Kia Rio: Engine Control / Fuel System

Kia Rio 2017-2020 YB Service Manual / Engine Control / Fuel System

Specifications
Specifications
Fuel Delivery System

Items
Specification
Fuel Tank
Capacity
45 lit (11.8 U.S.gal., 47.5 U.S.qt., 39.5 lmp.qt.)
Fuel Filter
Type
Paper type
Fuel Pressure
RegulatedFuel Pressure
330 - 370kpa (3.36 - 3.77kgf/cm², 47.86 - 53.66 psi)
Fuel Pump
Type
Electrical, in-tank type
Driven by
Electric motor
Supply Voltage
12 V
Current
Max. 6.0 A
Fuel Retrun System
Type
Returnless

Engine Control System

ETC Module

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

▷ Type: Hall IC Non-contact sensor type

▷ Specification

Throttle angle(°)
Output Voltage (V) [Vref=5V]
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

DC Motor [integrated into ETC module]

Item
Specification
Coil Resistance (Ω)
0.3 - 100 [20°C(68°F)]

Manifold Absolute Pressure Sensor (MAPS)

▷ Type: Piezo-resistive pressure sensor type

Pressure
[kPa (kgf/cm², psi)]
Output Voltage (V) [Vref = 5V]
20.0 (0.20, 2.9)
0.79
46.7 (0.47, 6.77)
1.84
101.32 (1.03, 14.7)
4.0

Intake Air Temperature Sensor (IATS)

▷ Type: Thermistor type

Temperature
Resistance (kΩ)
°C
°F
-40
-40
40.93 - 48.35
-30
-22
23.43 - 27.34
-20
-4
13.89 - 16.03
-10
14
8.5 - 9.7
0
32
5.38 - 6.09
10
50
3.48 - 3.90
20
68
2.31 - 2.57
30
86
1.9 - 2.1
40
104
1.08 - 1.21
50
122
0.76 - 0.85
60
140
0.54 - 0.62
70
158
0.40 - 0.45
80
176
0.29 - 0.34
90
194
0.22 - 0.26
100
212
0.17 - 0.20
110
230
0.13 - 0.15
120
248
0.10 - 0.12
130
266
0.08 - 0.09

Engine Coolant Temperature Sensor (ECTS)

▷ Type: Thermistor type

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
60
140
0.59
80
176
0.32
100
212
0.19
110
230
0.145 - 0.149
120
248
0.12

Crankshaft Position Sensor (CKPS)

NON- ISG Type

Item
Specification
Coil Resistance (Ω)
819 - 1001 [20°C (68°F)]
Pin
2

With ISG Type

Item
Specification
Type
Hall effect type
Air Gap (mm)
0.9 - 1.1
Pin
3

Camshaft Position Sensor (CMPS)

Item
Specification
Type
Hall effect type
Output Pulse (V)
0 - 5
Air Gap [mm (in.)]
0.5 - 1.5 (0.0079 - 0.079)
Pin
3

Knock Sensor (KS)

Item
Specification
Resistance(MΩ)
4.87
Capacitance (pF)
950 - 1,350
Type
Piezo-electricity
Pin
2

Heated Oxygen Sensor (HO2S)

HO2S [Bank 1/Sensor 1]

Item
Specification
Heater Resistance (Ω)
Approximately 9.3 [20°C(68°F)]
Type
Binary
Pin
4

HO2S [Bank 1/Sensor 2]

Item
Specification
Heater Resistance (Ω)
Approximately 9.3 [20°C(68°F)]
Type
Binary
Pin
4

Accelerator Position Sensor (APS)

Accelerator
Position
Output Voltage (V) [Vref = 5V]
APS1
APS2
C.T
0.7 - 0.8
0.32 - 0.42
W.O.T
3.98 - 4.22
1.93 - 2.17

Injector

Item
Specification
Coil Resistance (Ω)
Approximately 9.6
Minimum Injection Time (ms)
2.5
Fuel Pressure
bar
2 - 7
kPa
200 - 700
kgf/cm²
2.04 - 7.14
psi
29.0 - 101.5
Pin
2

