Top Kia Techs Take On The World - Kia
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1. TECHNICIAN LIMES Volume 5 Issue 2 2002 Top Kia Techs Take On The World bolt on a Sedona a personal friend How about the Sorento Well T you know your way around a Sportage Is every nut and these guys do Beach Florida Frank Rosing of Southlake Kia INO02 Merrillville Indiana Ken Sessom of Mitchell Kia TX014 San Angelo Texas and Jim Schofield of Cowboy Corral Kia CO16 Longmont Colorado These men have all achieved their ASE Master and ASE LI certifica tions and performed very well on the Skill WorldCup test They are the best of the best when it comes to turning wrenches And to prove it they re going to the Chon An Training Center in Korea from April 22 26 to represent the USA in the Ist Kia Skill WorldCup 2002 N solid week of intensive training at the corporate offices in Irvine a left to right Jeffrey Jacobs of Delray Kia FL032 Delray California along with thousands of hours in the service bays have prepared them to take on the world And that s just who they com pete against when they go head to head with Kia s top techs from around the globe The top prize is a gold plaque and 3 000 in cold hard cash Inside this E 2 3 issue KU Tests Online Reman A T Fluid Specs RKE DTC Input Requested 4 SPG Rear Window Regulator Silencer Design Thermostat Housing 5 SPT ECM Data P0121 Code Engine Condenser Fan Control 4 6 7 OPT Rear Hub Bearing Assy 4 Cyl DTC P0128 New ABS Syste2. TECHNICAL OPERATIONS BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 13514 IRVINE CA POSTAGE WILL BE PAID BY THE ADDRESSEE KIA MOTORS AMERICA INC PO BOX 52410 IRVINE CA 92619 2410 TeleccobabalbansncUDadaabedackadasccladbesodelDacd P N UN020 PS 032B
3. deflection After adjusting the cruise control cable check the accelerator cable deflection and adjust if necessary to 4 7 mm by remov ing the clip at the cable retainer and moving the cable casing in or out of the retainer Remove Clip to Adjust Accelerator P Cable B E Bend Bracket to Adjust Cruise Control Cable Spectra Engine Condenser Fan Control From 11 1 01 production Spectra uses a two speed fan control The condenser fan now has a second relay controlled by the ECM The previously used AC dual pressure switch has been replaced by a triple pressure version Due to these changes several wire harnesses and the engine compartment fuse and relay box have been changed Watch for updated information in future Spectra Service documentation For immediate assis tance contact Kia s Techline at 1 800 494 4542 5 KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 Optima Rear Hub amp Bearing Assembly Non ABS To prevent bearing contamination from outside elements the non ABS rear hub and bearing assembly has been improved as of 5 3 01 production The new hub has a longer boss where the assembly bolts to the rear axle carrier and a dust cap has been added as a secondary seal Despite the visual differences the new assembly is a direct replacement for the old assembly New Hub and Bearing Assembly 2001 Optima 4 Cylinder DTC P012 Under certain cold weather operating conditions 200IMY 4 cylind
4. Bosch 5 3 has been widely used throughout the industry Bosch 5 3 ABS comes equipped with Electronic Brake force Distribution EBD and can be expanded in the future to include a Traction Control System TCS Self diagnosis capabilities are built in and fault codes will be retrievable using the Hi Scan Pro Watch for additional information in future Optima Service documentation Should you encounter a problem in a Bosch 5 3 ABS equipped Optima before the updated documentation is pub lished contact Kia s Technical Assistance Hotline at 1 800 494 4542 for additional information Brake Upgrade TSB for 4 Cyl Optima Delayed In Kia Technician Times Vol 4 Issue 6 we informed you about the change in the rear brake shoes and backing plate for Optimas equipped with rear drum brakes Although the change went into effect on 11 1 01 KMA has not been able to release the TSB due to temporary unavailability of the new brake shoes Efforts are underway to resolve this situation as soon as possible Sedona PVC Valve amp Cylinder Head Cover A change has been made to the PCV valve and cylin der head cover on the 02 Sedona for improved crankcase sealing From June 2001 the PCV valve was changed from a push in rubber grommet type to a threaded type The part number for the new threaded PCV valve is 26740 32804 The next edition of the Sedona Parts Catalog should reflect this change and have the part number for the threaded cylin
