05 Fuel System

Fuel System
Fuel System
General Information
Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >
Wiring diagram
KV6 DOHC
2000 > 2.5L GASOLIN(K5) >
Special service tools

Emission control system special service tool
Tool (Name and number) Illustration Use
0K2A1 189 AA0 Used for diagnoses and DTC retrieval and
KIA power scan erasing.
0K2A1 131 001A

Used for measuring fuel pressure.
Fuel pressure gauge
0K2A1 189 B0B/0K2A1 189

Used for measuring ECM terminal voltage
134
and resistance.
Break out box
Special service tools

Emission control system special service tool
Tool (Name and number) Illustration Use
0K2A1 189 AA0 Used for diagnoses and DTC retrieval and
KIA power scan erasing.
0K2A1 131 001A
Used for measuring fuel pressure.
Fuel pressure gauge
0K2A1 189 B0B/0K2A1 189

Used for measuring ECM terminal voltage
134
and resistance.
Break out box
2000 > 2.5L GASOLIN(K5) >
Basic inspection
Ignition timing
1. Apply parking brake.
2. Warm up engine to normal operating temperature.
3. Turn OFF all electrical loads.
4. Connect timing light to number one spark plug wire.
A rubber inspection plug has been provided in the plastic coil cover (center of the cylinder head cover)
directly over the number one (1) spark plug wire.
Remove the inspection plug and connect the inductive pick-up of your tachometer or timing light to the
number one (1) spark plug wire. If our tachometer/timing light inductive pick-up is too large, the coil
cover will have to be removed.
5. Verify that ignition timing marks on crankshaft pulley and timing mark on timing belt cover are aligned.
Ignition timing : BTDC 12°±5° (at idle speed)
Ignition timing is not adjustable.
6. If timing is not within the specified range, replace the ECM.
Idle speed
1. Apply parking brake.
2. Warm up engine to normal operating temperature.
3. Turn OFF all electrical loads.
4. Connect inductive tachometer to number one (1) spark plug wire or connect tachometer pick-up lead to
terminal 'O' in the data link connector (DLC).
In case of using scan tool connect Kia Power Scan to the DLC.
The base idle speed is not adjustable. The idle speed is automatically controlled by the engine control
module. Incorrect idle speed indicates a potential problem with the IAC system or an intake manifold
leak.
5. Check that idle speed is within specified range.
Idle speed (transaxle in "NEUTRAL") : 725±50 rpm
This is a "wasted spark" ignition system, some tachometers will indicate twice the actual engine speed.
6. Disconnect tachometer from DLC or spark plug wire.

7. Turn off engine.
2000 > 2.5L GASOLIN(K5) >
Specifications
Engine
KV6 Gasoline
Item
Idle speed* (rpm) 725±50
Ignition timing* (BTDC) 12°±5°
Type Horizontal draft
Throttle body Throat diameter (in[mm]) 1.8 (42) X 2
Type Rotary
Idle air control Resistance (at Opening 16.5~18.5

valve 68°F[20°C])Ω Closing 14.5~16.5
Mass air flow sensor Heated resistor (Hot film)
Air cleaner element Dry, paper type
EVAP canister
Resistance (at 68°F[20°C]) (Ω) 26
purge valve
-4°F(-20°C) 15.04 (+1.79, -1.60)
Engine coolant
temperature Resistance (KΩ) 68°F(20°C) 2.45 (+0.19, -0.18)
sensor
176°F(80°C) 0.318±0.011
Type of drive Electromechanical
Fuel injector Number of Spray ports 2
Resistance (at 68°F[20°C]) (Ω) 14.5
Heated oxygen
Resistance (at 68°F[20°C]) (Ω) 6
sensor
VICS valve Resistance (at 68°F[20°C]) (Ω) 13.8 ± 3.5
Main relay Resistance (at 68°F[20°C]) (Ω) 85
Specifications
Item Specifications
Accelerator cable free play (mm [in]) 3 (0.12)
Fuel injection volume (cu in/min [cc/min]) 11.8~13.3 (192~216)
Fuel pressure₁ (psi [kPa, kg/cm²]) 43~46 (294~314, 3.0~3.1)
Fuel pressure₂ (psi [kPa, kg/cm²]) 25 (180, 1.8)
Low-pressure side Nylon element (in fuel pump)
Fuel filter Type
High-pressure side Paper element
Fuel pump pressure (min) (psi [kPa, kg/cm²]) 65~85 (450~600, 4.5~6.0)
Fuel specification Unleaded
Fuel tank capacity (gal [liter]) 13 gal. (50 liter)
Injector Type High ohmic electra mechanical
Resistance (Ω) 14.5
₁Fuel pressure with fuel pressure regulator (With vacuum hose disconnected)
₂Minimum fuel pressure fifteen minutes after ignition key is switched "OFF",
Fuel System
Fuel System
Engine Control System - Mass Air Flow Sensor
(MAFS)

