Engine+Control+-+Fuel+System Kia Sorinto 3500 13-16 PDF

Engine Control / Fuel System
Specifications
Fuel Delivery System
Items Specification
Fuel Tank Capacity 66 lit. (17.4 U.S.gal., 69.7 U.S.qt., 58.0 Imp.qt.)
Fuel Filter Type Paper type
Low Pressure Fuel Line 500 kPa (5.1 kgf/cm², 72.5 psi)
Fuel Pressure 3.0 ~ 15.0 MPa (30.6 ~ 153.0 kgf/cm², 435.1 ~
High Pressure Fuel Line
2175.6 psi)
Type Electrical, in-tank type
Fuel Pump
Driven by Electric motor
Type Mechanical type
High Pressure Fuel Pump
Driven by Camshaft
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Sensors
Barometric Pressure Sensor (BPS)
Type: Piezo-resistive pressure sensor
Specification
Pressure [kPa (kgf/cm²,
Output Voltage (V)
psi)]
10.0 (0.01, 0.15) 0.50
55.0 (0.56, 7.98) 2.21
115.0 (1.17, 16.9) 4.50
Intake Air Temperature Sensor (IATS)

Type: Thermistor type
Specification
Temperature
Resistance (kΩ)
°C °F
-40 -40 40.93 ~ 48.35
-20 -4 13.89 ~ 16.03
0 32 5.38 ~ 6.09
10 50 3.48 ~ 3.90
20 68 2.31 ~ 2.57
40 104 1.08 ~ 1.21
60 140 0.54 ~ 0.66
80 176 0.29 ~ 0.34
Manifold Absolute Pressure Sensor (MAPS)

Type: Piezo-resistive pressure sensor
Specification
C:\Users\ej20\Desktop\KI 15\Sorento 2015\Engine Control - Fuel System.mht 2014-06-10

Output Voltage (V)
psi)]
20.0 (0.20, 2.90) 0.79
46.66 (0.47, 6.77) 1.84
101.32 (1.03, 14.7) 4.0
Engine Coolant Temperature Sensor (ECTS)

Specification
Temperature
Resistance (kΩ)
°C °F
-40 -40 48.14
-20 -4 14.13 ~ 16.83
0 32 5.79
20 68 2.31 ~ 2.59
40 104 1.15
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60 140 0.59
80 176 0.32
Throttle Position Sensor (TPS) [integrated into ETC module]

Type: Hall IC Non-contact sensor type
Specification
Output Voltage (V) [Vref=5V]
Throttle angle(°)
TPS1 TPS2
0 0.5 4.5
10 0.96 4.05
20 1.41 3.59
30 1.87 3.14
40 2.32 2.68
50 2.78 2.23
60 3.23 1.77
70 3.69 1.32
80 4.14 0.86
90 4.6 0.41
98 4.65 0.35
C.T (0) 0.5 4.5
W.O.T (86) 4.41 0.59

Crankshaft Position Sensor (CKPS)
Type: Magnetic field sensitive sensor
Specification
Item Specification
Coil Resistance (Ω) 500 ~ 620
[20°C(68°F)]
Camshaft Position Sensor (CMPS)
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Type: Hall effect type
Specification
Item Specification
Output Voltage High: 5.0V
(V) Low: 0.7V
Air Gap (mm) 0.5 ~ 1.5
Knock Sensor (KS)

Type: Piezo-electricity type
Specification
Item Specification
Capacitance
950 ~ 1,350
(pF)
Resistance
4.87
(MΩ)
Heated Oxygen Sensor (HO2S)

Type: Zirconia (ZrO2) [Binary] Type
Specification
Output
A/F Ratio (λ)
Voltage(V)
RICH Min. 0.8
LEAN Max. 0.1
Item Specification
Heater Resistance (Ω) 3.3 ~
4.1[20°C(68°F)]

Rail Pressure Sensor (RPS)
Type: Piezo-electricity type
Specification
CVVT Oil Temperature Sensor (OTS)

Specification
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Temperature
Resistance (kΩ)
°C °F
-40 -40 52.15
-20 -4 16.52
0 32 6.0
20 68 2.45
40 104 1.11
60 140 0.54
80 176 0.29
Accelerator Position Sensor (APS)

Type: Variable resistor type
Specification
Accelerator Output Voltage (V)
Position APS1 APS2
C.T 0.7 ~ 0.8 0.29 ~ 0.46
W.O.T 3.85 ~ 4.35 1.93 ~ 2.18
Fuel Tank Pressure Sensor (FTPS)

Type: Piezo - Resistivity type
Specification
Output Voltage (V)
psi)]
-3.75 (-0.038, -15.05) 4.5
0 1.5
+1.25 (0.013, 5.02) 0.5

Actuators
Injector
Specification
Item Specification
Coil Resistance (Ω) 0.98 ~ 1.14
[20°C(68°F)]
ETC Motor [integrated into ETC Module]

Specification
Item Specification
Coil Resistance (Ω) 0.3 ~ 100
[20°C(68°F)]
Purge Control Solenoid Valve (PCSV)

Specification
Item Specification
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[20°C(68°F)]
CVVT Oil Control Valve (OCV)

Specification
Item Specification
Coil Resistance (Ω) 9.4 ~10.4
[20°C(68°F)]
Variable Intake Solenoid (VIS) Valve

Specification
Item Specification
[20°C(68°F)]
Ignition Coil
Type: Stick type
Specification
Item Specification
Primary Coil Resistance (Ω) 0.62 ± 10 [20°C(68°F)]
Secondary Coil Resistance
7.0 ± 15 [20°C(68°F)]
(kΩ)
Fuel Pressure Control Valve (FPCV)

Specification
Item Specification
1.04 ~ 1.27
Coil Resistance (Ω)
[23°C(73.4°F)]

Canister Close Valve (CCV)
Specification
Item Specification
[20°C(68°F)]
Service Standard
Item Specification
Ignition Timing (°) BTDC 10° ± 5°
Neutral, N, P-
A/C 650 ± 100
range
OFF
Idle Speed D-range 580 ± 100
(rpm) Neutral, N, P-
650 ± 100
A/C ON range
D-range 650 ± 100
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Tightening Torques
Engine Control System
Item kgf.m N.m lb-ft
ECM bracket installation bolt / nut 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
IDB bracket installation nut 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Barometric pressure sensor installation bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Engine coolant temperature sensor installation 3.0 ~ 4.0 29.4 ~ 39.2 21.7 ~ 28.9
Manifold absolute pressure sensor installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Intake air temperature sensor installation bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Crankshaft position sensor installation bolt 0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
Camshaft position sensor (Bank 1/Intake)
0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
installation bolt
Camshaft position sensor (Bank 1/Exhaust)
0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
installation bolt
Camshaft position sensor (Bank 2/Intake)
0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
installation bolt
Camshaft position sensor (Bank 2/Exhaust)
0.7 ~ 1.0 6.9 ~ 9.8 5.1 ~ 7.2
installation bolt
Knock sensor #1 (Bank 1) installation bolt 1.6 ~ 2.4 15.7 ~ 23.5 11.6 ~ 17.4
Knock sensor #2 (Bank 2) installation bolt 1.6 ~ 2.4 15.7 ~ 23.5 11.6 ~ 17.4
Heated oxygen sensor (Bank 1 / sensor 1)
3.6 ~ 4.6 35.3 ~ 45.1 26.0 ~ 33.3
installation
3.6 ~ 4.6 35.3 ~ 45.1 26.0 ~ 33.3
installation
3.6 ~ 4.6 35.3 ~ 45.1 26.0 ~ 33.3
installation

3.6 ~ 4.6 35.3 ~ 45.1 26.0 ~ 33.3
installation
Rail pressure sensor installation 3.0 ~ 3.5 29.4 ~ 34.3 21.7 ~ 25.3
CVVT oil temperature sensor installation 3.5 ~ 4.5 34.4 ~ 41.1 25.3 ~ 32.5
Electronic throttle body installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Purge control solenoid valve bracket installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
CVVT oil control valve (Bank 1 / Intake)
1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
installation bolt
CVVT oil control valve (Bank 1 / Exhaust)
1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
installation bolt
CVVT oil control valve (Bank 2 / Intake)
1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
installation bolt
CVVT oil control valve (Bank 2 / Exhaust)
1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
installation bolt
Variable intake solenoid valve installation nut 0.6 ~ 0.9 5.9 ~ 8.8 4.3 ~ 6.5
Ignition coil installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
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Fuel Delivery System
Item kgf.m N.m lb-ft
Fuel tank band installation bolt 4.0 ~ 6.0 44.1 ~ 58.8 38.5 ~ 43.4
Filler-neck assembly bracket installation nut 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Accelerator pedal module installation bolt 0.9 ~ 1.4 8.8 ~ 13.7 6.5 ~ 10.1
Accelerator pedal module installation nut 1.7 ~ 2.6 8.8 ~ 13.7 6.5 ~ 10.1
Delivery pipe installation bolt 1.9 ~ 2.4 18.6 ~ 23.5 13.7 ~ 17.4
High pressure fuel pipe function block installation
0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
bolt
High pressure fuel pump installation bolt 1.3 ~ 1.5 12.8 ~ 14.7 9.4 ~ 10.9
High pressure fuel pipe installation nut 3.0 ~ 3.6 29.4 ~ 35.3 21.7 ~ 26.0
High pressure fuel pipe bracket installation bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Special Service Tools

Item Illustration Application
Fuel Pressure Gauge Measuring the fuel line pressure
(09353-24100)
Fuel Pressure Gauge Adapter Connection between the high pressure fuel
(09353-02100) pump and the fuel feed line
Heated Oxygen Sensor Socket Removal and installation of the heated

Wrench oxygen sensor
(09392-1Y100) SST No.09392-2H100 model also can
be used for removing the Heated Oxygen
Sensor.
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Torque Wrench Socket (17mm) Removal and installation of the high pressure
(09314-3V100) fuel pipe
Injector Combustion Seal Guide & Installation of the injector combustion seal
Sizing tool
(09353-2B000)
Fuel Pump Locking Ring Remover Removal and installation of the fuel pump (or
This tool can be purchased from sub fuel sender) locking ring
KMA or Other tool supplier. (Not
Mobis)
Basic Troubleshooting
Basic Troubleshooting Guide

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Customer Problem Analysis Sheet

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Basic Inspection Procedure

Measuring Condition of Electronic Parts' Resistance
The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured
at ambient temperature (20°C, 68°F), unless stated otherwise.
The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Intermittent Problem Inspection Procedure
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during
testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when warm. In
this case, the technician should thoroughly make out a "Customer Problem Analysis Sheet" and recreate (simulate) the
environment and condition which occurred when the vehicle was having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins,
and then verify that the connectors are always securely fastened.
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3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
● Simulating Vibration
1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.
Strong vibration may break sensors, actuators or

relays
2) Connectors and Harness

: Lightly shake the connector and wiring harness vertically and then horizontally.
● Simulating Heat
1) Heat components suspected of causing the malfunction with a hair dryer or other heat source.
• DO NOT heat components to the point where they may be damaged.

• DO NOT heat the ECM directly.
● Simulating Water Sprinkling

1) Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
DO NOT sprinkle water directly into the engine compartment or electronic

components.
● Simulating Electrical Load

1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window defogger, etc.).
Connector Inspection Procedure
1. Handling of Connector
A. Never pull on the wiring harness when disconnecting connectors.
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B. When removing the connector with a lock, press or pull locking lever.
C. Listen for a click when locking connectors. This sound indicates that they are securely locked.

D. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness
side.
E. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from
harness side.
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• Use a fine wire to prevent damage to the terminal.
• Do not damage the terminal when inserting the tester lead.
2. Checking Point for Connector

A. While the connector is connected:
Hold the connector, check connecting condition and locking efficiency.
B. When the connector is disconnected:
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
C. Check terminal tightening condition:
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
D. Pull lightly on individual wires to ensure that each wire is secured in the terminal.

3. Repair Method of Connector Terminal
A. Clean the contact points using air gun and/or shop rag.
Never use sand paper when polishing the contact points, otherwise the contact point may be
damaged.
B. In case of abnormal contact pressure, replace the female terminal.

Wire Harness Inspection Procedure
1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.
Electrical Circuit Inspection Procedure
● Check Open Circuit
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1. Procedures for Open Circuit
A. Continuity Check
B. Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or
Step 3 (Voltage Check Method) as shown below.

