Kia Stinger CK Quiz

Engine Control System/Fuel System

In this manual: Engine Control System/Fuel System
General Information — 8Maintenance — 27Engine Mechanical System — 47Engine Electrical System — 19Emission Control System — 12Engine Control System/Fuel System — 51Automatic Transmission System — 34All-Wheel Drive (AWD) System — 7Drive Shaft and Axle — 15Suspension System — 25Steering — 8Restraints — 19Brake System — 22Body (Interior and Exterior) — 47Front Seat Belt — 63Body Electrical System — 99Windshield Wiper/Washer — 11Heating, Ventilation, and Air Conditioning — 32
59steps
~389min
5/5difficulty
7special tools
Done 0 of 59

Special Service Tools

Special Service Tools

Tool Name/Number Illustration Description
Fuel Pressure Sensor
09353-24100
Used to measure the fuel rail pressure.
Fuel Pressure Sensor Adapter
0K353-D4100
Used to connect between the high-pressure fuel pump and the low-pressure fuel feed hose to measure fuel line pressure.

※ SST 09353-02100 can also be used.
Heated Oxygen Sensor Socket Wrench
09392-1Y100
Heated Oxygen Sensor Removal and Installation

※ SST No. 09392-2H100 can also be used to remove the heated oxygen sensor.
Torque Wrench Head (19 mm)
09314-3Q100
Used for removal/installation of high-pressure fuel line.

※ SST No. 09314-27130 can also be used.
Injector Seal Guide and Sizing Tool
09353-2B000
Used to install the injector combustion seal onto the injector.
Fuel Sender Gauge Cover Plate Remover
09310-B9100
Used for removal/installation of fuel pump.
Low Pressure Fuel Pump Cover Plate Remover
09310-B8100
Used for removal/installation of fuel pump.

Troubleshooting

Basic Troubleshooting Procedures

Basic Troubleshooting Procedure Guide

Customer Problem Analysis Sheet

Basic Inspection Procedure

Electronic Component Resistance Measurement Conditions

Measured resistance may be high or low when the vehicle is at high temperature after driving. Therefore, all resistance values must be measured at ambient temperature (20 °C, 68°F) unless otherwise specified.

Intermittent Problem Inspection Procedure

Sometimes the most difficult case in troubleshooting is when the symptom occurs but does not reproduce during testing. For example, the problem may appear only when the vehicle is cold and never when it is hot. In this case, the technician should carefully complete the "Customer Problem Analysis Sheet" and recreate (simulate) the environment and conditions under which the problem occurred.

  1. Clear the Diagnostic Trouble Code (DTC).

  2. Inspect all connections. Check the terminal for poor contact, loose wires, bent, broken or corroded terminals, then make sure connectors are securely engaged at all times.

  3. Gently shake the connector and wiring harness vertically and horizontally.

  4. Repair or replace the faulty component.

  5. Perform a road test to confirm that the problem has disappeared.

● Simulate vibration

a.

Sensors and Actuators

: Lightly tap sensors, actuators or relays with your finger.
b.

Connectors and Harness

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

● Simulate heat

a.

Heat the components suspected of causing the malfunction using a hair dryer or other heat source.

● Simulate water spray

a.

Spray water on the vehicle to simulate a rainy day or high humidity condition.

● Simulate electrical load

a.

Turn on all electrical systems to simulate excessive electrical load (radio, fans, headlights, rear window defogger, etc.).

Connector Inspection Procedure

  1. Connector Handling

    a.

    Never pull on the wire harness when disconnecting connectors.
    b.

    When disconnecting a connector with a lock, press or pull the lock lever.
    b.

    Listen for a click when connectors lock. This sound indicates they are securely locked.
    d.

    When using a tester to check continuity or measure voltage, always insert the tester probe from the wire harness side.
    e.

    Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from the wire harness side.

  2. Connector Checkpoints

    a.

    While the connector is connected:

    While holding the connector, check the connection condition and locking efficiency.
    b.

    When the connector is disconnected:

    Check for a missing terminal, crimped terminal or broken wire core by lightly pulling on the wire harness.