2000 > 2.5L GASOLIN(K5) >
Removal
Do not drop or subject the sensor to shock. Do not put objects inside the sensor.
1. Disconnect mass air flow sensor connector.

2. Loosen air intake hose retaining clamps on both sides of mass air flow sensor.
3. Disconnect air intake hose from mass air flow sensor.
4. Remove two bolts attaching mass air flow sensor to mounting bracket.
5. Remove mass air flow sensor.
Installation
1. Attach mass air flow sensor to air intake hose and to mounting bracket.
2. Replace two bolts to retain mass air flow sensor to mounting bracket.
Tightening torque : 69~96.3 lb-in (7.8~10.8 N·m, 0.8~1 kg-m)
3. Reconnect air intake hose to the mass air flow sensor.

4. Tighten bolts of retaining clamps on both sides of mass air flow sensor.
5. Reconnect mass air flow sensor connector to sensor.
6. Warm up engine to normal operating temperature and let engine idle.
7. Connect voltmeter between terminal 2 (BLK/WHT wire) and ground.
8. Verify that the voltage varies between 0.8V~1.2V.
9. Rev up engine and verify that voltage varies between 3.5V~4V.
10. If voltage is not within specification, replace mass air flow sensor.
Inspection
1. Check mass air flow sensor for damage, replace if necessary.
Fuel System
Fuel System
Engine Control System -
Engine Coolant Temperature Sensor (ECTS)

2000 > 2.5L GASOLIN(K5) >
Removal
Engine coolant temperature sensor is located near thermostat.
1. Disconnect engine coolant temperature sensor connector.

2. Remove engine coolant temperature sensor.
Installation
1. Install a new washer and engine coolant temperature sensor onto engine.
Tightening torque : 18-22 lb-ft (25-29 N·m, 2.5~2.9 kg-m)
2. Connect engine coolant temperature sensor connector.

3. Start engine and check for coolant leakage.
Inspection
1. Measure resistance of sensor using ohmmeter.
Water temperature °F(°C) Resistance (KΩ)

68°F(20°C) 2.45±0.24
176°F(80°C) 0.318±0.011
2. If resistances are not within specification, replace engine coolant temperature sensor.
Fuel System
Fuel System
Engine Control System - Throttle Position Sensor
(TPS)

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Disconnect connector from throttle position sensor.
2. Connect ohmmeter between sensor terminals 1 and 3.
3. Verify that resistance increases linearly according to throttle angle.
Specification : 2 kΩ ± 0.4 kΩ (with throttle valve closed)
4. If resistance is not as specified, replace the throttle position sensor.

5. Connect throttle position sensor connector.
Inspection(Voltage)
1. Verify that throttle is at the closed throttle position.
2. Turn ignition switch ON.
3. Connect voltmeter between terminal A (YEL/BRN wire) and C (BLU/WHT wire) on throttle position sensor
connector.
4. Verify that throttle valve is at closed throttle position.
5. Fully open throttle valve and verify that voltage at terminal a is within specification.
6. If not as specified, replace throttle position sensor.
Specification :
Measuring condition Voltage (V)

Fully closed 0.4~0.8V
Fully open 4.0~4.4V
Removal
The throttle position sensor is not adjustable or replaceable. The throttle position sensor is part of the
throttle body assembly.
Fuel System
Fuel System
Engine Control System - Heated Oxygen Sensor
(HO2S)

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Warm up the engine to normal operating temperature.
2. Run engine at idle speed.
3. Connect a voltmeter between terminal a (RED wire) and ground.
4. Increase and decrease engine speed quickly several times.