2. Continuity Check Method
When measuring for resistance, lightly shake the wire harness above and below or from side to side.
Specification (Resistance)
1Ω or less → Normal Circuit
1MΩ or Higher → Open Circuit
A. Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1MΩ and below 1 Ω respectively. Specifically
the open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as described in next
step.
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B. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and
(A) as shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1MΩ and the open circuit is
between terminal 1 of connector (C) and terminal 1 of connector (B1).

3. Voltage Check Method
A. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each
connectors (A), (B) and (C) as shown in [FIG. 4].
The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between
connector (C) and (B).
● Check Short Circuit

1. Test Method for Short to Ground Circuit
A. Continuity Check with Chassis Ground
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If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2
(Continuity Check Method with Chassis Ground) as shown below.
2. Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness above and below, or from side to side when measuring the resistance.
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1MΩ or Higher → Normal Circuit

A. Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as
shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively.
Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line
of line 1 as described in the following step.
B. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between
(B1) and chassis ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground circuit is
between terminal 1 of connector (C) and terminal 1 of connector (B1).
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● Testing For Voltage Drop
This test checks for voltage drop along a wire, or through a connection orswitch.
1) Connect the positive lead of a voltmeter to the end of the wire (or to the side of the connector or switch) closest to
the battery.
2) Connect the negative lead to the other end of the wire. (or the other side of the connector or switch)
3) Operate the circuit.
4) The voltmeter will show the difference in voltage between the two points. A difference, or drop of more than 0.1
volts (50mV in 5V circuits), may indicate a problem. Check the circuit for loose or dirty connections.

Symptom Troubleshooting Guide Chart
Main symptom Diagnostic procedure Also check for
Unable to start 1. Test the battery.
(Engine does not turn (Refer to Engine Electrical System - "Battery")
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over) 2. Test the starter.
(Refer to Engine Electrical System - "Starter")
3. Inhibitor switch (A/T) or clutch start switch (M/T)
Unable to start 1. Test the battery.
(Incomplete (Refer to Engine Electrical System - "Battery")
• DTC
combustion) 2. Check the fuel pressure.
• Low compression
(Refer to Fuel Delivery System - "Fuel Pressure Test")
• Intake air leaks
3. Check the ignition circuit.
• Slipped or broken timing
(Refer to Engine Electrical System - "Ignition System")
belt
4. Troubleshooting the immobilizer system.
• Contaminated fuel
(Refer to Body Electrical System - "Immobilizer System")
(In case of immobilizer lamp flashing)
Difficult to start 1. Test the battery.
(Refer to Engine Electrical System - "Battery") • DTC
2. Check the fuel pressure. • Low compression
(Refer to Fuel Delivery System - "Fuel Pressure Test" • Intake air leaks
3. Check the ECT sensor and circuit (Check DTC) • Contaminated fuel
4. Check the ignition circuit. • Weak ignition spark
Poor idling 1. Check the fuel pressure.
(Rough, unstable or (Refer to Fuel Delivery System - "Fuel Pressure Test")
incorrect Idle) 2. Check the Injector. • DTC
(Refer to Engine Control System - "Injector") • Low compression
3. Check the long term fuel trim and short term fuel trim • Intake air leaks
(Refer to CUSTOMER DATASTREAM) • Contaminated fuel
4. Check the idle speed control circuit (Check DTC) • Weak ignition spark
5. Inspect and test the Throttle Body
6. Check the ECT sensor and circuit (Check DTC)

Engine stall 1. Test the battery.
(Refer to Engine Electrical System - "Battery")
2. Check the fuel pressure. • DTC
(Refer to Fuel Delivery System - "Fuel Pressure Test") • Intake air leaks
3. Check the idle speed control circuit (Check DTC) • Contaminated fuel
4. Check the ignition circuit. • Weak ignition spark
5. Check the CKPS Circuit (Check DTC)
Poor driving 1. Check the fuel pressure.
(Surge) (Refer to Fuel Delivery System - "Fuel Pressure Test")
2. Inspect and test Throttle Body
• DTC
3. Check the ignition circuit.
• Low compression
• Intake air leaks
4. Check the ECT Sensor and Circuit (Check DTC)
• Contaminated fuel
5. Test the exhaust system for a possible restriction.
• Weak ignition spark
(Refer to Engine Mechanical System - "Exhaust Manifold")
6. Check the long term fuel trim and short term fuel trim.
(Refer to CUSTOMER DATASTREAM)
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Knocking 1. Check the fuel pressure.
(Refer to Fuel Delivery System - "Fuel Pressure Test")
2. Inspect the engine coolant.
(Engine Mechanical System - "Radiator") • DTC
3. Inspect the radiator and the electric cooling fan. • Contaminated fuel
(Engine Mechanical System - "Radiator")
4. Check the spark plugs.
Poor fuel economy 1. Check customer's driving habitsIs
· A/C on full time or the defroster mode on?
· Are tires at correct pressure?
· Is excessively heavy load being carried? • DTC
· Is acceleration too much, too often? • Low compression
2. Check the fuel pressure. • Intake air leaks
(Refer to Fuel Delivery System - "Fuel Pressure Test") • Contaminated fuel
3. Check the injector. • Weak ignition spark
(Refer to Engine Control System - "Injector")
4. Test the exhaust system for a possible restriction
5. Check the ECT sensor and circuit
Hard to refuel 1. Test the canister close valve.
(Overflow during (Refer to Engine Control System - "Canister Close Valve)
refueling) • Malfunctioning gas station
2. Inspect the fuel filler hose/pipe
filling nozzle (If this
· Pinched, kinked or blocked?
problem occurs at a
· Filler hose is torn
specific gas station during
3. Inspect the fuel tank vapor vent hose between the EVAP.
refueling)
canister and air filter
4. Check the EVAP. canister

OBD-II review
1. Overview
The California Air Resources Board (CARB) began regulation of On Board Diagnostics (OBD) for vehicles sold in
California beginning with the 1988 model year. The first phase, OBD-I, required monitoring of the fuel metering system,
Exhaust Gas Recirculation (EGR) system and additional emission related components. The Malfunction Indicator Lamp
(MIL) was required to light and alert the driver of the fault and the need for repair of the emission control system.
Associated with the MIL was a fault code or Diagnostic Trouble Code (DTC) idenfying the specific area of the fault.
The OBD system was proposed by CARB to improve air quality by identifying vehicle exceeding emission standards.
Passage of the Federal Clean Air Act Amendments in 1990 has also prompted the Environmental Protection Agency
(EPA) to develop On Board Diagnostic requirements. CARB OBD-II regulations were followed until 1999 when the
federal regulations were used.
The OBD-II system meets government regulations by monitoring the emission control system. When a system or
component exceeds emission threshold or a component operates outside tolerance, a DTC will be stored and the MIL
illuminated.
The diagnostic executive is a computer program in the Engine Control Module (ECM) or PowertrainControl Module
(PCM) that coordinates the OBD-II self-monitoring system. This program controls all the monitors and interactions, DTC
and MIL operation, freeze frame data and scan tool interface.
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Freeze frame data describes stored engine conditions, such as state of the engine, state of fuel control, spark, RPM, load
and warm status at the point the first fault is detected. Previously stored conditions will be replaced only if a fuel or misfire
fault is detected. This data is accessible with the scan tool to assist in repairing the vehicle.
The center of the OBD-II system is a microprocessor called the Engine Control Module (ECM) or Powertrain Control
Module(PCM).
The ECM or PCM receives input from sensors and other electronic components (switches, relays, and others) based on
information received and programmed into its memory (keep alive random access memory, and others), the ECM or
PCM generates output signals to control various relays, solenoids and actuators.
2. Configuration of hardware and related terms
1) GST (Generic scan tool)

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2) MIL (Malfunction indication lamp) - MIL activity by transistor
The Malfunction Indicator Lamp (MIL) is connected between ECM or PCM-terminal Malfunction Indicator Lamp and
battery supply (open collector amplifier).
In most cars, the MIL will be installed in the instrument panel. The lamp amplifier can not be damaged by a short circuit.
Lamps with a power dissipation much greater than total dissipation of the MIL and lamp in the tester may cause a fault
indication.
At ignition ON and engine revolution (RPM)< MIN. RPM, the MIL is switched ON for an optical check by the
driver.
3) MIL illumination
When the ECM or PCM detects a malfunction related emission during the first driving cycle, the DTC and engine data
are stored in the freeze frame memory. The MIL is illuminated only when the ECM or PCM detects the same malfunction
related to the DTC in two consecutive driving cycles.

4) MIL elimination
• Misfire and Fuel System Malfunctions:
For misfire or fuel system malfunctions, the MIL may be eliminated if the same fault does not reoccur during
monitoring in three subsequent sequential driving cycles in which conditions are similar to those under which the
malfunction was first detected.
• All Other Malfunctions:
For all other faults, the MIL may be extinguished after three subsequent sequential driving cycles during which the
monitoring system responsible for illuminating the MIL functions without detecting the malfunction and if no other
malfunction has been identified that would independently illuminate the MIL according to the requirements outlined
above.
5) Erasing a fault code
The diagnostic system may erase a fault code if the same fault is not re-registered in at least 40 engine warm-up cycles,
and the MIL is not illuminated for that fault code.
6) Communication Line (CAN)
• Bus Topology : Line (bus) structure
• Wiring : Twisted pair wire
• Off Board DLC Cable Length : Max. 5m
• Data Transfer Rate
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- Diagnostic : 500 kbps
- Service Mode (Upgrade, Writing VIN) : 500 or 1Mbps)
7) Driving cycle
A driving cycle consists of engine start up, and engine shut off.
8) Warm-up cycle
A warm-up cycle means sufficient vehicle operation such that the engine coolant temperature has risen by at least 40
degrees Fahrenheit from engine starting and reaches a minimum temperature of at least 160 degrees Fahrenheit.
9) DTC format
• Diagnostic Trouble Code (SAE J2012)
• DTCs used in OBD-II vehicles will begin with a letter and are followed by four numbers.
The letter of the beginning of the DTC identifies the function of the monitored device that has failed. A "P" indicates a
powertrain device, "C" indicates a chassis device. "B" is for body device and "U" indicates a network or data link code.
The first number indicates if the code is generic (common to all manufacturers) or if it is manufacturer specific. A "0" &
"2" indicates generic, "1" indicates manufacturer-specific. The second number indicates the system that is affected with a
number between 1 and 7.
The following is a list showing what numbers are assigned to each system.
• 1 : Fuel and air metering
• 2 : Fuel and air metering(injector circuit malfunction only)
• 3 : Ignition system or misfire
• 4 : Auxiliary emission controls
• 5 : Vehicle speed controls and idle control system
• 6 : Computer output circuits
• 7 : Transmission
The last two numbers of the DTC indicates the component or section of the system where the fault is located.
10) Freeze frame data
When a freeze frame event is triggered by an emission related DTC, the ECM or PCM stores various vehicle information
as it existed the moment the fault ocurred. The DTC number along with the engine data can be useful in aiding a technician
in locating the cause of the fault. Once the data from the 1st driving cycle DTC ocurrence is stored in the freeze frame
memory, it will remain there even when the fault ocurrs again (2nd driving cycle) and the MIL is illuminated.
• Freeze Frame List
1) Calculated Load Value
2) Engine RPM
3) Fuel Trim
4) Fuel Pressure (if available)
5) Vehicle Speed (if available)
6) Coolant Temperature
7) Intake Manifold Pressure (if available)
8) Closed-or Open-loop operation
9) Fault code
3. OBD-II Readiness Test
[Kia Motors Drive Cycle]
Kia OBDII Drive Cycle is designed to execute and complete the OBDII monitors. To complete a specific monitor for
repair verification, follow the Drive Cycle chart below.
Kia OBDII Drive Cycle consists of two modes (Mode 1 and Mode 2) and the Mode 2 is to perform the catalyst
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diagnostics on Dephi EMS only.
- Continental, Bosch or Kefico EMS : Mode 1 drive cycle should be done one time for diagnostics on all systems.
- Dephi EMS : Mode 2 drive cycle should be done two times in a row after Mode 1 is carried out one time for
diagnostics on all systems
• Mode 1

• Mode 2
Speed Duration E/Time

Mode No Operation Remarks
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(mph) (s) (s)
ECT @ Start
1 Engine Start 0 0 0
32~104°F
2 Idling (N) 0 30 30 Neutral Range
3 Idling (D) 0 270 300 D Range
4 Acceleration 0 → 50 15 315
5 Steady Speed 50 230 545
6 Deceleration 50 → 45 5 550
12 Repeat 8 through 11 ten times. - 180 755
Mode 1

28 Acceleration 40 → 50 15 2035
30 Deceleration 50 → 40 15 2055
Repeat 28 through 31 five
32 - 380 2495
times.
33 Acceleration 40 → 50 15 2510
Mode 1
1 Engine Start 0 0 0
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Lift Foot Up : APS =
0
Middle Tip In or
Deep Accel
0
Mode 2 10 Deceleration 52 → 45 3 288
0
Repeat 6 through 11 twelve
12 - 330 620
times.
Repeat 15 through 18 two
19 - 175 1035
times.