Purge Control Solenoid Valve (PCSV)

Item
Specification
Coil Resistance (Ω)
18.5 - 22.5 [23°C (73.4°F)]
Pin
2

Variable Force Solenoid (VFS)

Item
Specification
Coil Resistance (Ω)
6.9 - 7.9 Ω
Operation Voltage (V)
12 V

CVVT Oil Control Valve (OCV)

[Bank 1 / Exhaust]

Item
Specification
Coil Resistance (Ω)
6.9 - 7.9 [20°C(68°F)]
Control Current (mA)
100 - 1000
Reted Voltage (V)
12
Insulation resistance (MΩ)
50 [DC 500 V/1 Min]
Oil Pressure
bar
2.9 - 3.1
kPa
290 - 310
kgf/cm²
2.96 - 3.16
psi
42.1 - 44.96
Pin
2

Service Standard

Ignition Timing
BTDC 6° ± 10°
Idle Speed
A/CON OFF
Neutral,N,P-range
660 ± 100 rpm
D-range
660 ± 100 rpm
A/CON ON
Neutral
660 ± 100 rpm
D, N, P-range
660 ± 100 rpm

Tightening Torques
Engine Control System

Item
Kgf.m
N.m
lb-ft
ECM mounting screws
0.09 - 0.097
0.9 - 0.95
0.66 - 0.7
ECM bracket mounting bolt / nut
1.0 - 1.2
9.8 - 11.8
7.2 - 8.7
Electronic Throttle Control (ETC) moule mounting bolt
0.8 - 1.0
7.8 - 9.8
5.8 - 7.2
Engine Coolant Temperature Sensor (ECTS)
2.0 - 4.0
19.6 - 39.2
14.4 - 28.9
Crankshaft Position Sensor (CKPS) mounting bolt
1.0 - 1.2
9.8 - 11.8
7.2 - 8.7
Camshaft position sensor [Bank 1 / Intake] mounting bolt
1.0 - 1.2
9.8 - 11.8
7.2 - 8.7
Camshaft position sensor [Bank 1 / Exhaust] mounting bolt
1.0 - 1.2
9.8 - 11.8
7.2 - 8.7
Knock Sensor (KS) mounting bolt
1.9 - 2.4
18.6 - 23.5
13.7 - 17.4
Heated oxygen sensor [Bank 1 / Sensor 1]
4.0 - 5.0
39.2 - 49.1
28.9 - 36.2
Heated oxygen sensor [Bank 1 / Sensor 2]
4.0 - 5.0
39.2 - 49.1
28.9 - 36.2
Accelerator pedal position sensor (APS) mounting nut[APS integrated into Accelerator pedal module]
1.3 - 1.6
12.7 - 15.7
9.4 - 11.6
Accelerator pedal position sensor (APS) mounting bolt[APS integrated into Accelerator pedal module]
0.9 - 1.04
8.8 - 13.7
6.5 - 10.1
CVVT Oil Control Valve (OCV) [Bank 1 / Intake] mounting bolt
1.0 - 1.2
9.8 - 11.8
7.2 - 8.7
CVVT Oil Control Valve (OCV) [Bank 1 / Exhaust] mounting bolt
1.0 - 1.2
9.8 - 11.8
7.2 - 8.7

Fuel Delivery System

Item
Kgf.m
N.m
lb-ft
Fuel tank mounting nut
4.0 - 5.5
39.2 - 53.9
28.9 - 39.8
Fuel pump plate cover mounting bolt
0.2 - 0.3
2.0 - 2.9
1.4 - 2.2
Filler-neck assembly mounting bolt
0.8 - 1.2
7.8 - 11.8
5.8 - 8.7
Filler-neck assembly bracket mounting bolt
0.4 - 0.6
3.9 - 5.9
2.9 - 4.3
Delivery pipe mounting bolt
1.9 - 2.4
18.6 - 23.5
13.7 - 17.4
Delivery pipe mounting nut(↔ Fuel feed tube)
0.4 - 0.6
3.9 - 5.9
2.9 - 4.3

Special service tools
Special Service Tools

Tool Name / Number
Illustration
Description
Fuel Pressure Gauge
09353-24100

Measuring the fuel line pressure
Fuel Pressure Gauge Adapter
09353-38000

Connection between the delivery pipe and fuel feed line
Fuel Pressure Gauge Connecto
09353-24000

Connection between Fuel Pressure Gauge (09353-24100) and Fuel Pressure Gauge Adapter (09353-38000)
Heated Oxygen Sensor Socket Wrench
09392-1Y100

Removal and installation of the heated oxygen sensor

Troubleshooting
Basic Troubleshooting

Basic Troubleshooting Guide

Customer Problem Analysis Sheet

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.