5. NTENDED FOR USE measuring the voltage of the transmitter battery as BY PROFESSIONAL KIA AUTOMOTIVE TECH well as inspecting cleaning the battery contacts see NICIANS ONLY IT IS WRITTEN TO INFORM chart If these checks are done first it may help to TECHNICIANS OF CONDITIONS THAT MAY reduce unnecessary RKE repairs OCCUR ON SOME VEHICLES TRAINED KIA TECHNICIANS HAVE THE EQUIPMENT TIONS AND EXPERTISE TO PERFORM THE Sephia Spectra Sportage Code Alarm 12V JOB CORRECTLY AND SAFELY Optima OEMS 3V each 2 batteries This Newsletter is to be distributed to Kia dealership personnel only It is not under any circumstances to be given to customers or other non Kia dealership personnel for any reason CAUTION VEHICLE SERVICING PERFORMED BY DTC Input Requested for Warranty Processing ENa o aie One of the many recent upgrades to the Warranty NOTICE Administration System is a separate field in the war ranty claim screen to record the primary DTC involved e The topics covered in this newsletter are designed to assist you with the diagnosis and in a repair This DTC data on the claims will enable repair of specific vehicle conditions Just KMA and KMC to develop countermeasures more because a condition is described in this quickly than before newsletter do not assume that it applies to your vehicle or that your vehicle will have To ensure maximum effectiveness of this new upgrade in that condition a
6. Taylor Neem van der Reest 2nd Quarter 2002 KU Masters Online Tests Are Ready for the Taking Kia University is pleased to announce the release of the 2nd Quarter 2002 certification tests for all dealership personnel As you know completion of the quarterly tests is required for certification under the Kia Masters Program The tests are based on information from two primary sources 1 Information mailed to Kia dealerships during the Ist Quarter 2002 if you no longer have the paper copies this information is now available at www kdealer net 2 Specific online course modules available at www kiauniversity com For the 2nd quarter different online modules will be tested to based on job title Test is based on information related to your specific job description See your manager for fur ther details Please refer to the list below to see what modules should be reviewed e GM Dealer Principal The Growing Impact of the Internet and Using the Internet as a Sales Tool e Sales Manager Building a Successful Sales Team and Creating a Positive Sales Environment e Sales Consultant Building Value Through Delivery and Putting Customers First e Receptionist Porter Putting Customers First e Service Manager Building Customer Loyalty and Making the Service Environment Inviting e Service Advisor Fixing It Right The First Time and Demonstrating Knowledge and Expertise e Warranty Administrator Success In The Service Lane e C
7. ashier Positive Service Consultation and Vehicle Pickup e Parts Manager and Parts Counterperson Online modules not required Registration Reminder 1 If you haven t registered see your dealership business manager to obtain your kdealer net dealership user name and password 2 Once at kdealer net click on the KU logo to register at kiauniversity com 3 Take courses when it s convenient anytime anywhere 24 7 Take your 2nd Quarter 2002 tests now Get online get tested and Kia Masters Certified Reman A T Fluid Specs Change The automatic transmission fluid specification has changed to Kia SP Ill ATF for all older Sephia vehicles and all remanufactured automatic transmissions See chart below for all Kia vehicle ATF application information Front Wheel Drive Sephia Spectra Rio Optima Sedona Rear Wheel Drive Sportage NOTICE All remanufactured automatic transmissions now use Kia SP Ill ATF If an older vehicle with a reman needs service that requires draining the ATF refill with SP Ill KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 2 A WARNING Remote Keyless Entry e VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN i INJURY TO THOSE PERSONS OR TO OTHERS When diagnosing complaints for inoperative or inter mittent remote keyless entry RKE system it is THE KIA TECHNICIAN NEWSLETTER KIA important to check the transmitter first This consists of TECHNICIAN TIMES IS I
8. der head cover Phd A i Old Valve x Pushes Into I Rubber Grommet TER In Head Cover j fh ay P i ing ee a 7 KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 Sedona Double Hinged Seat From 2 15 02 production the Sedona 2nd and 3rd row seats have a double hinge mechanism for folding the seat back To fold the seat back all the way flat pull up on seat back adjustment lever to partially fold seat then push forward on the secondary release knob to fold seat back flat To return seat back to upright position lift seat back until secondary mechanism latches then lift seat back adjustment lever and adjust to desired position Seat Back Adjustment Lever Secondary Release Knob sedona ACU Change During a 5 mph bumper procedure recently conducted by the Insurance Institute for Highway Safety IIHS an organization funded by insurance companies the airbags in the Sedona deployed causing the alleged repair costs for the Sedona to increase Kia engineers concluded that the deployment was unique to the HHS procedure and does not reflect what happens in real world collisions However to eliminate the possibility that a deploy ment would occur the next time HHS conducted it s procedure and to protect Kia from resulting negative PR re repair costs a production running change was made in the ACU logic from 2 20 02 Sedona owners have been told about this change For owners of Sedonas produced befor