1) Catalyst monitoring
The catalyst efficiency monitor is a self-test strategy within the ECM or PCM that uses the downstream Heated Oxygen
Sensor (HO2S) to determine when a catalyst has fallen below the minimum level of effectiveness in its ability to control
exhaust emission.
2) Misfire monitoring
Misfire is defined as the lack of proper combustion in the cylinder due to the absence of spark, poor fuel metering, or
poor compression. Any combustion that does not occur within the cylinder at the proper time is also a misfire. The misfire
detection monitor detects fuel, ignition or mechanically induced misfires. The intent is to protect the catalyst from
permanent damage and to alert the customer of an emission failure or an inspection maintenance failure by illuminating the
MIL . When a misfire is detected, special software called freeze frame data is enabled. The freeze frame data captures
the operational state of the vehicle when a fault is detected from misfire detection monitor strategy.
3) Fuel system monitoring
The fuel system monitor is a self-test strategy within the ECM or PCM that monitors the adaptive fuel table The fuel
control system uses the adaptive fuel table to compensate for normal variability of the fuel system components caused by
wear or aging. During normal vehicle operation, if the fuel system appears biased lean or rich, the adaptive value table will
shift the fuel delivery calculations to remove bias.
4) Engine cooling system monitoring
The cooling system monitoring is a self-test strategy within the ECM or PCM that monitors ECTS (Engine Coolant
Temperature Sensor) and thermostat about circuit continuity, output range, rationality faults.
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5) O2 sensor monitoring
OBD-II regulations require monitoring of the upstream Heated O2 Sensor (H2OS) to detect if the deterioration of the
sensor has exceeded thresholds. An additional HO2S is located downstream of the Warm-Up Three Way Catalytic
Converter (WU-TWC) to determine the efficiency of the catalyst.
Although the downstream H2OS is similar to the type used for fuel control, it functions differently. The downstream
HO2S is monitored to determine if a voltage is generated. That voltage is compared to a calibrated acceptable range.
6) Evaporative emission system monitoring
The EVAP. monitoring is a self-test strategy within the ECM or PCM that tests the integrity of the EVAP. system. The
complete evaporative system detects a leak or leaks that cumulatively are greater than or equal to a leak caused by a
0.040 inch and 0.020 inch diameter orifice.
7) Air conditioning system monitoring
The A/C system monitoring is a self-test strategy within the ECM or PCM that monitors malfunction of all A/C system
components at A/C ON.
8) Comprehensive components monitoring
The comprehensive components monitoring is a self-test strategy within the ECM or PCM that detects fault of any
electronic powertrain components or system that provides input to the ECM or PCM and is not exclusively an input to
any other OBD-II monitor.
9) A/C system component monitoring
Requirement:
If a vehicle incorporates an engine control strategy that alters off idle fuel and/or spark control when the A/C system is on,
the OBD II system shall monitor all electronic air conditioning system components for malfunctions that cause the system
to fail to invoke the alternate control while the A/C system is on or cause the system to invoke the alternate control while
the A/C system is off.
Additionally, the OBD II system shall monitor for malfunction all electronic air conditioning system components that are
used as part of the diagnostic strategy for any other monitored system or component.
Implementation plan:
No engine control strategy incorporated that alters offidle fuel and/or spark control when A/C system is on. Malfuction of
A/C system components is not used as a part of the diagnostic strategy for other monitored system or component.
Components Location

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1. ECM (Engine Control Module) 21. A/C Pressure Transducer (APT)
2. Barometric Pressure Sensor (BPS) 22. Fuel Tank Pressure Sensor (FTPS)
3. Manifold Absolute Pressure Sensor (MAPS) 23. Fuel Level Sender (FLS)
4. Intake Air Temperature Sensor (IATS) 24. ETC Motor [integrated into ETC Module]
5. Engine Coolant Temperature Sensor (ECTS) 25. Injector
6. Throttle Position Sensor (TPS) [integrated into ETC 26. Purge Control Solenoid Valve (PCSV)
Module] 27. CVVT Oil Control Valve (OCV) [Bank 1 / Intake]
7. Crankshaft Position Sensor (CKPS) 28. CVVT Oil Control Valve (OCV) [Bank 1 /
8. Camshaft Position Sensor (CMPS) [Bank 1 / Intake] Exhaust]
9. Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust] 29. CVVT Oil Control Valve (OCV) [Bank 2 / Intake]
10. Camshaft Position Sensor (CMPS) [Bank 2 / Intake] 30. CVVT Oil Control Valve (OCV) [Bank 2 /
11. Camshaft Position Sensor (CMPS) [Bank 2 / Exhaust] Exhaust]
12. Knock Sensor (KS) [Bank 1] 31. Variable Intake Solenoid (VIS) Valve #1
13. Knock Sensor (KS) [Bank 2] 32. Variable Intake Solenoid (VIS) Valve #2
14. Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 1] 33. Fuel Pressure Control Valve (FPCV)
15. Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 2] 34. Canister Close Valve (CCV)
16. Heated Oxygen Sensor (HO2S) [Bank 2 / Sensor 1] 35. Injector Drive Box (IDB)
17. Heated Oxygen Sensor (HO2S) [Bank 2 / Sensor 2] 36. Ignition Coil
18. Rail Pressure Sensor (RPS) 37. Main Relay
19. CVVT Oil Temperature Sensor (OTS) 38. Fuel Pump Relay
20. Accelerator Position Sensor (APS) 39. Data Link Connector (DLC) [16 Pin]
40. Multi-Purpose Check Connector [20 Pin]

1. ECM (Engine Control Module) 2. Barometric Pressure Sensor (BPS)
4. Intake Air Temperature Sensor (IATS)
3. Manifold Absolute Pressure Sensor (MAPS) 5. Engine Coolant Temperature Sensor (ECTS)
6. Throttle Position Sensor (TPS) [integrated into ETC
Module]
26. Purge Control Solenoid Valve (PCSV)
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7. Crankshaft Position Sensor (CKPS) 8. Camshaft Position Sensor (CMPS) [Bank 1 / Intake]
9. Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust] 10. Camshaft Position Sensor (CMPS) [Bank 2 / Intake]

11. Camshaft Position Sensor (CMPS) [Bank 2 / Exhaust] 12. Knock Sensor (KS) [Bank 1]
13. Knock Sensor (KS) [Bank 2]
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14. Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 1] 15. Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 2]
16. Heated Oxygen Sensor (HO2S) [Bank 2 / Sensor 1] 17. Heated Oxygen Sensor (HO2S) [Bank 2 / Sensor 2]
18. Rail Pressure Sensor (RPS) 19. CVVT Oil Temperature Sensor (OTS)

20. Accelerator Position Sensor (APS) 21. A/C Pressure Transducer (APT)
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22. Fuel Tank Pressure Sensor (FTPS) 23. Fuel Level Sender (FLS)
25. Injector 27. CVVT Oil Control Valve (OCV) [Bank 1 / Intake]
29. CVVT Oil Control Valve (OCV) [Bank 2 / Intake]
28. CVVT Oil Control Valve (OCV) [Bank 1 / Exhaust] 30. CVVT Oil Control Valve (OCV) [Bank 2 / Exhaust]

31. Variable Intake Solenoid (VIS) Valve #1 32. Variable Intake Solenoid (VIS) Valve #2
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33. Fuel Pressure Control Valve (FPCV) 35. Injector Drive Box (IDB)
36. Ignition Coil
37. Main Relay 39. Data Link Connector (DLC) [16 Pin]
38. Fuel Pump Relay
40. Multi-Purpose Check Connector [20 Pin]

ECM Terminal And Input/Output signal
ECM Terminal Function

Connector [E500-A]
Pin
Description Connected to
No.
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1 -
2 -
3 -
4 Immobilizer Lamp control output Immobilizer Lamp [Without Button Engine Start System]
5 Power ground Chassis Ground
7 -
8 -
9 2nd CAN [High] Multi-Purpose Check Connector
Other control module, Data Link Connector (DLC), Multi-Purpose
10 CAN [High]
Check Connector
Fuel Tank Pressure Sensor (FTPS) signal
11 Fuel Tank Pressure Sensor (FTPS)
input
12 Electrical Load signal input Head Lamp Relay
13 -
14 Sensor power (+5V) Accelerator Position Sensor (APS) 1
A/C Pressure Transducer (APT)
15 Sensor power (+5V)
Rail Pressure Sensor (RPS)
Fuel Level Sensor (FLS) [TOTAL] signal
16 Fuel Level Sensor (FLS)
input
17 -
18 -
19 -
20 A/C Compressor relay signal output A/C Control Module
21 Brake Switch 2 signal input Brake Switch

22 -
23 -
24 Alternator (FR) Alternator
25 -
26 -
27 Battery power (B+) Ignition Switch
28 Rail Pressure Sensor (RPS) signal input Rail Pressure Sensor (RPS)
29 -
31 -
32 -
33 -
34 2nd CAN [Low] Multi-Purpose Check Connector
Other control module, Data Link Connector (DLC), Multi-Purpose
35 CAN [Low]
Check Connector
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36 -
37 Sensor ground Rail Pressure Sensor (RPS)
Accelerator Position Sensor (APS) 1
38 Accelerator Position Sensor (APS) 1
signal input
39 -
40 -
Fuel Level Sensor (FLS) [MIDDLE]
41 Fuel Level Sensor (FLS)
signal input
42 A/C Switch "ON" signal input A/C Control Module
43 Brake Switch 1 signal input Brake Switch
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
52 Battery power (B+) Battery
53 -
54 -
56 -
A/C Compressor Clutch Relay control
57 A/C Control Module [With Immobilzer]
output

