ECM.
4. Short to power or short to ground in Green/Orange wire or Orange/Black wire between VSS and ECM.
5. VSS malfunction.
6. Speedometer malfunction.

Code will set when engine is idling, vehicle speed is zero MPH, engine coolant temperature is 176°F (80°C) or more and actual RPM is more than 100 RPM less than desired RPM and IAC valve integrator value is less than -8.0 kg/hr, or fuel cut-off counter is more than 3. Monitor runs continuously. Two trip fault.

Check for

1. High resistance in circuit between INJ fuse (10-amp) and IAC valve.
2. High resistance in circuit between IAC valve and Engine Control Module (ECM).
3. IAC valve malfunction.

When engine is idling, vehicle speed is zero MPH and engine coolant temperature is 176°F (80°C) or more, code will set if actual RPM is more than 200 RPM less than desired RPM and IAC valve integrator value is more than 6.0 kg/hr. Monitor runs continuously. Two trip fault.

Check for

1. Improperly adjusted accelerator cable.
2. Manifold vacuum leak.
3. Faulty PCV valve.
4. Carbon fouled throttle plate.
5. Throttle Position (TP) sensor malfunction.
6. High resistance between IAC valve and Engine Control Module (ECM).
7. IAC valve malfunction.

DTC P0561 will set if system voltage is less than 2.5 volts. DTC P0562 will set if 2 minutes or more after engine starts, system voltage is 2.5-10 volts. DTC P0563 will set if 2 minutes or more after engine starts, vehicle speed is zero MPH and system voltage is more than 16 volts. Monitor runs continuously. Malfunction Indicator Light (MIL) will not illuminate when code sets.

Check for

1. Generator malfunction.
2. Faulty battery.
3. Open, high resistance, short to ground or intermittent poor contact between IG COIL fuse (10-amp), INJ fuse (10-amp) or ECM B+ fuse (10-amp) and Engine Control Module (ECM).

DTC P0601 will set if, at ECM power up, checksum error exists. DTC P0604 will set if, at ECM power up, RAM error exists. Monitor runs once per drive cycle. Two trip fault.

Check for

1. Open ECM B+ fuse (10-amp) in passenger compartment fuse box.
2. Open BTN fuse (30-amp) in engine compartment fuse/relay box.
3. ECM malfunction.

Code will set when Engine Control Module (ECM) determines an open or short exists on Throttle Position (TP) sensor signal wire between ECM and Transaxle Control Module (TCM). TP sensor signal input line to TCM is used to input either throttle position or water temperature information to TCM. TP sensor signal is sent whenever ignition is on and signal line frequency is 100 Hz. During cranking (31-500 RPM), TP sensor signal frequency changes to 200 Hz and water temperature information is being sent. The duty cycle of the signal determines engine coolant temperature based on Engine Coolant Temperature (ECT) sensor output.

Check for

1. Open, high resistance, short to power or short to ground on Light Green/Yellow wire (TP sensor signal line) between ECM and TP sensor.
2. Open, high resistance, short to power or short to ground on Blue/Yellow wire (ECT signal line) between ECT sensor and ECM

Code will set when Engine Control Module (ECM) determines chassis acceleration input signals are out of expected parameters. Monitor runs continuously. Two trip fault.

Check for

1. Open in Red/Black wire or Black/Green wire between CAS and ECM.
2. Short to power or short to ground in Red/Black wire between CAS and ECM.
3. CAS malfunction.

When engine starts, or when engine speed is more than 2200 RPM, engine coolant temperature is more than 140°F (40°C) and load value is more than 3.0 ms, code will set if knock sensor output is more than 293 millivolts. Monitor runs continuously. Two trip fault.

Check for

1. Open or short to ground in Yellow/Blue wire between knock sensor and Engine Control Module (ECM).
2. Knock sensor malfunction.

DIAGNOSTIC TROUBLE CODE DIAGNOSIS CHART

INSPECTION CHART

DIAGNOSTIC TROUBLE CODE DIAGNOSIS CHART

INSPECTION CHART

DIAGNOSTIC TROUBLE CODE DIAGNOSIS CHART

INSPECTION CHART

Scheme 25

Code will set if engine is cranking or running and voltage is detected at ECM connector terminal No. 64, but not at ECM connector terminal No. 65. Monitor runs continuously. Two trip fault.

Check for

1. Open or short to power in wire between grounding junction connector No. 20 and Engine Control Module (ECM) when A/C switch is on.
2. Short to ground between A/C switch and ECM when A/C switch is off.
3. A/C switch malfunction.

DTC 1505 will set when Engine Control Module (ECM) has determined IAC valve opening coil signal is too low. DTC 1506 will set when ECM has determined IAC valve opening coil signal is too high. Monitor runs continuously. One trip fault.

Check for

1. Open, short to ground or short to power in White/Green wire between IAC valve and ECM.
2. IAC valve malfunction.

DTC 1507 will set when Engine Control Module (ECM) has determined IAC valve closing coil signal is too low. DTC 1508 will set when ECM has determined IAC valve closing coil signal is too high. Monitor runs continuously. One trip fault.

Check for

1. Open, short to ground or short to power in White/Yellow wire between IAC valve and Engine Control Module (ECM).
2. IAC valve malfunction.

When engine speed is more than 2000 RPM and load value is more than 2.2 ms, code will set if voltage is not present at ECM connector terminals No. 72 and 86 (A/T coding signal is on and drive position switch is off), or voltage is present at ECM connector terminals No. 72 and 86 (A/T coding signal is off and drive position switch is on). Monitor runs continuously. Two trip fault.

On automatic transaxles, check for

1. Open in Black/Yellow wire between ECM connector terminal No. 72 and ground.
2. Short to ground in Red/Yellow wire at ECM connector terminal No. 86.

On manual transaxles, check for

1. Open in Red/Yellow wire between ECM connector terminal No. 86 and ground.
2. Wire installed in ECM connector terminal No. 72.

Code will set when Engine Control Module (ECM) determines MIL request line voltage is too high or too low. DTC P1611 monitor runs continuously when ignition is on. DTC P1614 monitor runs once per drive cycle at ECM power up. Two trip fault.

Check for

1. Open between ECM and Transaxle Control Module (TCM) on MIL request line.
2. Short to power or short to ground between ECM and TCM on MIL request line.

This is only a request from Transaxle Control Module (TCM) to Engine Control Module (ECM) to turn MIL on after a fault is detected by TCM. The fault code is stored in TCM. Freeze frame data is stored in ECM under P1624 request code. Retrieve freeze frame data before clearing DTC P1624 from ECM.

Check for

1. Only on automatic transaxle equipped vehicle.
2. Transaxle Control Module (TCM) DTCs.

Code will set when Engine Control Module (ECM) detects open or short in cooling fan circuit. Monitor runs continuously. Two trip fault.

Check for

1. Cooling fan relay malfunction.
2. Open in Light Green/Black wire between cooling fan relay and ECM.
3. Short to power or short to ground in Light Green/Black wire between ECM or underhood Data Link Connector (DLC).
4. Open between cooling fan relay and EGI main relay.

Code will set when Engine Control Module (ECM) detects open or short in MIL circuit. Monitor runs continuously. No MIL illumination.

Check for

1. Open, short to power or short to ground in Brown/White wire between MIL and Engine Control Module (ECM).
2. MIL bulb blown.

Code will set when Engine Control Module (ECM) detects open or short in transmission controlled spark advance circuit. Monitor runs continuously. No Malfunction Indicator Light (MIL) illumination.

Check for

1. Open, short to power or short to ground in Red/Brown wire between ECM and Transaxle Control Module (TCM).