Kia Rio YB Quiz

Engine Control System/Fuel System

In this manual: Engine Control System/Fuel System
General Information — 8Maintenance — 31Engine Mechanical System — 44Engine Electrical System — 14Emission Control System — 9Engine Control System/Fuel System — 30Clutch System — 10Manual Transmission — 10Automatic Transmission — 23Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 14Brake System — 22Body (Interior and Exterior) — 115Body Electrical System — 84Heating, Ventilation, and Air Conditioning — 28
59steps
~374min
5/5difficulty
4special tools
Done 0 of 59

Specifications

Specifications

Fuel Delivery System

Items Specification
Fuel tank Capacity 45 liters (11.8 US gal, 47.5 US qt, 39.5 Imp. qt)
Fuel filter Type Paper Type
Fuel Pressure Regulated Fuel Pressure 330–370 kPa (3.36–3.77 kgf/cm², 47.86–53.66 psi)
Fuel pump Type Electric, In-Tank Type
Which was driven Electric Motor
Supply Voltage 12 V
Current Max. 6.0 A
Fuel Return System Type Returnless

Engine Control System

ETC Module

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

▷ Type: Non-contact Hall IC sensor

▷ Specifications

Throttle Angle (°) Output Voltage (V) [Vref=5V]
TP1 TP2
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
THA (0) 0,5 4,5
THW (86) 4.41 0,59

DC Motor [Built into ETC Module]

Item Specification
Coil Resistance (Ω) 0,3–100 [20 °C]

Manifold Absolute Pressure (MAP) Sensor

▷ Type: Piezoresistive pressure sensor

Pressure
[kPa (kgf/cm², psi)]		 Output Voltage (V) [Vref = 5 V]
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 (kOhm)
°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 (kOhm)
°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]
Pin 2

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 - 1350
Type Piezoelectric
Pin 2

Heated Oxygen Sensor (HO2S)

HO2S [Bank 1 / Sensor 1]

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

HO2S [Bank 1 / Sensor 2]

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

Accelerator Pedal Position Sensor (APS)

Accelerator
Position		 Output Voltage (V) [Vref = 5 V]
VPA1 VPA2
THA 0,7 - 0,8 0,32 - 0,42
THW 3,98 - 4,22 1,93 - 2,17

Injector

Item Specification
Coil Resistance (Ω) Approximately 9.6
Minimum Input 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]
Pin 2

Variable Force Solenoid (VFS)

Item Specification
Coil Resistance (Ω) 6.9–7.9 Ω
Operating Voltage (V) 12 V

CVVT Oil Control Valve (OCV)

[Bank 1/Exhaust]

Item Specification
Coil Resistance (Ω) 6,9–7,9 [20 °C]
Control Current (mA) 100 - 1000
Rated Voltage (V) 12
Insulation Resistance (MΩ) 50 [500 V DC/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/C OFF Neutral, N, P Range 660 ± 100 rpm
D Range 660 ± 100 rpm
A/C ON Neutral 660 ± 100 rpm
D, N, P Range 660 ± 100 rpm

Tightening torque

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 Module Bracket Mounting Bolt/Nut 1,0 - 1,2 9,8 - 11,8 7,2 - 8,7
Electronic Throttle Control (ETC) Module 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 Mounting Bolt [Bank 1/Intake] 1,0 - 1,2 9,8 - 11,8 7,2 - 8,7
Camshaft Position Sensor Mounting Bolt [Bank 1/Exhaust] 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 is 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 is integrated into Accelerator Pedal Module] 0,9 - 1,04 8,8 - 13,7 6,5 - 10,1
CVVT Oil Control Valve (OCV) Mounting Bolt [Bank 1/Intake] 1,0 - 1,2 9,8 - 11,8 7,2 - 8,7
CVVT Oil Control Valve (OCV) Mounting Bolt [Bank 1/Exhaust] 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 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 Sensor
09353-24100
Fuel Line Pressure Measurement
Fuel Pressure Sensor Adapter
09353-38000
Connection Between Delivery Pipe and Fuel Feed Line
Fuel Pressure Sensor Connector
09353-24000
Connection between Fuel Pressure Sensor (09353-24100) and Fuel Pressure Sensor Adapter (09353-38000)
Heated Oxygen Sensor Socket Wrench
09392-1Y100
Heated Oxygen Sensor Removal and Installation

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 problem symptom occurs but does not recur during testing. For example, if the problem appears only when the vehicle is cold but does not appear when it is warm. In this case, the technician should carefully complete the CUSTOMER PROBLEM ANALYSIS SHEET and try to reproduce (simulate) the environment and conditions that existed when the vehicle problem occurred.