58 -
59 Sensor ground Accelerator Position Sensor (APS) 2
60 Sensor ground Accelerator Position Sensor (APS) 1
61 Sensor ground Fuel Tank Pressure Sensor (FTPS)
62 Ground Cruise Control Switch
63 Sensor ground A/C Pressure Transducer (APT)
64 -
65 Sensor Power (+5V) Fuel Tank Pressure Sensor (FTPS)
66 Cruise Control Switch signal input Cruise Control Switch
A/C Pressure Transducer (APT) signal
67 A/C Pressure Transducer (APT)
input
Accelerator Position Sensor (APS) 2
68 Accelerator Position Sensor (APS) 2
signal input
69 -
70 Engine speed signal output Power Distribution Module (PDM)
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71 Cooling Fan Relay [High] control output Cooling Fan Relay [High]
72 Alternator (COM) Alternator
73 -
Smart Key Control Module [With Button Engine Start System]
74 Immobilizer communication line
Immobilizer Control Unit [Without Button Engine Start System]
75 Battery power (B+) Main Relay
76 -
77 Battery power (B+) Battery
78 -
79 -
80 Power ground Chassis ground
81 -
82 -
83 -
84 -
85 -
86 -
LIN (Local Interconnect Network) Serial
87 Battery Sensor
Bus Line
88 -
89 -
90 Sensor power (+5V) Accelerator Position Sensor (APS) 2
91 -
92 -
93 Starter Relay control output Starter Relay
94 Main Relay control output Main Relay
95 Fuel pump Relay control output Fuel pump Relay
Canister Close Valve (CCV) control
96 Canister Close Valve (CCV)
output
97 -
98 -
Connector [C500-B]
Pin
No.
1 -
2 -
3 -
4 -
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Camshaft Position Sensor (CMPS) [Bank 1/Intake]
5 Sensor power (+5V)
Camshaft Position Sensor (CMPS) [Bank 2/Exhaust]
6 Sensor power (+5V) Throttle Position Sensor (TPS)
7 -
Power Distribution Module (PDM) [With Button
8 Crank request signal output Engine Start System]
Ignition Switch [Without Button Engine Start System]
9 Barometric Pressure Sensor (BPS) signal input Barometric Pressure Sensor (BPS)
10 CVVT Oil Temperature Sensor (OTS) signal input CVVT Oil Temperature Sensor (OTS)
11 A/C Blower “MAX” signal input A/C Control Module
12 Throttle Position Sensor (TPS) 1 signal input Throttle Position Sensor (TPS) 1
13 Manifold Absolute Pressure Sensor (MAPS) signal input Manifold Absolute Pressure Sensor (MAPS)
14 Intake Air Temperature Sensor (IATS) signal input Intake Air Temperature Sensor (IATS)
Power Distribution Module (PDM) [With Button
Engine Start System]
15 Vehicle speed signal input
ABS/ESP Control Module [Without Button Engine
Start System]
16 Knock Sensor (KS) [Bank 2] [High] signal input Knock Sensor (KS) [Bank 2]
17 Knock Sensor (KS) [Bank 1] [High] signal input Knock Sensor (KS) [Bank 1]
18 Crankshaft Position Sensor (CKPS) [High] signal input Crankshaft Position Sensor (CKPS)
19 Sensor ground CVVT Oil Temperature Sensor (OTS)
20 -
21 Camshaft Position Sensor (CMPS) [Bank 2/Intake]
signal input
22 -
23 -
24 Ignition Coil (Cylinder #1) control output Ignition Coil (Cylinder #1)
25 -
26 -
27 -
28 -
29 -
30 -
31 Sensor ground Throttle Position Sensor (TPS) 1
32 Sensor ground
33 Sensor ground Heated Oxygen Sensor (HO2S) [Bank 2/Sensor 2]
34 Throttle Position Sensor (TPS) 2 signal input Throttle Position Sensor (TPS) 2
35 Engine Coolant Temperature Sensor (ECTS) signal input Engine Coolant Temperature Sensor (ECTS)
36 -
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37 -
Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1] signal
38 Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]
input
Crankshaft Position Sensor (CKPS)
40 Sensor Shield Knock Sensor (KS) #1 [Bank 1]
Knock Sensor (KS) #2 [Bank 2]
41 Knock Sensor (KS) [Bank 2] [Low] signal input Knock Sensor (KS) [Bank 2]
42 Knock Sensor (KS) [Bank 1] [Low] signal input Knock Sensor (KS) [Bank 1]
43 Crankshaft Position Sensor (CKPS) [Low] signal input Crankshaft Position Sensor (CKPS)
44 Sensor ground
45 -
46 Camshaft Position Sensor (CMPS) [Bank 2/Exhaust]
signal input
47 -
48 Sensor power (+5V) Manifold Absolute Pressure Sensor (MAPS)
VCM Position Sensor
50 -
51 -
52 -
53 -

54 -
55 -
56 Sensor ground Manifold Absolute Pressure Sensor (MAPS)
Engine Coolant Temperature Sensor (ECTS)
57 -
input
input
61 -
62 -
input
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65 Variable Intake Solenoid (VIS) Valve 1 control output Variable Intake Solenoid (VIS) Valve 1
66 Purge Control Solenoid Valve (PCSV) control output Purge Control Solenoid Valve (PCSV)
67 -
68 -
69 Variable Intake Solenoid (VIS) Valve 2 control output Variable Intake Solenoid (VIS) Valve 2
70 Camshaft Position Sensor (CMPS) [Bank 1/Exhaust]
signal input
71 Camshaft Position Sensor (CMPS) [Bank 1/Intake]
signal input
72 -
73 Sensor Power (+5V)
75 -
76 -
77 -
78 -
79 -
80 ETC Motor [+] control output ETC Motor
81 ETC Motor [-] control output ETC Motor
Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2]
Heater control output
84 Fuel Pressure Control Valve (FPCV) control output Injector Drive Box (IDB)
85 Injector (Cylinder #2) control output Injector Drive Box (IDB)
Heated Oxygen Sensor (HO2S ) [Bank 1/Sensor 1]
CVVT Oil Control Valve (OCV) [Bank 2/Exhaust]
93 CVVT Oil Control Valve (OCV) [Bank 2/Exhaust]
control output
CVVT Oil Control Valve (OCV) [Bank 1/Exhaust]
94 CVVT Oil Control Valve (OCV) [Bank 1/Exhaust]
control output
CVVT Oil Control Valve (OCV) [Bank 2/Intake] control
95 CVVT Oil Control Valve (OCV) [Bank 2/Intake]
output
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CVVT Oil Control Valve (OCV) [Bank 1/Intake] control
96 CVVT Oil Control Valve (OCV) [Bank 1/Intake]
output
100 -
ECM Terminal Input/Output Signal

Connector [E500-A]
Pin
Description Condition Type Level
No.
1 -
2 -
3 -
Lamp OFF Battery Voltage
4 Immobilizer Lamp control output DC
Lamp ON Max. 1.1V
5 Power ground Idle DC Max. 0.1V
7 -
8 -
Recessive 2.0 ~ 3.0V
9 2nd CAN [High] Pulse
Dominant 2.75 ~ 4.5V
10 CAN [High] Pulse
11 Fuel Tank Pressure Sensor (FTPS) signal input Idle Analog 0.4 ~ 4.6V

Head Lamp OFF Battery Voltage
12 Electrical Load signal input DC
Head Lamp ON Max. 1.0V
13 -
IG OFF Max. 0.5V
14 Sensor power (+5V) DC
IG ON 4.9 ~ 5.1V
IG OFF Max. 0.5V
IG ON 4.9 ~ 5.1V
16 Fuel Level Sensor (FLS) [ TOTAL] signal input IG ON Analog 0.88 ~ 8.45V
17 -
18 -
19 -
A/C OFF Max. 1.0V
20 A/C Compressor relay signal output DC
A/C ON Battery Voltage
Brake OFF Battery Voltage
21 Brake Switch 2 signal input DC
Brake ON Max. 0.5V
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22 -
23 -
High: Battery Voltage
Low: Max. 2.0V
24 Alternator (FR) Idle PWM
133
5
25 -
26 -
IG OFF Battery Voltage
27 Battery power (B+) DC
IG ON Max. 1.0V
28 Rail Pressure Sensor (RPS) signal input Idle DC 1.0 ~ 2.0V
29 -
31 -
32 -
33 -
34 2nd CAN [Low] Pulse
35 CAN [Low] Pulse
36 -
37 Sensor ground Idle DC Max. 0.1V
C.T 0.7 ~ 0.8V
38 Accelerator Position Sensor (APS) 1 signal input Analog
W.O.T 3.85 ~ 4.35V

39 -
40 -
41 Fuel Level Sensor (FLS) [MIDDLE] signal input IG ON Analog 0.88 ~ 8.45V
A/C OFF Max. 1.0V
42 A/C Switch "ON" signal input DC
A/C ON Battery Voltage
Brake OFF Max. 0.5V
43 Brake Switch 1 signal input DC
Brake ON Battery Voltage
44 -
45 -
46 -
47 -
48 -
49 -
50 -
51 -
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Always (Without Ignition
52 Battery power (B+) DC Battery Voltage
key)
53 -
54 -
56 -
Fuel Pump Relay control output [Without Immobilzer] Relay OFF Battery Voltage
57 A/C Compressor Clutch Relay control output [With DC
Relay ON Max 1.1V
Immobilzer]
58 -
62 Ground Idle DC Max. 0.1V
64 -
IG OFF Max. 0.5V
65 Sensor Power (+5V) DC
IG ON 4.75 ~ 5.25V
“MAIN” 11.1 ~ 12.1V
“SET” 1.0 ~ 1.8V
66 Cruise Control Switch signal input Analog
“CANCEL” -0.5 ~ 0.5V
“RESUME” 2.5 ~ 3.5V
67 A/C Pressure Transducer (APT) signal input A/C ON Analog 0.5 ~ 4.5V

C.T 0.29 ~ 0.46V
68 Accelerator Position Sensor (APS) 2 signal input Analog
W.O.T 1.93 ~ 2.18V
69 -
Low: Max. 1.1V
70 Engine speed signal output Engine Running Pulse
0
47.5
71 Cooling Fan Relay [High] control output A/C ON Pulse
Low: Max. 1.1V
High: Min. 4.0V
72 Alternator (COM) IG ON PWM Low: Max. 2.0V
Frequency = 125Hz
73 -
High: Min. Vbatt X
80%
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Transmitting
Low: Max. Vbatt X
20%
74 Immobilizer communication line DC
High: Min. Vbatt X
70%
Receiving
Low: Max. Vbatt X
30%
IG ON Max. 1.0V
76 -
Always (Without Ignition
77 Battery power (B+) DC Battery Voltage
key)
78 -
79 -
81 -
82 -
83 -
84 -
85 -
86 -
High: Min. Vbatt X
80%
Transmitting
Low: Max. Vbatt X
20%
87 LIN (Local Interconnect Network) Serial Bus Line DC

87 LIN (Local Interconnect Network) Serial Bus Line DC
High: Min. Vbatt X
70%
Receiving
Low: Max. Vbatt X
30%
88 -
89 -
IG OFF Max. 0.5V
IG ON 4.75 ~ 5.25V
91 Cooling Fan Relay [Low] control output A/C ON Pulse
Low: Max. 1.1V
92 -
Relay OFF Battery Voltage
93 Starter Relay control output DC
Relay ON Max 1.1V
94 Main Relay control output DC
Relay ON Max 1.7V
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95 Fuel Pump Relay control output DC
Relay ON Max 1.1V
Active High: Battery Voltage
96 Canister Close Valve (CCV) control output Inactive Pulse Low: Max. 1.0V
Vpeak: Max. 70V
97 -
98 -
IG ON Max. 1.0V
IG ON Max. 1.0V
Connector [C500-B]
Pin
Description Condition Type Level
No.
1 -
2 Variable Charge Motion Actuator (VCMA) PWM output Engine Running PWM
Low: 1.1V
3 -
4 -
IG OFF Max. 0.5V
IG ON 4.75 ~ 5.25V
IG OFF Max. 0.5V
IG ON 4.75 ~ 5.25V
7 Throttle Position Sensor PWM signal output

S/W OFF Max. 1.0V
8 Crank request signal output DC
S/W ON Battery Voltage
9 Barometric Pressure Sensor (BPS) signal input IG ON Analog Approx. 4.0V
3.2V at -40°C(-
40°F)
10 CVVT Oil Temperature Sensor (OTS) signal input IG ON Analog
0.1V at
150°C(302°F)
11 A/C Blower “MAX” signal input IG ON DC
Low: 0V
C.T 0.25 ~ 0.9V
12 Throttle Position Sensor (TPS) 1 signal input Analog
W.O.T Min. 4.0V
IG ON Approx. 4.44V
13 Manifold Absolute Pressure Sensor (MAPS) signal input Analog
Idle Approx. 0.75V
3.2V at -40°C(-
40°F)
14 Intake Air Temperature Sensor (IATS) signal input IG ON Analog
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0.05V at
125°C(257°F)
Vehicle Low: Max. 0.5V
15 Vehicle speed signal input Pulse
Running 0.7(1kph)
44
Knocking Variable -0.3 ~ 0.3V
16 Knock Sensor (KS) [Bank 2] [High] signal input
Normal Frequency 0V
17 Knock Sensor (KS) [Bank 1] [High] signal input
Normal Frequency 0V
SINE 0.4
18 Crankshaft Position Sensor (CKPS) [High] signal input Idle
Wave 55
20 -
High: 3.2 ~ Vcc
Camshaft Position Sensor (CMPS) [Bank 2/Intake] signal
21 Idle Pulse Low: Max. 0.7V
input
0
22 -
23 -
Vpeak = 400V
24 Ignition Coil (Cylinder #1) control output Engine Running Pulse
0
25 -
26 -
27 -
28 -

29 -
30 -
C.T Min. 4.0V
34 Throttle Position Sensor (TPS) 2 signal input Analog
W.O.T 0.25 ~ 0.9V
3.22V at -40°C(-
40°F)
35 Engine Coolant Temperature Sensor (ECTS) signal input IG ON Analog
0.29V at
125°C(257°F)
36 -
37 -
Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1] signal RICH Min. 0.8V
38 Analog
input LEAN Max. 0.1V
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40 Sensor Shield Idle DC Max. 0.1V
41 Knock Sensor (KS) [Bank 2] [Low] signal input
Normal Frequency 0V
42 Knock Sensor (KS) [Bank 1] [Low] signal input
Normal Frequency 0V
SINE 0.4
43 Crankshaft Position Sensor (CKPS) [Low] signal input Idle
Wave 55
45 -
High: 3.2 ~ Vcc
Camshaft Position Sensor (CMPS) [Bank 2/Exhaust] signal
input
0
47 -
IG OFF Max. 0.5V
IG ON 4.75 ~ 5.25V
Vpeak = 400V
0
50 -
51 -
52 -
53 -
54 -
55 -