5. Verify that meter reading varies between 0~1.0V.
Rear oxygen sensor voltage does not fluctuate as quickly as front oxygen sensor.
6. If not as specified, inspect :

A. On-board diagnostic system
B. System inspection
C. Intake manifold vacuum
D. Fuel line pressure
7. If all systems are normal, replace the heated oxygen sensor.
Inspection of front & rear heated oxygen sensor heaters

1. Ensure ignition switch is OFF.
2. Disconnect heated oxygen sensor connector.
3. Connect ohmmeter between terminals c and d and measure resistance.
Specification : Approx. 6Ω (68°F (20°C)).
4. If not as specified, replace heated oxygen sensor.
Tightening torque : 22~36 lb-ft (30~49 N·m, 3~5 kg-m)
5. Reconnect heated oxygen sensor connector.

Removal
1. Disconnect heated oxygen sensor connector.
2. With standard oxygen sensor socket, remove heated oxygen sensor and washer.
Installation
1. Install heated oxygen sensor and washer.
Tightening torque : 22~36 lb-ft (30~49 N·m, 3~5 kg-m)
2. Reconnect heated oxygen sensor connector.

Fuel System
Fuel System
Engine Control System - Main Relay

2000 > 2.5L GASOLIN(K5) >
Inspection
1. Remove cover from main fuse box.
2. Place a finger on main relay.
3. Verify that relay clicks when ignition switch is turned ON.
4. Verify that main relay clicks when ignition switch is turned ON and OFF.
5. Apply battery voltage (B+) to terminal 86 and ground terminal 85 of the relay.
6. Check continuity of relay as shown.
Terminals B+ applied B+ not applied

87~30 Continuity No continuity
7. If not as specified, replace main relay.

8. Turn ignition switch OFF.
9. Replace the cover on main fuse box.
Fuel System
Fuel System
Engine Control System - Fuel Pump Relay

2000 > 2.5L GASOLIN(K5) >
Inspection
Check operation
THE FUEL SYSTEM REMAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE
FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE THE CHANCE
OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONENTS.
Listen for fuel pump relay clicking as ignition switch is turned "ON".
Continuity inspection
• Check continuity between relay terminals.
B+ : Battery positive voltage
Terminal 85-86 Terminal 87-30

Apply B+ and ground Continuity
B+ and ground not applied No continuity Continuity
Fuel System
Fuel System
Engine Control System