9. e TPS at closed throttle now shows 0 instead of the 9 12 we used to see when in doubt use TPS voltage parameter e Inhibitor switch now shows off in park and neu tral on when in gear starting inhibited the old system showed the opposite e ISC opening and closing and evaporative purge solenoid are shown in percentage instead of milliseconds e ECT voltage reads lower at the same temperature In addition other components were changed at the same time as the ECM causing some data to change e JAT temperature reads slightly lower at the same ambient temperature due to the integration of the IAT sensor into the MAF sensor e MAF voltages have changed but read the same grams per second The new system also turns on the fuel pump for about two seconds at key on to aid start up Bottom line is that if you are diagnosing a 2002 Spectra please don t replace parts because of unusual readings first take into account the changes men tioned above 2002 Spectra P0121 Code When servicing a 2002 Spectra with a P0121 code TP Sensor Circuit Range Performance Problem make sure the cruise control cable is properly adjusted Even though no other drivability symptoms exist the cruise control cable bracket that bolts to the intake manifold may have been bent during other servicing making the cable too tight To adjust the cruise control cable bend the bracket towards the throttle body until you get approximately 4 mm cable
10. e headliner pillar trim and related interior components after side curtain deployment and replace as required 3 Inspect the side airbag sensors and airbag harness at the sill and B Pillar area after side or curtain airbag deployment 4 Inspect inside the front fenders and bumper for damage to the front sensors and airbag harness after frontal collision 5 The Sephia Spectra Rio ADU will be in an After Deployment Mode and must be cleared Clear the ADU by performing the scan tool airbag code clear function 6 Carefully inspect the drivers airbag connector for melting and replace the clockspring if necessary NOTICE After replacing inspecting parts check for any airbag DTCs if airbag indicator light stays on Diagnose inspect and repair in accordance with the appropriate Service Manual KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 10 Model Year Condition Incident Solution Repair Suggestion If necessary include a sketch and or page reference for the applicable Service Manual or Electrical Troubleshooting Manual All information received by Kia Motors America KMA becomes the property of KMA All respondents consent to allow KMA to publish their name and suggestions in the Kia Technician Times Your Name Signature Dealer Code Dealer Name City Town State Zip Code Date Phone Fax Number 949 470 2800 Attn Technical Operations Newsletter Its about time everyone had a well made car ATTN
11. e the ACU logic change who also request that their vehicle s ACU be changed a reprogramming card will be available soon A TSB will be issued Sedona Spark Plug Interval Update 2002 Owners Manual for Sedona incorrectly shows three different types of spark plugs as well as two different service intervals Incorrect service intervals are also shown in the Fixed Operations Information Guide or FOIG The only correct service interval for the platinum spark plugs used for USA market Sedona is 60 000 miles For correct part number information see the current Sedona Parts Catalog Sedona Roof Rack Installation When installing a Sedona roof rack or any Kia approved roof rack it is very important to use only the hardware that comes with the kit Do not substitute components or hardware The roof rack is rated for a maximum load capacity and by substituting components or hardware the load capacity of the roof rack may be compro mised The Sedona roof rack footings are affixed to the vehi cle s roof by steel rivet nuts supplied with the kit Without the proper installation tool the steel rivet nuts are very difficult to compress install Please use or acquire appropriate rivet nut installation tool manual or pneumatic when installing a roof rack Contact a tool distributor in your area if needed KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 8 2000 amp Later Sephia Spectra Evap Testing When testing evap l