57 -
58 Analog
59 Analog
61 -
62 -
63 Analog
65 Variable Intake Solenoid (VIS) Valve 1 control output Engine Running PWM
Low: Max. 1.1V
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66 Purge Control Solenoid Valve (PCSV) control output Engine Running PWM
Low: Max. 1.0V
67 -
68 -
69 Variable Intake Solenoid (VIS) Valve 2 control output Engine Running PWM
Low: Max. 1.1V
High: 3.2 ~ Vcc
Camshaft Position Sensor (CMPS) [Bank 1/Exhaust] signal
input
0
High: 3.2 ~ Vcc
Camshaft Position Sensor (CMPS) [Bank 1/Intake] signal
input
0
72 -
IG OFF Max. 0.5V
73 Sensor Power (+5V) DC
IG ON 4.75 ~ 5.25V
Vpeak = 400V
0
75 -
76 -
77 -
78 -
79 -
Low: Max.1.0V
80 ETC Motor [+] control output Engine Running PWM
1,500

0
Low: Max.1.0V
81 ETC Motor [-] control output Engine Running PWM
1,500
0
Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2] Heater
82 Engine Running PWM Low: Max. 1.15V
control output
0
control output
0
84 Fuel Pressure Control Valve (FPCV) control output
Low: Max. 1.0V
85 Injector (Cylinder #2) control output Engine Running PWM
0
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47
Low: Max. 1.0V
0
47
Low: Max. 1.0V
0
47
Low: Max. 1.0V
0
47
Low: Max. 1.0V
0
47
Low: Max. 1.0V
0
47
Heated Oxygen Sensor (HO2S ) [Bank 1/Sensor 1] Heater
control output
0

control output
0
CVVT Oil Control Valve (OCV) [Bank 2/Exhaust] control Low: Max. 1.0V
93 Engine Running PWM
output Frequency = 128Hz
0
CVVT Oil Control Valve (OCV) [Bank 1/Exhaust] control Engine Low: Max. 1.0V
94 PWM
output Running Frequency = 128Hz
0
CVVT Oil Control Valve (OCV) [Bank 2/Intake] control Engine Low: Max. 1.0V
95 PWM
output Running Frequency = 128Hz
0
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CVVT Oil Control Valve (OCV) [Bank 1/Intake] control Low: Max. 1.0V
96 Engine Running PWM
output Frequency = 128Hz
0
Vpeak = 400V
0
Vpeak = 400V
0
Vpeak = 400V
0
100 -
Circuit Diagram

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Removal

When replacing the ECM, the vehicle equipped with the immobilizer must be performed procedure as below.
[In the case of installing used ECM]
1. Perform "ECM Neutral mode" procedure with GDS.
2. After finishing "ECM Neutral mode", perform "Key teaching" procedure with GDS.
[In the case of installing new ECM]
Perform "Key teaching" procedure with GDS.
When replacing the ECM, the vehicle equipped with the smart key system (Button start) must be performed procedure
as below.
2. After finishing "ECM Neutral mode", insert the key (or press the start button) and turn it to the IGN ON and OFF
position. Then the ECM learns the smart key information automatically.
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Insert the key (or press the start button) and turn it to the IGN ON and OFF position. Then the ECM learns the smart
key information automatically.
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the battery.
(Refer to Engine Electrical System - "Battery")
3. Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
4. Disconnect the ECM connector (A).
5. Remove the ECM bracket installation bolt (B) and nuts (C).

6. Remove the ECM after loosening the screws (A) from ECM bracket.
Installation
When replacing the ECM, the vehicle equipped with the immobilizer must be performed procedure as below.
2. After finishing "ECM Neutral mode", perform "Key teaching" procedure with GDS.
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Perform "Key teaching" procedure with GDS.
When replacing the ECM, the vehicle equipped with the smart key system (Button start) must be performed procedure
as below.
2. After finishing "ECM Neutral mode", insert the key (or press the start button) and turn it to the IGN ON and OFF
position. Then the ECM learns the smart key information automatically.
Insert the key (or press the start button) and turn it to the IGN ON and OFF position. Then the ECM learns the smart
key information automatically.
1. Install in the reverse order of removal.
ECM bracket installation bolt/nut:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbf.ft)
Perform TCM learning after replacing the PCM.

(Refer to Automatic Transaxle Control System - "Adjustment")
ECM Problem Inspection Procedure

1. TEST ECM GROUND CIRCUIT: Measure resistance between ECM and chassis ground using the backside of
ECM harness connector as ECM side check point. If the problem is found, repair it.
Specification: Below 1Ω
2. TEST ECM CONNECTOR: Disconnect the ECM connector and visually check the ground terminals on ECM side
and harness side for bent pins or poor contact pressure. If the problem is found, repair it.
3. If problem is not found in Step 1 and 2, the ECM could be faulty. If so, replace the ECM with a new one, and then
check the vehicle again. If the vehicle operates normally then the problem was likely with the ECM.
4. RE-TEST THE ORIGINAL ECM: Install the original ECM (may be broken) into a known-good vehicle and check
the vehicle. If the problem occurs again, replace the original ECM with a new one. If problem does not occur, this is
intermittent problem.
(Refer to “Intermittent Problem Inspection Procedure” in Basic Inspection Procedure)
VIN Programming Procedure
VIN (Vehicle Identification Number) is a number that has the vehicle's information (Maker, Vehicle Type, Vehicle
Line/Series, Body Type, Engine Type, Transmission Type, Model Year, Plant Location and so forth. For more
information, please refer to the group "GI" in this SERVICE MANUAL). When replacing an ECM, the VIN must be
programmed in the ECM. If there is no VIN in ECM memory, the fault code (DTC P0630) is set.
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The programmed VIN cannot be changed. When writing the VIN, confirm the VIN carefully
1. Select "VIN Writing" function in "Vehicle S/W Management".
2. Select "Write VIN" in "ID Register".

3. Input the VIN.
Before inputing the VIN, confirm the VIN again because the programmed VIN cannot be changed.
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4. Turn the ignition switch OFF, then back ON.
IDB terminal and Inoutput
IDB terminal function

Connector [E500-IDB]
Pin
No.
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
15 -
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16 Injector (Cylinder #3) [Low] control output Injector (Cylinder #3)
18 Injector (Cylinder #6) [High] control output Injector (Cylinder #6)
21 -
22 Injector (Cylinder #2) signal input Engine Control Module (ECM)
24 -
25 Fuel Pressure Control Valve (FPRV) logic input Engine Control Module (ECM)
Other control module, Data Link Connector (DLC),
26 CCP-CAN [Low]
Multi-purpose check connector
Other control module, Data Link Connector (DLC),
27 CCP-CAN [High]
Multi-purpose check connector
28 Battery power (B+) Ignition switch
29 Battery power (B+) Main relay
36 -
37 -

39 -
42 Battery power (B+) Ignition switch
Fuel Pressure Control Valve (FPRV) [High] control
45 Fuel Pressure Control Valve (FPRV)
output
48 ECM ground Chassis ground
51 -
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54 -
56 -
57 -
58 -
Fuel Pressure Control Valve (FPCV) [Low] control
60 Fuel Pressure Control Valve (FPCV)
output
IDB Terminal input/output signal

Connector [E500-IDB]
Pin No. Description Condition Type Level
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 -
15 -
Idle High: Battery voltage
16 Injector (Cylinder #3) [Low] control output Pulse
Relay ON Low: Max. 1.0V
High: Battery voltage ~
Idle
18 Injector (Cylinder #6) [High] control output Pulse 80V
Relay ON Low: Battery voltage
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21 -
High: Battery voltage
22 Injector (Cylinder #2) signal input Idle Pulse
Low: Max. 1.0V
Low: Max. 1.0V
24 -
25 Fuel Pressure Control Valve (FPRV) logic input

26 CCP-CAN [Low] Pulse
27 CCP-CAN [High] Pulse
IG OFF DC Max. 0.5V
28 Battery power (B+)
IG ON voltage Battery voltage
IG OFF DC Max. 0.5V
IG OFF DC Max. 0.5V
Idle
Idle

Idle
Idle
Idle
36 -
37 -
Low: Max. 1.0V
39 -
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Low: Max. 1.0V
Low: Max. 1.0V
IG OFF DC Max. 0.5V
IG OFF DC Max. 0.5V
IG OFF DC Max. 0.5V
Fuel Pressure Control Valve (FPRV) [High] control DC Battery voltage
45 Idle
output voltage Max. 1.0V
DC
48 ECM ground Idle Max. 50mV
voltage
DC
voltage
DC
voltage
51 -
DC
voltage
DC
voltage

54 -
Low: Max. 1.0V
56 -
57 -
58 -
IG OFF DC Max. 0.5V
Fuel Pressure Control Valve (FPRV) [Low] control DC Battery voltage
60 Idle
output voltage Max. 1.0V
Circuit Diagram
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Removal
1. Turn the ignition switch off and disconnect the battery negative (-) cable.
2. Disconnect the IDB connector (A).
3. Remove the IDB bracket assembly (B) after removing the nuts.
4. After removing the installation bolts (A), remove the IDB from the bracket.

Installation
IDB bracket installation nut (on vehicle):

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Description
The Electronic Throttle Control (ETC) System consists of a throttle body with an integrated control motor and throttle
position sensor (TPS). Instead of the traditional throttle cable, an Accelerator Position Sensor (APS) is used to receive
driver input. The ECM uses the APS signal to calculate the target throttle angle; the position of the throttle is then
adjusted via ECM control of the ETC motor. The TPS signal is used to provide feedback regarding throttle position to
the ECM. Using ETC, precise control over throttle position is possible; the need for external cruise control
modules/cables is eliminated.
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1. Dry bearing 5. Magnet
2. DC motor 6. Hall IC
3. Non-contact 7. Yoke
hall sensor 8. Stator
4. Gear
Schematic Diagram
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Fail-Safe Mode
Item Fail-Safe
ETC Motor Throttle valve stuck at 7°
TPS 1 fault ECM looks at TPS2
TPS TPS 2 fault ECM looks at TPS1
TPS 1,2 fault Throttle valve stuck at 7°
APS 1 fault ECM looks at APS 2
APS APS 2 fault ECM looks at APS 1
APS 1,2 fault Engine idle state
When throttle value is stuck at 7°, engine speed is limited at below 1,500rpm and vehicle speed at maximum 40 ~ 50
km/h (25 ~ 31 mph)
Specification
[Throttle Position Sensor (TPS)]

Output Voltage (V) [Vref = 5V]
Throttle angle(°)
TPS1 TPS2
0 0.5 4.5
10 0.96 4.05
20 1.41 3.59
30 1.87 3.14
40 2.32 2.68
50 2.78 2.23
60 3.23 1.77
70 3.69 1.32
80 4.14 0.86
90 4.6 0.41
98 4.65 0.35
C.T (0) 0.5 4.5
W.O.T (86) 4.41 0.59
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[ETC Motor]
Item Specification
Coil Resistance (Ω) 0.3 ~100 [20°C(68°F)]
Circuit Diagram

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Inspection
Throttle Position Sensor (TPS)
1. Connect the GDS on the Data Link Connector (DLC).
2. Start the engine and measure the output voltage of TPS 1 and 2 at C.T. and W.O.T.
Output Voltage (V)
Throttle angle(°)
TPS1 TPS2
C.T 0.5 4.5
W.O.T 4.41 0.59
ETC Motor
1. Turn the ignition switch OFF.
2. Disconnect the ETC module connector.
3. Measure resistance between the ETC module terminals 1 and 2.
4. Check that the resistance is within the specification.
Specification: Refer to “Specification”
Removal
1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
2. Remove the air intake hose.
3. Disconnect the ETC module connector (A).
4. Disconnect the coolant hoses (B).
5. Remove the installation bolts, and then remove the ETC module (C) from the engine.
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Installation
• Install 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.
Electronic throttle body Installation bolt:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Adjustment
ETC module learning procedure
When installing new ETC module or re-installing it, ETC module learning procedure must be performed.
1. Hold the ignition key or the start button at th IG ON position during 5 seconds.
2. Turn ignition swich OFF and then start the engine.
DTC codes (P0638, P2110) might be displayed if ETC module learning procedure does not performed after replacing
ETC module.
Description
Barometric Pressure Sensor (BPS) is a speed-density type sensor and is installed on the air cleaner assemby. It senses
absolute pressure of the air cleaner assemby and transfers the analog signal proportional to the pressure to the ECM. By
using this signal, the ECM calculates the intake air quantity and engine speed.
The BPS consists of a piezo-electric element and a hybrid IC amplifying the element output signal. The element is silicon
diaphragm type and adapts pressure sensitive variable resistor effect of semi-conductor. Because 100% vacuum and the
manifold pressure apply to both sides of the sensor respectively, this sensor can output analog signal by using the silicon
variation proportional to pressure change.
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Specification
Output Voltage (V)
psi)]
10.0 (0.01, 0.15) 0.50
55.0 (0.56, 7.98) 2.21
115.0 (1.17, 16.9) 4.50
Circuit Diagram

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Inspection
2. Measure the output voltage of the BPS at idle and IG ON.
Specification: Refer to "Specification"
Removal
2. Disconnect the barometric pressure sensor connector (A).
3. Remove the installation bolt (B), and then remove the sensor from the air cleaner assembly.