2000 > 2.5L GASOLIN(K5) >
Component description table
Component Function Remark

Controls A/C operation according to vehicle
Controls condenser fan
A/C Cut Relay conditions and sends A/C operation condition
operation
signals to ECM
A/C Switch Controls battery power to A/C relay Normally open type
Air cleaner Filters air entering throttle body Dry type
Detects No. 1 cylinder TDC : sends signal to Installed at rear of cylinder
Camshaft Position (CMP) Sensor
ECM head
Maintains pressure in the fuel tank and
Located in evaporative system
Check Valve regulates vapor flow to the evaporative
lines next to the fuel tank
emissions canister
Detects crank shaft angle from flywheel
Crankshaft Position (CKP) Sensor SGT signal
rotation and sends signal to ECM
Centralized service connector for on-board For on board diagnosis and
Data Link Connector (DLC)
diagnosis service/inspection
1. Normally open type
EGI Main Relay Supplies battery power to electrical devices
2. Controlled by ECM
Controls exhaust gas flow from exhaust Actuated by EGR control signal
EGR solenoid valve
manifold to intake manifold (dynamic chamber) of ECM
Engine Control Module (ECM) Detects the following :
1. A/C operation 1. Air conditioning switch
2. Air/fuel ratio (oxygen concentration) 2. Heated oxygen sensor
3. Cranking Signal 3. Ignition switch
4. Engine coolant temperature 4. Engine coolant temperature
5. Engine speed sensor
6. Ignition ON signal 5. Crankshaft position (CKP)
7. In-gear condition (A/T only) sensor (SGT signal)
8. Intake air amount 6. Ignition switch
9. Intake air temperature 7. Transmission range switch
10. No. 1 piston TDC (compression stroke) (A/T)
11. Throttle valve opening angle 8. Mass air flow sensor
Controls operation of following : 9. Intake air temperature
1. A/C (cutoff) sensor
2. Self-diagnosis function 10. Camshaft position (CMP)
sensor (SGC signal)
3. Fuel injection system
11. Throttle position sensor
4. Idle speed control
5. Monitor function
1. A/C cut relay
6. Purge control system
2. Hi-Scan Tool & MIL
7. Fuel pump control
3. Injector
8. Cooling fan control
4. Idle air control valve
5. Engine monitor output to
DLC
6. EVAP canister purge valve
7. EGR solenoid valve
8. Fuel pump relay
9. Cooling fan control relay
(High, Low)
Engine Coolant Temperature (ECT) Detects engine coolant temperature and sends Installed at cylinder head
Sensor signal to ECM (Bank 1)
Evaporative Emission Canister Stores fuel tank vapors (engine stopped) -
Filters fine dirt particles in fuel discharged from
Fuel Filter (High Pressure Side) -
the fuel pump
Fuel Filter (Low Pressure Side) Filters fuel in fuel tank -
Controlled by signals from
Fuel injector Injects fuel into intake port
ECM
Controlled by intake manifold
Fuel Pressure Regulator Regulates fuel pressure supply to injectors
vacuum
Actuated by fuel pump relay
Fuel Pump Supplies fuel from fuel to fuel under pressure
installed
1. Normally open type
2. Actuated by ECM fuel
Fuel Pump Relay Controls battery power to fuel pump pump control signal or by
jumping data link connector
terminal #1 to B+
1. Located in exhaust
Detects oxygen density in exhaust gas and manifold
Heated Oxygen Sensor
sends signal to ECM 2. For air/fuel mixture
adjustment
1. For idle speed control
Supplies intake air to engine, bypassing
Idle Air Control (IAC) Valve 2. Actuated by ECM idle
throttle valve
speed control signal
Mounted directly above spark
Ignition Coils Supplies secondary voltage to spark plugs
plugs
Ignition Control Module Controls operation of ignition coils Incorporated into ECM
Starts engine and controls battery power to
Ignition Switch -
electrical devices
Intake Manifold Supplies intake air to all cylinders -
Main Relay Supplies current to output devices and ECM -
Detects amount of intake air and sends signal
Mass Air Flow (MAF) Sensor Hot film type
to ECM
1. For purge control
Controls fuel vapor from emission canister to
EVAP canister purge valve 2. Actuated by RCM purge
intake manifold (dynamic chamber)
control signal
Reduces intake air suction noise and increases
Resonance Chamber -
engine torque
Starter Crank engine by rotating flywheel ring gear -
Reduces HC, CO, and NOx in exhaust through For exhaust gas emissions
Three Way Catalytic Converter
chemical reaction reduction
Throttle Body Controls intake air amount -
Detects throttle valve opening angle and sends
Throttle Position Sensor Installed on throttle body
signal to ECM
Located below instrumental
Controls functions of transmission for batter
Transmission Control Module (A/T) panel behind left lower trim
performance and shift quality
panel
Detects shift lever position and sends signal to 1. For idle speed control
Transmission Range Switch (A/T)
ECM 2. Load/no-load determination
VICS valve Controls shutter valve in dynamic chamber
Diagnostic trouble codes

Diagnostic trouble codes retrieval procedure
1. Connect the Kia Power Scan to the Data Link Connector (DLC).
2. Turn the ignition switch ON.
3. Retrieve any DTC in ECM memory.
Clearing diagnostic trouble codes

1. Connect the Kia Power Scan to the Data Link Connector (DLC).
2. Turn the ignition switch ON.
3. Erase any DTC stored in ECM.
Data link connector 20 pin layout