12. eaks on DM TL Diagnostic Module Tank Leakage systems the hardest part may be deter mining if the DM TL itself is leaking or another part of the system After performing a visual inspection and running an evaporative leakage test with the Hi Scan Pro if a small or large leak code resets you may want to test the DM TL by itself The best way to check the DM TL is to isolate it from the rest of the system by plugging the hose from the DM TL at the charcoal canister then clear codes and run another test See the following chart for test results Scan Tool EVAP Test Interpretation and Next Aborts after changeover Pass Diagnose remainder of 2000 Completes a a A Fail Swap DMTL and retest Aborts after changeover Pass Diagnose remainder of 2001 Completes o A a ea Fail Swap DMTL 2002 Aborts after changeover Communication Pass Diagnose remainder of valve cycles error message EVAP system 2002 Completes a a Fail Swap DMTL and retest Remember that this system tests by monitoring the current draw of the DM TL as the pressure in the fuel tank increases See Technician Times Vol 2 Issue 4 page 10 When blocking off the hose from the DM TL the current ramps up so quickly if there is no leakage that the ECM aborts the test right after the changeover valve cycles The Monitoring Test Results in the Hi Scan Pro also may be of some help when analyzing a test failure see the fol lowing sample test result screens Go to Monitoring Test Results OBD Monito
13. er Optima may set a DTC P0128 thermostat malfunction even though no driveability concerns exist the thermostat is operating properly and a normal operating temperature is reached without noticeable delay 2001MY 4 cylinder Optima P0128 logic uses a tem perature threshold of 82 C 179 6 F This threshold must be reached within a certain time after start up or the ECM will consider the thermostat inoperative stuck open Note that time after start up in this case 1s actually a function of mass air flow For more details and additional parameters refer to the Hi Scan Pro with the P0128 DTC displayed on screen then hit the help button and select tips For 2002MY 4 cylinder Optima the DTC P0128 logic temperature threshold was reduced to 75 C 167 F to reduce incidence of P0128 code It is suspected that in certain ambient temperature operating conditions the higher threshold in 2001 MY causes the DTC to be stored even though the thermostat did not fail A P0128 logic software fix is being developed for 2001MY vehicles The fix should be available in May and will be downloadable to the ECM through Hi Scan Pro A TSB will be issued KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 6 New ABS System For Optima Starting with 12 12 01 production the ABS system on V6 equipped Optimas is supplied by Bosch The new system replaces the previous Teves Mk 20i version Although new for Optima the system known as
14. f ne Old Style P N 0K013 15 150 Sportage Silencer Design Change From 10 5 01 production the main body of the Sportage silencer muffler has been changed from rolled to stamped construction There is no interchange ability between the new and previous parts Old Style Silencer Assembly P N OKO7A 40 100 New Style Silencer Assembly Effective Production Date 10 5 01 P N 0K07B 40 100A KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 E3 e 7 wo 2 2 J y Weu T New Style P N i A 0K013 15 150A Notice the Difference in Sensor Mounting Location Height Note the difference in sensor mounting boss height between the old and the new parts The new thermo stat housing causes the tip of the ECT sensor to pro trude further into the coolant flow resulting in a more responsive and more accurate temperature reading Do not use the old style thermostat housing on Sportages built after 9 18 00 as under certain circum stances the ECM may inadvertently set a DTC P0128 thermostat malfunction due to perceived slower temperature changes 2002 Spectra ECM Data As you may have noticed the data stream on the 02 Spectra has a few changes from what we were used to seeing on earlier models The ECM was changed in 02 from a Motronic 4 6 to a Motronic 7 9 system The new system has a few new parameters but also inter prets some of the common parameters differently Some examples are