Installation

before installing.
• Insert the sensor in the installation hole and be careful not to damage when installation.
Barometric pressure sensor installation bolt:

3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
Description
Intake Air Temperature Sensor (IATS) is included inside Barometric Pressure Sensor (BPS) and detects the intake air
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temperature.
To calculate precise air quantity, correction of the air temperature is needed because air density varies according to the
temperature. So the ECM uses not only BPS signal but also IATS signal. This sensor has a Negative Temperature
Coefficient (NTC) thermistor and it's resistance changes in reverse proportion to the temperature.
Specification
Temperature
Resistance (kΩ)
°C °F
-40 -40 40.93 ~ 48.35
-20 -4 13.89 ~ 16.03
0 32 5.38 ~ 6.09
10 50 3.48 ~ 3.90
20 68 2.31 ~ 2.57
40 104 1.08 ~ 1.21
60 140 0.54 ~ 0.66
80 176 0.29 ~ 0.34

Circuit Diagram
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Inspection
2. Disconnect the IATS connector.
3. Measure resistance between the IATS terminals 3 and 4.
Removal
2. Disconnect the intake air temperature sensor connector (A).

3. Remove the installation bolts (B), and then vertically remove the sensor from the air cleaner assembly.
Installation

before installing.
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Intake air temperature sensor installation bolt:

3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
Description
Manifold Absolute Pressure Sensor (MAPS) is a speed-density type sensor and is installed on the surge tank. It senses
absolute pressure of the surge tank and transfers the analog signal proportional to the pressure to the ECM.
By using this signal, the ECM calculates the intake air quantity and engine speed.
The MAPS consists of a piezo-electric element and a hybrid IC amplifying the element output signal. The element is
silicon diaphragm type and adapts pressure sensitive variable resistor effect of semi-conductor.
Because 100% vacuum and the manifold pressure apply to both sides of the sensor respectively, this sensor can output
analog signal by using the silicon variation proportional to pressure change.
Specification
Output Voltage (V)
psi)]
20.0 (0.20, 2.90) 0.79
46.66 (0.47, 6.77) 1.84
101.32 (1.03, 14.7) 4.0
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Circuit Diagram
Inspection

2. Measure the output voltage of the MAPS at idle and IG ON.
Condition Output Voltage (V)
IG ON Approx. 4.44V
Idle Approx. 0.75V
Removal
2. Disconnect the manifold absolute pressure sensor connector (A).
3. Remove the installation bolt (B), and then vertically remove the sensor from the surge tank.
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Installation

before installing.
Manifold absolute pressure sensor Installation bolt:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Description
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for detecting
the engine coolant temperature. The ECTS uses a thermistor whose resistance changes with the temperature.
The electrical resistance of the ECTS decreases as the temperature increases, and increases as the temperature
decreases. The reference +5V is supplied to the ECTS via a resistor in the ECM. That is, the resistor in the ECM and the
thermistor in the ECTS are connected in series. When the resistance value of the thermistor in the ECTS changes
according to the engine coolant temperature, the output voltage also changes.ion duration and controls the ignition timing
using the information of engine coolant temperature to avoid engine stalling and improve drivability.
During cold engine operation, the ECM increases the fuel injection duration and controls the ignition timing using the
information of engine coolant temperature to avoid engine stalling and improve drivability.

Specification
Temperature
Resistance (kΩ)
°C °F
-40 -40 48.14
-20 -4 14.13 ~ 16.83
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0 32 5.79
20 68 2.31 ~ 2.59
40 104 1.15
60 140 0.59
80 176 0.32
Circuit Diagram

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Inspection
2. Disconnect the ECTS connector.
3. Remove the ECTS (Refer to "Removal").
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between the ECTS terminals 3
and 4.
Removal

3. Disconnect the engine coolant temperature sensor connector (A).
4. Remove the spring clip (B), and then pull the sensor from the water temperature control assembly.
• Note that engine coolant may be flowed out from the water temperature control assembly when removing
the sensor.
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Installation
before installing.
• Apply the engine coolant to the O-ring.
Engine coolant temperature sensor installation:

29.4 ~ 39.2 N.m (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft)
• Supplement the engine coolant. (Refer to Engine Mechanical System - "Coolant")
Description
Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of the most important sensors of the
engine control system. If there is no CKPS signal input, the engine may stop because of CKPS signal missing. This sensor
is installed on the cylinder block or the transaxle housing and generates alternating current by magnetic flux field which is
made by the sensor and the target wheel when engine runs.
The target wheel consists of 58 slots and 2 missing slots on 360 degrees CA (Crank Angle).
Specification
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Item Specification
500 ~ 620
[20°C(68°F)]
Wave Form

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Circuit Diagram

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Inspection
1. Check the signal waveform of the CMPS and CKPS using the GDS.
Specification: Refer to “Wave Form”
Removal
3. Disconnect the crankshaft position sensor connector (A).
4. Remove the installation bolt (B), and then vertically remove the sensor from the transaxle housing.

Installation

before installing.
• Apply the engine oil to the O-ring.
Crankshaft position sensor installation bolt:

6.9 ~ 9.8 N.m (0.7 ~ 1.0 kgf.m, 5.1 ~ 7.2 lb-ft)
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Description
Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element.
It is related with Crankshaft Position Sensor (CKPS) and detects the piston position of each cylinder which the CKPS
can't detect.
The two CMPS are installed on engine head cover of bank 1 and 2 respectively and uses a target wheel installed on the
camshaft. The Cam Position sensor is a hall-effect type sensor. As the target wheel passes the Hall sensor, the magnetic
field changes in the sensor. The sensor then switches a signal which creates a square wave.
Specification
Item Specification
Output Voltage High: 5.0V
(V) Low: 0.7V
Air Gap (mm) 0.5 ~ 1.5
Wave Form

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Circuit Diagram

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Inspection
1. Check the signal waveform of the CMPS and CKPS using the GDS.
Specification: Refer to “Wave Form”
Removal

• DON'T remove the camshaft position sensor while the engine is running or right after engine is turned off. The part
and engine oil is hot and can cause burns.
2. Disconnect the camshaft position sensor connector (A).
3. Remove the installation bolt (B), and then vertically remove the sensor from the cylinder head.
[Bank 1/Intake]
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[Bank 1/Exhaust]
[Bank 2/Intake]
[Bank 2/Exhaust]

Installation

before installing.
• Apply the engine oil to the O-ring.
• Be careful not to damage the sensor housing and the connector.

• Be careful not to damage the O-ring.
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Camshaft position sensor installation bolt:
6.9 ~ 9.8N.m (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)
Description
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine damage. The two
Knock Sensor (KS) are installed inside the V-valley of the cylinder block and senses engine knocking.
When knocking occurs, the vibration from the cylinder block is applied as pressure to the piezoelectric element.
When a knock occurs, the sensor produces voltage signal. The ECM retards the ignition timing when knocking occurs. If
the knocking disappears after retarding the ignition timing, the ECM will advance the ignition timing. This sequential
control can improve engine power, torque and fuel economy.
Specification
Item Specification
Capacitance
950 ~ 1,350
(pF)
Resistance 4.87
(MΩ)
Circuit Diagram
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Removal
[Knock Sensor #1 (Bank 1)]

2. Disconnect the knock sensor connector (A).
3. Remove the intake manifold.

(Refer to Engine Mechanical System - "Intake Manifold")
4. Remove the installation bolt (A), and then remove the sensor from the cylinder block.
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[Knock Sensor #2 (Bank 2)]
2. Disconnect the knock sensor connector (A).


4. Remove the installation bolt (A), and then remove the sensor from the cylinder block.
Installation

• Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
• The sensor connector must be installed parallel to the direction of the engine.
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Knock sensor installation bolt:

15.7 ~ 23.5 N.m (1.6 ~ 2.4 kgf.m, 11.6 ~ 17.4 lb-ft)
Description
Heated Oxygen Sensor (HO2S) consists of the zirconium and the alumina and is installed on upstream and downstream
of the Warm-up Catalytic Converter (WCC).
After it compares oxygen consistency of the atmosphere with the exhaust gas, it transfers the oxygen consistency of the
exhaust gas to the ECM. When A/F ratio is rich or lean, it generates approximately 1V or 0V respectively. In order that
this sensor normally operates, the temperature of the sensor tip is higher than 370°C (698°F). So it has a heater which is
controlled by the ECM duty signal.
When the exhaust gas temperature is lower than the specified value, the heater warms the sensor tip.
Specification

Output
A/F Ratio (λ)
Voltage(V)
RICH Min. 0.8
LEAN Max. 0.1
Item Specification
3.3 ~
Heater Resistance (Ω)
4.1[20°C(68°F)]
Wave Form
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Circuit Diagram

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Inspection
2. Disconnect the HO2S connector.
3. Measure resistance between the HO2S terminals 3 and 4.

Removal
2. Disconnect the connector (A), and then remove the sensor (B).
Note that the SST (Part No.: 09392-2H100 or 09392-1Y100) is useful when removing the heated oxygen
sensor.
[Bank 1/Sensor 1]
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[Bank 1/Sensor 2]
[Bank 2/Sensor 1]

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[Bank 2/Sensor 2]
Installation


• DON’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).
Heated oxygen sensor installation:

35.3 ~ 45.1 N.m (3.6 ~ 4.6 kgf.m, 26.0 ~ 33.3 lb-ft)
Description
Rail Pressure Sensor (RPS) is installed on the delivery pipe and measures the instantaneous fuel pressure in the delivery
pipe. The sensing element (Semiconductor element) built in the sensor converts the pressure to voltage signal. By using
this signal, the ECM can control correct injection amount and timing and adjusts the fuel pressure with the fuel pressure
regulator valve if the target pressure and the actual pressure calculated by the RPS output signal are different.
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Specification
Signal Waveform

Circuit Diagram
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Inspection

2. Measure the output voltage of the RPS at idle and various engine speed.
Condition Output Voltage (V)
Idle Approx. 1.2
1,500 rpm 2.0 ~ 2.2
6,300 rpm Approx. 2.8
Removal
2. Release the residual pressure in fuel line.
(Refer to the Fuel Delivery System - Repair Procedures - "Release Residual Pressure in Fuel Line")
When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the
GDS after completion of “Release Residual Pressure in Fuel Line” work.