    Visually check for rust, contamination, deformation, and bending.
    b.

    Check the terminal tightening condition:

    Insert a spare plug into the socket, then check the terminal tightening condition.
    d.

    Gently pull on individual wires to make sure each wire is secured in the terminal.

  3. Connector Repair Method

    a.

    Clean the contact points using compressed air and/or a cloth.
    b.

    If contact pressure is abnormal, replace the female terminal.

Wire Harness Inspection Procedure

  1. Before removing the harness, check the harness position and clamps so that it can be reinstalled correctly.

  2. Check the wiring harness for twisted, stretched, or loose harness sections.

  3. Check that the wire harness is not exposed to excessive temperature.

  4. Check that the wiring harness does not rub, move, or vibrate against sharp edges of parts.

  5. Check the connection between the wire harness and any installed part.

  6. If the harness covering is damaged, secure, repair or replace the harness.

Electrical Circuit Inspection Procedure

● Open Circuit Test

  1. Open Circuit Procedures

    • Continuity Check

    • Voltage Check

    If an open circuit occurs (as shown in [FIG. 1]), it can be located by performing Step 2 (continuity check method) or Step 3 (voltage check method), as shown in the figures below.

  2. Continuity Check Method

    Specification (Resistance)

    1 Ω or less → Normal circuit

    1 MΩ or more → Open circuit

    a.

    Disconnect connectors (A) and (C), and measure the resistance between connectors (A) and (C), as shown in [FIG. 2].

    In [FIG. 2], if the measured resistances of lines 1 and 2 are "more than 1 MΩ" and "less than 1 Ω" respectively, line 1 has an open circuit. (Line 2 is normal.) To find the exact point of the break, inspect line 1 as described in the following step.
    b.

    Disconnect connector (B) and measure the resistance between connectors (C) and (B1), and between (B2) and (A), as shown in [FIG. 3].

    In this case, the measured resistance between connectors (C) and (B1) is more than 1 MΩ, 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 chassis ground and terminal 1 of each of connectors (A), (B) and (C), as shown in [FIG. 4].

    The measured voltages at the connectors are 5 V, 5 V and 0 V respectively. Therefore, there is an open circuit between connectors (C) and (B).

● Short Circuit Test

  1. Short to Ground Check Method

    • Continuity Check with Chassis Ground

    If a short to ground occurs (as shown in [FIG. 5]), the fault location can be found by performing Step 2 (continuity check method with ground) as shown below.

  2. Continuity Check Method (with Chassis Ground)

    Specification (Resistance)

    1 Ω or less → Short to ground

    1 MΩ or more → Normal circuit

    a.

    Disconnect connectors (A) and (C), and measure the resistance between connector (A) and body ground, as shown in [FIG. 6].

    If the measured resistances of lines 1 and 2 are "less than 1 Ω" and "more than 1 MΩ" respectively, line 1 is shorted. (Line 2 is normal.) To find the exact point of the short, inspect 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 1 Ω or less. There is a short to ground between terminal 1 of connector (C) and terminal 1 of connector (B1).

● Voltage Drop Test

This test checks for voltage drop in a wire, connection or switch.

A.

Connect the positive lead of the voltmeter to the end of the wire (or the connector or switch side) closest to the battery.
B.

Connect the negative wire to the other end of the wire (or to the other side of the connector or switch).
C.

Operate the circuit.
D.

The voltmeter will display the voltage difference between two points. A difference or drop of more than 0.1 V (50 mV in 5 V circuits) may indicate a problem. Check the circuit for loose or dirty connections.