15. m Brake Upgrade for TSB Delayed SDN PVC Valve amp Cylinder Head Cover 8 SDN Double Hinged Seat ACU Change Spark Plug Interval Roof Rack Install 9 10 2000 amp Later SPA SPT Evap Testing Airbag Deployment Inspection lt y main goal is to change people s perceptions of just what a technician does said Sessom We are more than just grease monkeys Maybe but Jacobs has other plans I want to take home the gold he said And a bunch of money wouldn t hurt either Rosing and Schofield kept quiet In fact it was difficult to get any of them to chit chat for very long They were all too focused on repairing the hunk of metal sitting before them In better days it had been a transmission Not surpris ingly they all looked very confident that it could be fixed Good luck in Korea gentlemen Kia Motors America Inc cay Published by the Kia Motors America Inc Technical Operations Department The Kia Technician Times is a newsletter for the Kia dealership technician Subscriptions and outside mailings are not available All rights reserved Director Technical Operations Tim McCurdy Executive Coordinators Charles Lee James Lee Jack Ban Manager Technical Training Larry Boland Editor Dianne Soeder Desktop Publishing Barbara Mikus Engineering Support Contributing Writers Alan Dow Richard Downing James Hope Dale Johnson Greg Swanson Jeff
16. nd to allow proper warranty claim processing please 7 qll E T T E A make sure to select and identify the one DTC that iden Service Manual and or Electrical Troubleshooting tifies the primary concern on the vehicle being Manual should be performed first repaired and record it on the R O As always also remember to write down the accom TSB U pdate panying Freeze Frame Data on the R O as well TSBs issued in February and March 2002 e Climate Control 006 Rear HVAC Blend Air Door e Transmission Driveline 003 Revised Sephia Spectra Remanufactured Automatic Transmission Program e Transmission Driveline 008 Automatic Transaxle Diagnosis for Sephia Spectra Rio 3 KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 Sportage Rear Window Regulator Update Sportage Thermostat Housing Beginning 3 11 02 an improved regulator has been put into production The armature end piece has changed from a nylon button to a steel ball To aid in identify ing the improved regulator the part number has been changed see chart Starting with 6 17 00 production the engine thermo stat housing on Sportage was changed from P N OKO13 15 150 to P N OKO13 15 150A Note that ITC is C and that the change occurred at the same time the thermostat was changed in preparation for thermo stat monitoring The thermostat monitoring function was introduced on 9 18 00 4dr and 10 2 00 2dr a an 0K07 72 seoa okor 72 S808 sanmo
17. ring Test Evap Emission Monitoring The line labeled Data is the measured current draw of the DM TL during the test The line labeled Limit is the reference current that set at the beginning of the test If the data current is lower than the limit current the sys tem in this case the DM TL has a leak If the data current is higher than the limit current then no leaks are present Remember to clear any pending DTCs before releasing the vehicle ap hiia ioa EET Large Leak CID LARGE LEAK With DM TL CID CHANE OJER VALVE epee erer urrent 14 inched T Draw is Result W S Hee TWA Lower Than raw is Ta Limit Data 17 641 FA Higher Than lata 5 211 ri imit Lindt 18 532 rfl Linit 24 307 Fi Possible Falfiunmetian Causes Possible Falfumotion Causes SS aaa Se a ee Far ete linn fio F of 2 i 2 Bap Friesion Noni torim 2 Ewap Eetewion Honi toriy Small Leak CID SALL LEAR Passed Test CIO SALL LEAK a seth urrent urrent T Draw is lesult WA Craw Result W ower Than eache l Limit Data 18 953 Hil Limit Data 25 12 Fi Linit 22 559 FH Linit 25 125 Ff Possible falfemetiion Cause Possible Pallumction Causes final Laai Bhall Leak itan fin Z of PUF PDA linn fio of 2 Cer FAIA o KIA TECHNICIAN TIMES Volume 5 Issue 2 2002 Kia Vehicle After Airbag Deployment Inspection Replacement After a collision in which the airbags deploy there are certain parts that require replacement and some
18. that only require inspection to ensure their serviceability Refer to the chart for specific inspection replacement information A WARNING e Always wear safety glasses when handling airbag modules e Always wear rubber gloves when handling deployed or damaged airbag modules e Airbag surfaces may be contaminated with small amounts of Sodium Hydroxide NaOH Prevent contact of the airbag module with liquids combustibles and flammable materials Immediately wash contaminated hands and skin areas with mild soap and water Flush eyes with water if exposed to by products Failure to follow these instructions could result in chemical burns and personal injury Drivers Pass Knee Side airbag Side Seat belt Side airbag Frt sensors ADU or Clockspring Airbag Model airbag airbag P driver pass curtain pre sensors amp harness SRSCM strg wheel harness 2 tensioner 3 4 5 6 inst panel a 95 96 Sion Point cc cer Le vam wm we wm fom swf e e wal wm wn e we we fom rome fe fe wa wm wm wm fmm mm fe fs fo werna e e ef we wal wmf wm wm fe Cm fete uaf wm mele wm me fom fo om fete p a mele fs fel see fe fe nsf wm wef e fom mm fef fo sow Pete uf we fete tele R Replace I Inspect Clear Perform scan tool airbag clear function N A Not Applicable 1 The plastic knee airbag mounting screws must be replaced according to the Sportage Service Manual Clear 2 Inspect th
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