(Refer to Engine Mechanical System - “Intake Manifold”)
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4. Disconnect the rail pressure sensor connector (A), and then remove the sensor from the delivery pipe.
Installation

before installing.
Rail Pressure Sensor Installation:

29.4 ~ 34.3 N.m (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)
Description
Continuous Variable Valve Timing (CVVT) system advances or retards the valve timing of the intake and exhaust valve in
accordance with the ECM control signal which is calculated by the engine speed and load.
By controlling CVVT, the valve over-lap or under-lap occurs, which makes better fuel economy and reduces exhaust
gases (NOx, HC) and improves engine performance through reduction of pumping loss, internal EGR effect,
improvement of combustion stability, improvement of volumetric efficiency, and increase of expansion work.
This system consist of
- the CVVT Oil Control Valve (OCV) which supplies the engine oil to the cam phaser or cuts the engine oil from the cam
phaser in accordance with the ECM PWM (Pulse With Modulation) control signal,
- the CVVT Oil Temperature Sensor (OTS) which measures the engine oil temperature,
- and the Cam Phaser which varies the cam phase by using the hydraulic force of the engine oil.
The engine oil getting out of the CVVT oil control valve varies the cam phase in the direction (Intake Advance/Exhaust
Retard) or opposite direction (Intake Retard/Exhaust Advance) of the engine rotation by rotating the rotor connected
with the camshaft inside the cam phaser.
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Specification
Temperature
Resistance (kΩ)
°C °F
-40 -40 52.15
-20 -4 16.52
0 32 6.0
20 68 2.45
40 104 1.11
60 140 0.54
80 176 0.29
Circuit Diagram

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Inspection
2. Disconnect the OTS connector.
3. Remove the OTS. (Refer to "Removal")
4. After immersing the thermistor of the sensor into engine coolant, measure resistance between the OTS terminals 1
and 2.
Removal

3. Disconnect the connector (A), and then remove the CVVT oil temperature sensor (B).
Installation

before installing.
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• Apply the sealant (LOCTITE FED546 or equivalent) to the sensor.
CVVT oil temperature sensor installation:

34.3 ~ 41.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)
Description
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the rotation angle of the
accelerator pedal. The APS is one of the most important sensors in engine control system, so it consists of the two
sensors which adapt individual sensor power and ground line. The second sensor monitors the first sensor and its output
voltage is half of the first one. If the ratio of the sensor 1 and 2 is out of the range (approximately 1/2), the diagnostic
system judges that it is abnormal.

Specification
Accelerator Output Voltage (V)
Position APS1 APS2
C.T 0.7 ~ 0.8 0.29 ~ 0.46
W.O.T 3.85 ~ 4.35 1.93 ~ 2.18
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Circuit Diagram

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Inspection
2. Turn the ignition switch ON.
3. Measure the output voltage of the APS 1 and 2 at C.T and W.O.T.
Removal
1. Turn the ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the accelerator position sensor connector (A).

3. Remove the installation bolt (B) and nuts (C), and then remove the accelerator pedal module.
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Installation
Accelerator pedal module installation bolt:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
Accelerator pedal module installation nut:
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
Description
Fuel Tank Pressure Sensor (FTPS) is a component of the evaporative emission control system and is installed on the fuel
tank, the fuel pump, or the canister. It checks the purge control solenoid valve operation and detects a leakage of the
system.

Specification
Output Voltage (V)
in H20)]
-3.75 (-0.038, -15.05) 4.5
0 1.5
+1.25 (0.013, 5.02) 0.5
Circuit Diagram
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Inspection
2. Measure the output voltage of the FTPS.
Removal
2. Remove the rear seat.
(Refer to Body - "Rear Seat")
3. Remove the fuel pump service cover (A).
4. Disconnect the fuel tank pressure sensor connector (A).

5. Remove the fuel tank pressure sensor after releasing the hooks vertically.
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Installation

before installing.
Description
Based on information from various sensors, the ECM can calculate the fuel amount to be injected. The fuel injector is a
solenoid-operated valve and the fuel injection amount is controlled by length of injection time. The ECM controls each
injector by grounding the control circuit. When the ECM energizes the injector by grounding the control circuit, the circuit
voltage should be low (theoretically 0V) and the fuel is injected. When the ECM de-energizes the injector by opening
control circuit, the fuel injector is closed and circuit voltage should momentarily peak, and then settle at system voltage.

Specification
Item Specification
0.98 ~ 1.14
[20°C(68°F)]
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Signal Waveform
Circuit Diagram
Inspection
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2. Disconnect the injector connector.
3. Measure resistance between the injector terminals 1 and 2.
Removal

In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury
caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.
3. Remove the delivery pipe & injector assembly.

(Refer to Fuel Delivery System - “Delivery Pipe”)
4. Remove the connector (A) and the fixing clip (B), and then separate the injector from the delivery pipe.
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Installation
1. Combustion seal
2. Rubber washer
3. Support disc
4. O-ring
• Do not reuse the used injector fixing clip.

before installing.
• Apply engine oil to the injector O-ring.

• Do not reuse the used injector O-ring.
• Do not reuse the used bolt.
• When inserting the injector, be careful not to damage the injector tip.
• Do not reuse the support disc.

• Do not reuse the injector rubber washer.
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• When replacing the rubber washer, the rounded edge (A) part should be faced the cylinder installation part and the
angulated edge (B) part should be faced the injector body part.
• Do not reuse the combustion seal.

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

1. Remove the combustion seal (A) with a wire cutter.
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.
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The surfaces of the new sealing ring must be clean and free of grease.
3. Place the seal installing guide (B) (SST No.: 09353-2B000) on the tip of the injector not to damage the injector tip
(A).
Push the sealing ring (C) with thumb and index finger over the conical assembly tool until it snaps into the groove.
The complete assembly must not take longer than 2 to 3 seconds.

4. To size the sealing ring the injector is first introduced into the sizing tool (A) (SST No.: 09353-2B000) and then
pressed and at the same time rotated 180° into the sizing tool.
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5. Pull the injector out of the sizing tool by turning it in the reverse direction to that used for the press-in process.
Check that the seal ring has not been damaged during assembly to the injector and that no circumferential
scratches are present.
Do not reuse the combustion seal.
The seal must be completely free of grease and oil.
6. Check the combustion seal (A) installation.
Description
Purge Control Solenoid Valve (PCSV) is installed on the surge tank and controls the passage between the canister and
the intake manifold. It is a solenoid valve and is open when the ECM grounds the valve control line. When the passage is
open (PCSV ON), fuel vapor stored in the canister is transferred to the intake manifold.

Specification
Item Specification
22.0 ~ 26.0
[20°C(68°F)]
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Circuit Diagram
Inspection
2. Disconnect the PCSV connector.
3. Measure resistance between the PCSV terminals 1 and 2.
Removal
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 from the bracket.
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Installation

before installing.
• Be sure not to apply oil or lubricant to the end of the hoses when connecting the PCSV hose.
• Be careful of foreign material not to flow into the valve.

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)
Description
Continuous Variable Valve Timing (CVVT) system advances or retards the valve timing of the intake and exhaust valve in
accordance with the ECM control signal which is calculated by the engine speed and load.
By controlling CVVT, the valve over-lap or under-lap occurs, which makes better fuel economy and reduces exhaust
gases (NOx, HC) and improves engine performance through reduction of pumping loss, internal EGR effect,
improvement of combustion stability, improvement of volumetric efficiency, and increase of expansion work.
This system consist of
- the CVVT Oil Control Valve (OCV) which supplies the engine oil to the cam phaser or runs out the engine oil from the
cam phaser in accordance with the ECM PWM (Pulse With Modulation) control signal,
- the CVVT Oil Temperature Sensor (OTS) which measures the engine oil temperature,

- and the Cam Phaser which varies the cam phase by using the hydraulic force of the engine oil.
The engine oil getting out of the CVVT oil control valve varies the cam phase in the direction (Intake Advance/Exhaust
Retard) or opposite direction (Intake Retard/Exhaust Advance) of the engine rotation by rotating the rotor connected
with the camshaft inside the cam phaser.
Specification
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Item Specification
9.4 ~ 10.4
[20°C(68°F)]
Circuit Diagram

Engine Control / Fuel System cardiagn.com
Inspection
2. Disconnect the OCV connector.
3. Measure resistance between the OCV terminals 1 and 2.
Removal
[CVVT Oil Control Valve (Intake)]

(Refer to Engine Mechanical System - “Intake Manifold”)
3. Disconnect the CVVT oil control valve connector (A).
4. Remove the installation bolt (B), and then remove the valve from the engine.
[Bank 1]
[Bank 2]
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[CVVT Oil Control Valve (Bank1/Exhaust)]
3. Remove the surge tank.

(Refer to Engine Mechanical System - "Surge Tank")
4. Remove the cylinder head cover.
(Refer to Engine Mechanical System - “Cylinder Head Cover”)

5. Remove the installation bolt (A), and then remove the valve from the engine.
[CVVT Oil Control Valve (Bank2/Exhaust)]

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3. Remove the cylinder head cover.
(Refer to Engine Mechanical System - “Cylinder Head Cover”)
4. Remove the installation bolt (A), and then remove the valve from the engine.
Inatallation

before installing.
• Apply the engine oil to the valve O-ring.

• Exactly distinguish the color of the valve and harness connectors in bank 1 and 2 when installing, or the engine will
operate abnormally (Refer to the table below).
Items Component Side Harness Side

Bank 1 (RH) Grey
Bank 2 (LH) Black
CVVT oil control valve installation bolt:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Description
Variable Intake manifold Solenoid (VIS) valves are installed on the intake manifold (VIS Valve 1) and the surge tank
(VIS Valve 2). These VIS valve 1 and 2 control vacuum modulators which activate valves in the intake manifold and the
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surge tank. These valves are opened or closed by ECM according to engine condition (Refer to below table).
Specification
Item Specification
30.0 ~ 35.0
[20°C(68°F)]
Circuit Diagram

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Inspection
2. Disconnect the VIS valve connector.
3. Measure resistance between the VIS valve terminals 1 and 2.
Removal
2. Disconnect the variable intake solenoid valve connector (A).
3. Disconnect the vacuum hoses (B, C) from the valve.

4. Remove the installation nut (D), and then remove the valve.
[Vave 1 (Intake manifold)]
[Vave 2 (Surge tank)]
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Installation

before installing.
• Be careful of foreign material not to flow into the valve.

Variable intake solenoid valve installation nut:

5.9 ~ 8.8 N.m (0.6 ~ 0.9 kgf.m, 4.3 ~ 6.5 lb-ft)
Description
Fuel Pressure Regulator Valve is installed on the high pressure fuel pump and controls fuel flow flowing into the injectors
in accordance with the ECM signal calculated based on various engine condition.

Specification
Item Specification
1.04 ~ 1.27
[23°C(73.4°F)]
Signal Waveform
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Circuit Diagram

Inspection
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2. Disconnect the fuel pressure regulator valve connector.
3. Measure resistance between the fuel pressure regulator valve terminals 1 and 2.
Removal
(Refer to Fuel Delivery System - "High Pressure Fuel Pump")
Installation
(Refer to Fuel Delivery System - "High Pressure Fuel Pump")
Description
Canister Close Valve (CCV) is installed on the canister ventilation line. It seals evaporative emission control system by
shutting the canister from the atmosphere when leakage detecting system operates.
Specification

Item Specification
19.8 ~ 21.8
(20°C)
Circuit Diagram
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Inspection
2. Disconnect the CCV connector.
3. Measure resistance between the CCV terminal 1 and 2.
5. Disconnect the vapor hose connected with the canister from the CCV.
6. Connect a vacuum pump to the nipple.
7. Ground the CCV control line and apply battery voltage to the CCV power supply line.
8. Apply vacuum and check the valve operation.
Specification: Vacuum maintained

Removal
2. Lift the vehicle.
3. Disconnect the canister close valve connector (A).
4. Disconnect the ventilation tube quick-connector (B) from the fuel tank air filter and canister close valve.
5. Disconnect the vapor tube quick-connector (A).

6. Remove the canister assembly bracket (D) after removing the mounting bolts (B) and nut (C).
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7. Remove the canister braket (B) installation bolt (A).