Symptom Troubleshooting Chart

Main Symptom Diagnostic Procedure Also check
Cannot Start
(Engine does not crank)

  1. Check the battery. (Refer to Engine Electrical System - "Battery")

  2. Test the starter. (Refer to Engine Electrical System - "Starter")

  3. Inhibitor switch (A/T) or clutch start switch (M/T)
Cannot Start
(Incomplete combustion)

  1. Check the battery. (Refer to Engine Electrical System - "Battery")

  2. Check fuel pressure (Refer to Fuel System - "Fuel Pressure Test").

  3. Check the ignition circuit (Refer to Engine Electrical System - "Ignition System").

  4. Troubleshoot the immobilizer system (Refer to Body Electrical System - "Immobilizer System").

    (If the immobilizer lamp is flashing)

  • Trouble Code

  • Low compression

  • Intake air leaks

  • Slipping or broken timing belt

  • Contaminated Fuel
Hard to Start

  1. Check the battery. (Refer to Engine Electrical System - "Battery")

  2. Check fuel pressure (Refer to Fuel System - "Fuel Pressure Test").

  3. Inspect the ECT sensor and its circuit. (Check the diagnostic trouble code.)

  4. Check the ignition circuit (Refer to Engine Electrical System - "Ignition System").

  • Trouble Code

  • Low compression

  • Intake air leaks

  • Contaminated Fuel

  • Weak ignition spark
Poor Idling
(Rough, unstable or incorrect idle)

  1. Check fuel pressure (Refer to Fuel System - "Fuel Pressure Test").

  2. Check the injector. (Refer to Engine Control System - "Injector")

  3. Check the long-term fuel trim and short-term fuel trim.

    (Refer to CUSTOMER DATA FLOW)

  4. Inspect the idle speed control circuit. (Check the diagnostic trouble code.)

  5. Inspect and check the throttle body.

  6. Inspect the ECT sensor and its circuit. (Check the diagnostic trouble code.)

  • Trouble Code

  • Low compression

  • Intake air leaks

  • Contaminated Fuel

  • Weak ignition spark
Engine Stalls

  1. Check the battery. (Refer to Engine Electrical System - "Battery")

  2. Check fuel pressure (Refer to Fuel System - "Fuel Pressure Test").

  3. Inspect the idle speed control circuit. (Check the diagnostic trouble code.)

  4. Check the ignition circuit (Refer to Engine Electrical System - "Ignition System").

  5. Inspect the CKPS circuit. (Check the diagnostic trouble code.)

  • Trouble Code

  • Intake air leaks

  • Contaminated Fuel

  • Weak ignition spark
Poor Driveability
(Surging)

  1. Check fuel pressure (Refer to Fuel System - "Fuel Pressure Test").

  2. Inspect and check the throttle body.

  3. Check the ignition circuit (Refer to Engine Electrical System - "Ignition System").

  4. Check the ECT sensor and circuit (check DTC)

  5. Check the exhaust system for possible clogging (Refer to Engine Mechanical System - "Exhaust Manifold").

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

  • Trouble Code

  • Low compression

  • Intake air leaks

  • Contaminated Fuel

  • Weak ignition spark
Knock

  1. Check fuel pressure (Refer to Fuel System - "Fuel Pressure Test").

  2. Inspect the engine coolant (Refer to Engine Mechanical System - "Radiator").

  3. Inspect the radiator and electric cooling fan (Refer to Engine Mechanical System - "Radiator").

  4. Check the spark plugs (Refer to Engine Electrical System - "Ignition System").

  • Trouble Code

  • Contaminated Fuel
Poor Fuel Economy

  1. Check the customer's driving habits.

    · Is the air conditioner or defroster mode on continuously?

    · Is the tire pressure correct?

    · Is an excessively heavy load being carried?

    · Is acceleration too strong or too frequent?

  2. Check fuel pressure (Refer to Fuel System - "Fuel Pressure Test").

  3. Check the injector. (Refer to Engine Control System - "Injector")

  4. Check the exhaust system for possible blockage

  5. Check the ECT sensor and circuit

  • Trouble Code

  • Low compression

  • Intake air leaks

  • Contaminated Fuel

  • Weak ignition spark
Hard to Refuel
(Overflow during refueling)

  1. Inspect the fuel tank hose/tube.

    · Is it pinched, kinked, or blocked?

    · Is the filler hose torn?

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

  3. Inspect the EVAP canister.

  • Defective fuel filler nozzle at gas station (If this problem occurs at a specific gas station during refueling)

Test yourself

A quick Kia Stinger CK quiz: every answer comes with an explanation and a link to the manual page.