  1. Clear the Diagnostic Trouble Code (DTC).

  2. Inspect the connector and check the terminals for poor contact, loose wires, bent, broken or corroded contacts, then make sure all connectors are always securely fastened.

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

  4. Repair or replace the faulty component.

  5. Confirm that the problem is resolved by performing a road test.

● VIBRATION SIMULATION

a.

Sensors and Actuators

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

Connectors and Harness

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

● HEAT SIMULATION

a.

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

● SIMULATING WATER SPRAY

a.

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

● ELECTRICAL LOAD SIMULATION

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 locking 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 lock effectiveness.
    b.

    When the connector is disconnected:

    Check for a missing terminal, crimped terminal, or broken wire by gently pulling on the wiring 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 Terminal 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 that the wire harness is not twisted, stretched or loose.

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

  4. Check whether the harness is rotating, moving, or vibrating, or whether it contacts a sharp edge of a part.

  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

● Check for open circuit

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

    In [FIG. 2], the measured resistance of lines 1 and 2 is more than 1 MΩ and less than 1 Ω, respectively. Therefore, the open circuit is line 1 (line 2 is normal). To find the exact break point, check the sub-line of line 1 as described in the next step.
    b.

    Disconnect connector (B) and measure the 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 more than 1 MΩ, and there is an open circuit 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 connector (A), (B), and (C), as shown in [FIG. 4].

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

● Check for short circuit

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

    In this example, the measured resistance of lines 1 and 2 is less than 1 Ω and more than 1 MΩ, respectively. Therefore, the short to ground is line 1 (line 2 is normal). To find the exact damaged point, check the sub-line of line 1 as described in the next 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).

Symptom Troubleshooting Chart

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

  1. Check the battery

  2. Check the starter

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

  1. Check the battery

  2. Check the fuel pressure

  3. Check the ignition circuit

  4. Immobilizer System Troubleshooting (Immobilizer indicator blinks)

  • Trouble Code

  • Low compression

  • Intake air leaks

  • Slipping or broken timing belt

  • Contaminated Fuel
Hard to Start

  1. Check the battery

  2. Check the fuel pressure

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

  4. Check the ignition circuit

  • Trouble Code

  • 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 DATA LIST)

  4. Check the idle air control circuit (check DTC).

  5. Inspect and check the throttle body

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

  • Trouble Code

  • Low compression

  • Intake air leaks

  • Contaminated Fuel

  • Weak ignition spark
Engine Stalls

  1. Check the battery

  2. Check the fuel pressure

  3. Check the idle air control circuit (check DTC).

  4. Check the ignition circuit

  5. Check the CKPS circuit (check DTC)

  • Trouble Code

  • Intake air leaks

  • Contaminated Fuel

  • Weak ignition spark
Poor Driveability
(Surging)

  1. Check the fuel pressure

  2. Inspect and check the throttle body

  3. Check the ignition circuit

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

  5. Check the exhaust system for possible blockage

  6. Check the long-term fuel trim and short-term fuel trim (Refer to DATA LIST)

  • Trouble Code

  • Low compression

  • Intake air leaks

  • Contaminated Fuel

  • Weak ignition spark
Knock

  1. Check the fuel pressure

  2. Inspect the engine coolant

  3. Inspect the radiator and the electric cooling fan.

  4. Check the spark plugs

  • Trouble Code

  • Contaminated Fuel
Poor Fuel Economy

  1. Check the customer's driving habits.

  • Is the air conditioner operating continuously or is the defroster mode on?

  • Is the tire pressure correct?

  • Is the vehicle carrying an excessively heavy load?

  • Is the vehicle accelerating too hard or too frequently?

  1. Check the fuel pressure

  2. Check the injector

  3. Check the exhaust system for possible blockage

  4. 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. Check the canister close valve

  2. Inspect the fuel tank hose/tube.

Pinched, twisted or blocked? Filler hose ruptured

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

  2. Check 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 Rio YB quiz: every answer comes with an explanation and a link to the manual page.