8. Remove the fuel tank air filter & canister close valve assembly (A) after rotating it in the direction of the arrow in the
figure.
9. Release the lever (A), and then separate the canister close valve (B) from the fuel tank air filter (C) after rotating it in
the direction of the arrow in the figure.
Installation
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Components Location

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1. Fuel Tank 8. Fuel Tank Pressure Sensor
2. Fuel Pump (FTPS)
3. Fuel Filter 9. Canister Close Valve (CCV)
4. Fuel Pressure Regulator 10. Fuel Level Sender (FLS)
5. Canister 11. Fuel Filler Hose
6. Fuel Tank Air Filter 12. Ventilation Hose
7. Fuel Tank Band 13. Vapor Tube
14. Fuel Pump Locking Ring
[High Pressure Fuel Line]

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1. High Pressure Fuel 3. Delivery Pipe
Pump 4. Injector
2. High Pressure Fuel
Pipe
Fuel Pressure Test (Low pressure system)


2. Install the Special Service Tool (SST).
(1) Disconnect the low pressure fuel feed tube from the low pressure inlet of high pressure fuel pump.
There may be some residual pressure even after “Release Residual Pressure in Fuel Line” work, so cover
the hose connection with a shop towel to prevent residual fuel from spilling out before disconnecting any
fuel connection.
(2) Install the special service tool for measuring the fuel pressure in between the low fuel feed tube and the low
pressure inlet of high pressure fuel pump (Refer to the figure below).
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3. Inspect fuel leakage on connections among the low fuel feed tube, the low pressure inlet of high pressure fuel pump,
and the SST components with IG ON.
4. Measure Fuel Pressure.
(1) Start the engine and measure the fuel pressure at idle.
Fuel Pressure: 500 kPa (5.1 kgf/cm², 72.5 psi)
If the fuel pressure differs from the standard value, repair or replace the related part (Refer to the table
below).
Fuel
Cause Related Part
Pressure
Fuel filter clogged Fuel Filter
Too Low
Fuel leakage Fuel Pressure Regulator
Too High Fuel pressure regulator stuck Fuel Pressure Regulator

(2) Stop the engine, and then check for the change in the fuel pressure gauge reading.
Standard Value: The gauge reading should hold for about 5 minutes after the engine stops
If the gauge reading should not be held, repair or replace the related part (Refer to the table below).
Fuel Pressure Related

Cause
(After Engine Stops) Part
Fuel Pressure Drops Slowly Leakage on injector Injector
Fuel Pressure Drops Immediately Check valve of fuel pump stuck open Fuel Pump
(3) Turn the ignition switch OFF.

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6. Test End
(1) Remove the Special Service Tool (SST) from the low pressure fuel feed tube and the low pressure inlet of high
pressure fuel pump.
(2) Connect the low pressure fuel feed tube and the low pressure inlet of high pressure fuel pump.
Release Residual Pressure in Fuel Line
Whenever the high pressure fuel pump, fuel pipe, delivery pipe, or injector is removed immediately after shutting off the
engine, an injury may be caused by the release of highly pressurized fuel. Release the residual pressure in the high
pressure fuel line by referring to the "Residual fuel pressure release procedure" below before removing any high
pressure fuel system components.
Wear safety glasses and fuel resistant gloves.

1. Turn the ignition off and disconnect the battery negative cable.
2. Remove the fuel pump fuse (A).

3. Reconnect the battery negative cable.
4. Run the engine for about 1 minutes to lower the pressure in the low pressure line.
5. Turn the engine off.
6. Disconnect the low pressure fuel line quick connector at the High Pressure Pump. Use rags to cover opening and
catch spills while removing the fuel line.
7. Start the engine and let it idle until the engine stops. At this point the pressure should be under 30 psi.
8. Proceed with the service or repair. Use rags to cover opening and catch spills when opening up the high pressure
system.
9. Reinstall / re-connect all components in reverse order of removal. Start engine and confirm proper operation, and
make sure there are no fuel leaks.
10. After completing, clear DTC(s) using GDS scan tool (the procedure described above will cause DTC to set).
Removal
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2. Remove the rear seat assembly.
(Refer to Body - “Rear Seat Assembly")
4. Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B).
5. Disconnect the fuel feed tube quick connector (C).
6. Remove the rear - LH wheel & tire.

7. Lift the vehicle and support the fuel tank with a jack.
8. Remove the center & rear muffler assembly.
(Refer to Engine Mechanical System - “Muffler”) [4 WD]

9. Remove the propeller shaft.
(Refer to Driveshaft and axle - “Propeller Shaft”) [4WD]
10. Disconnect the fuel filler hose (A) and the ventilation tube quick-connector (B).
11. Disconnect the ventilation tube quick-connector (A).

12. Disconnect the vapor tube quick-connector (B).
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13. Remove the fuel tank (B) from the vehicle after removing the fuel tank band (A).
When removing the fuel tank, the fuel tank must be tilted because of interfering with
coupling.
Installation
Fuel tank band installation bolt:

44.1 ~ 58.8 N.m (4.5 ~ 6.0 kgf.m, 32.6 ~ 43.4 lb-ft)

Inspection
[Fuel pump motor]
1. Turn the ignition switch OFF, and then remove battery (-) cable.
2. Remove the fuel pump assembly.
3. Check motor operation by fuel pump connector (A) connecting power (No.4) and ground (No.5).
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Pin No. Description
1 Fuel sender signal
2 -
3 Fuel sender ground
4 Fuel pump motor (+)
5 Fuel pump motor ground
[Fuel sender]
2. Remove the fuel pump assembly.
3. Using an ohmmeter, measure the resistance between terminals 1 and 3 of sender connector (A) at each float level.
Pin No. Description

1 Fuel sender signal
2 -
3 Fuel sender ground
4 Fuel pump motor (+)
5 Fuel pump motor ground
4. Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position Resistance(Ω)
E 197 ~ 203
Warning lamp 168 ~ 172
1/2 64.2 ~ 68.2
Sender (F) 6 ~ 10
Removal
2. Remove the rear seat.
(Refer to Body - “Rear Seat Assembly”)
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4. Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B).
5. Disconnect the fuel feed tube quick connector (C) and the vapor tube quick-connector (D).

6. Remove locking ring (A) by using the special service tool.
7. Disconnector the vapor tube quck-connector (A) at the fuel pump, and then remove the fuel pump from the fuel tank.
Fuel shouldn’t be come inside the vapor tube quick-connector while disconnecting the vapor tube quick-
connector.
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Installation
Be careful of fuel pump direction when installing (Refer to the groove in the fuel
tank).
Removal
1. Remove the fuel pump.
(Refer to Fuel Delivery System - “Fuel Pump”)

2. Disconnect the fuel sender connector (A).
3. Release the fixing hooks, and then remove the fuel sender (A).
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4. Release the fixing hooks (A), and then fuel filter & motor assembly from reservoir cup.
Installation
Removal
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4. Release the fixing hooks (A), and then fuel filter & motor assembly from reservoir cup.
Installation

Removal
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Installation
Removal

2. Release the fixing hooks, and then remove the regulator cup (A).
3. Remove the fuel pressure regulator (A).
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Installation
Removal
[Low pressure fuel line]

3. Disconnect the low pressure fuel quick-connector (A) and remove the installation nuts (B).
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4. Disconnect the vapor hose (A) which is connected from the PCSV.
5. Remove the fuel tank.

(Refer to Fuel Delivery System - " Fuel Tank")

6. Open the fuel feed line fixing clip (A) to using driver.
7. Remove the installation bolt, and then releasing the under cover (A).
8. Disconnect the fuel & brake line protect (B) from the fixing clip.
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9. Disconnect the fuel feed line fixing clip (A) from engine room lower.
10. Remove the fuel line.

[High pressure fuel line]

4. Remove the injector foam (A).
5. Remove the high pressure fuel pipe.

(1) Remove the high pressure pipe flange nut in order of A,B with the special service tool [SST No.: 09314-3V100]
(2) Remove the high pressure pipe bracket bolt (A).

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(3) Remove the function bolck installation bolt (A).
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Installation
• Do not use already used injector fixing clip again.

• Use the special service tool [SST No.: 09314-3V100] to install the high pressure fuel
pipe.

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High pressure fuel pipe installation nut:
29.4 ~ 35.3 N.m (3.0 ~ 3.6 kgf.m, 21.7 ~ 26.0 lb-ft)
High pressure pipe bracket installation bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.74 lb-ft)
High pressure pipe function block installation bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.74 lb-ft)
Removal
1. Lift the vehicle.
2. Disconnect the fuel filler hose (A).
3. Disconnect the ventilation tube quick-connector ( B).

4. Open the fuel filler door and unfasten the filler-neck assembly mounting screw (A).
5. Remove the rear-LH wheel, tire and the inner wheel house.
6. Remove the filler-neck assembly from the vehicle after removing the bracket mounting nut (A).
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Installation
Filler-neck assembly bracket installation nut :

3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
Removal
1. Turn the ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the accelerator position sensor connector (A).

3. Remove the installation bolt (B) and nuts (C), and then remove the accelerator pedal module.
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Installation
Accelerator pedal module installation bolt:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)
Accelerator pedal module installation nut:
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
Removal

3. Disconnect the injectors & rail pressure sensor connector (A).

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(1) Loosen the flange nut in the order of A,B with SST(09314-3V100).

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(3) Remove the function block installation bolt (A).
7. Remove the installation bolt (A), and then remove the delivery pipe and injector assembly from the engine.
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Installation
• Do not use already used injector fixing clip again.

• Apply engine oil to the injector O-ring.

• Do not use already used injector O-ring again.
• Do not use already used bolt again.

• When insert the injector, be careful not to damage the injector tip.
Delivery pipe installation bolt:

18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
29.4 ~ 35.3 N.m (3.0 ~ 3.6 kgf.m, 21.7 ~ 26.0 lb-ft)
High pressure fuel pipe function block installation bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
High pressure fuel pipe bracket installation bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Removal
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When removing the fuel pump fuse, 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 pump foam (A).

4. Disconnect the fuel pressure control valve connector (A) and the fuel feed tube quick-connector (B).

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(1) Remove the high pressure pipe flange nut in order of A,B with the special service tool [SST No.: 09314-3V100]

(3) Remove the function bolck installation bolt (A).
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8. Remove the installation bolts (A), and then remove the high pressure fuel pump (B) from the cylinder head assembly.
Unscrew in turn the two bolts in small step (0.5 turns). In case of fully unscrewing one of the two bolts with
the other bolt installed, the housing surface of the cylinder head may be broken because of tension of the
pump spring.
Installation
• Be sure to check the low pressure fuel hose quick-connector (A) is completely connected to the high pressure fuel
pump until a confirmation 'click' sound is heard.
• Be sure to re-check the low pressure fuel hose is completely connected to the high pressure fuel pump by pulling it
after connecting.
• Be sure to install the high pressure fuel pipe (B) with the specified torques.
• Because fuel leak may cause fire, securely Inspect leakage of all fuel line connection parts at engine start condition.

• Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the
crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.
• Do not reuse the used bolt.
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• Do not reuse the used high pressure fuel pipe.
• When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns)
after tightening them with hand-screwed torque.

• First hand-tighten the fasteners fully until they are not fastened any more in order to have them inserted in place and
then completely tighten to the specified torque using a torque wrench.
If not tightening the bolts or nuts in a straight line with the mating bolt holes or fittings, it may cause a fuel leak due to
broken threads.
• Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also
apply engine oil to the groove on the location where the protrusion (C) is installed.

Use the special service tool [SST No.: 09314-3V100] to install the high pressure fuel pipe.
High pressure fuel pump installation bolt:

12.8 ~ 14.7 N.m (1.3 ~ 1.5 kgf.m, 9.4 ~ 10.9 lb-ft)
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29.4 ~ 35.3 N.m (3.0 ~ 3.6 kgf.m, 21.7 ~ 26.0 lb-ft)
High pressure fuel pipe function block installation bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
High pressure fuel pipe bracket installation bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

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Engine Control / Fuel System

Intake Air Temperature Sensor (IATS)

Manifold Absolute Pressure Sensor (MAPS)

C:\Users\ej20\Desktop\KI 15\Sorento 2015\Engine Control - Fuel System.mht 2014-06-10

Engine Coolant Temperature Sensor (ECTS)

Throttle Position Sensor (TPS) [integrated into ETC module]

C:\Users\ej20\Desktop\KI 15\Sorento 2015\Engine Control - Fuel System.mht 2014-06-10

Camshaft Position Sensor (CMPS)

Knock Sensor (KS)

Heated Oxygen Sensor (HO2S)

C:\Users\ej20\Desktop\KI 15\Sorento 2015\Engine Control - Fuel System.mht 2014-06-10

CVVT Oil Temperature Sensor (OTS)

Accelerator Position Sensor (APS)

Fuel Tank Pressure Sensor (FTPS)

C:\Users\ej20\Desktop\KI 15\Sorento 2015\Engine Control - Fuel System.mht 2014-06-10

ETC Motor [integrated into ETC Module]

Purge Control Solenoid Valve (PCSV)

CVVT Oil Control Valve (OCV)

Variable Intake Solenoid (VIS) Valve

Fuel Pressure Control Valve (FPCV)

C:\Users\ej20\Desktop\KI 15\Sorento 2015\Engine Control - Fuel System.mht 2014-06-10

C:\Users\ej20\Desktop\KI 15\Sorento 2015\Engine Control - Fuel System.mht 2014-06-10