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

a.

Sensors and Actuators

: Slightly vibrate sensors, actuators or relays with finger.

  

Strong vibration may break sensors, actuators or relays

b.

Connectors and Harness

: Lightly shake the connector and wiring harness vertically and then horizontally.

● SIMULATING HEAT

a.

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

a.

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

a.

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.

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.

  

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

1.

Procedures for Open Circuit

Continuity Check

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.

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

Continuity Check with Chassis Ground

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).

Symptom Troubleshooting Guide Chart

Main Symptom
Diagnostic Procedure
Also Check For
Unable to start
(Engine does not turn over)
1)

Test the battery

2)

Test the starter

3)

Inhibitor switch (A/T) or clutch start switch (M/T)


Unable to start
(Incomplete combustion)
1)

Test the battery

2)

Check the fuel pressure

3)

Check the ignition circuit

4)

Troubleshooting the immobilizer system (In case of immobilizer lamp flashing)

DTC

Low compression

Intake air leaks

Slipped or broken timing belt

Contaminated fuel

Difficult to start
1)

Test the battery

2)

Check the fuel pressure

3)

Check the ECT sensor and circuit (Check DTC)

4)

Check the ignition circuit

DTC

Low compression

Intake air leaks

Contaminated fuel

Weak ignition spark

Poor idling
(Rough, unstable or incorrect Idle)
1)

Check the fuel pressure

2)

Check the Injector

3)

Check the long term fuel trim and short term fuel trim (Refer to CUSTOMER DATASTREAM)

4)

Check the idle speed control circuit (Check DTC)

5)

Inspect and test the Throttle Body

6)

Check the ECT sensor and circuit (Check DTC)

DTC

Low compression

Intake air leaks

Contaminated fuel

Weak ignition spark

Engine stall
1)

Test the Battery

2)

Check the fuel pressure

3)

Check the idle speed control circuit (Check DTC)

4)

Check the ignition circuit

5)

Check the CKPS Circuit (Check DTC)

DTC

Intake air leaks

Contaminated fuel

Weak ignition spark

Poor driving
(Surge)
1)

Check the fuel pressure

2)

Inspect and test Throttle Body

3)

Check the ignition circuit

4)

Check the ECT Sensor and Circuit (Check DTC)

5)

Test the exhaust system for a possible restriction

6)

Check the long term fuel trim and short term fuel trim (Refer to CUSTOMER DATASTREAM)

DTC

Low compression

Intake air leaks

Contaminated fuel

Weak ignition spark

Knocking
1)

Check the fuel pressure

2)

Inspect the engine coolant

3)

Inspect the radiator and the electric cooling fan

4)

Check the spark plugs

DTC

Contaminated fuel

Poor fuel economy
1)

Check customer's driving habits

Is A/C on full time or the defroster mode on?

Are tires at correct pressure?

Is excessively heavy load being carried?

Is acceleration too much, too often?

2)

Check the fuel pressure

3)

Check the injector

4)

Test the exhaust system for a possible restriction

5)

Check the ECT sensor and circuit

DTC

Low compression

Intake air leaks

Contaminated fuel

Weak ignition spark

Hard to refuel
(Overflow during refueling)
1)

Test the canister close valve

2)

Inspect the fuel filler hose/pipe

Pinched, kinked or blocked?

Filler hose is torn

3)

Inspect the fuel tank vapor vent hose between the EVAP. canister and air filter

4)

Check the EVAP. canister

Malfunctioning gas station filling nozzle (If this problem occurs at a specific gas station during refueling)


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