PIN No. Terminal function
a Power supply for fuel pump test
b Power supply for IG "ON"
f Air bag unit
j Test ground for A/T vehicle
k Communication diagnosis terminals for Kia Power Scan
m Fail code output terminal for A/T vehicle
n Fail code erasing terminal for A/T vehicle
o Engine rpm check terminal
p Engine fail code output terminal
r Ground
s Ground
2000 > 2.5L GASOLIN(K5) >
Engine control system components

2000 > 2.5L GASOLIN(K5) >
Diagnostic trouble codes diagnosis
Diagnostic
Items Diagnosis Fault type
Trouble code
Intake air mass is lower than 3kg/h when throttle
GND short,
angle is higher than 4.2° after engine starting except
Mass airflow (MAF) sensor Open
P0100 fuel cut-off operation
circuit malfunction
Intake air mass is higher than 700kg/h when engine
Battery short
is running after starting
IAT sensor signal is higher than 244°F (118°C)
SND short
Intake air temperature (IAT) approx. 60 seconds after engine starting
P0110
sensor circuit malfunction IAT sensor signal is lower than -36°F (-38°C) approx. Battery short,
60 seconds after engine starting Open
ECT sensor signal is higher than 280°F (138°C)
Engine coolant temperature GND short
approx. 60 seconds after engine starting
P0115 (ECT) sensor circuit
malfunction ECT sensor signal is lower than -36°F (-38°C) Battery short,
approx. 60 seconds after engine starting Open
TP sensor voltage is lower than 0.1V when ignition
GND short
Throttle position (TP) sensor switch is turned ON
P0120
circuit malfunction TP sensor voltage is higher than 4.86V when ignition Battery short,
switch is turned ON Open
Heated oxygen sensor
P0130 (HO2S) (Bank 1) circuit - HO2S voltage is lower than 0.06V after sensor GND short
malfunction heater operating
Heated oxygen sensor - HO2S voltage is higher than 1V after sensor heater
P0150 (HO2S) (Bank 2) circuit operating Battery short
malfunction
Heated oxygen sensor
P0135 heater (Bank 2) circuit - Signal above upper limit when ignition switch turned
malfunction ON Battery
- Signal below lower limit when ignition switch turned GND short
Heated oxygen sensor ON Open
P0155 heater (Bank 2) circuit - No signal when ignition switch turned ON
malfunction
P1166 Feed back system (Bank 1) - Adaptive air/fuel ratio correction is below lower limit Rich
P1167 Feed back system (Bank 2) - Adaptive air/fuel ratio correction is above upper limit Lean
Cyl. no.1 injector circuit

P0201
malfunction
- Signal above upper limit when engine speed is
P0202 Cyl. no. 2 injector
above 25 rpm Battery short
P0203 Cyl. no. 3 injector - Signal below lower limit when engine speed is GND short
P0204 Cyl. no. 4 injector above 25 rpm Open
- No signal when engine speed is above 25 rpm
Signal below lower limit when fuel pump relay is not
Fuel pump relay circuit GND short, open
P0230 operating
malfunction
Signal above upper limit when fuel relay is operating Battery short
NO CKP sensor signal No signal
Crankshaft position (CKP)
P0335 Valid crankshaft slot detected but synchronization not
sensor circuit malfunction Invalid signal
successful
Number of crankshaft slots is not correct (<56 slots
or >60 slots)
NO CMP sensor signal when CKP sensor is not
NO signal
Camshaft position (CMP) faulty
P0340
sensor circuit malfunction CMP sensor is detected out of window range of CKP
Invalid signal
sensor when CKP sensor is not faulty
Signal below lower limit when ignition switch turned
ON GND short
EVAP canister valve circuit Battery short
P0443 Signal above upper limit when ignition switch turned
malfunction
ON
No signal when ignition switch turned ON Open
NO VSS signal for more than 4 seconds when
Vehicle speed sensor circuit engine speed is above 2688 rpm, intake air mass is
P0500 -
malfunction more than 272mg/TDC, and engine coolant is above
140°F(60°C)
P0606 ECM Internal malfunction is ECM -
IAC valve (Opening coil) Signal below lower limit when ignition switch turned
P1505 ON GND short
circuit malfunction
Signal above upper limit when ignition switch turned Battery short
IAC valve (Closing coil) ON Open
P1507
circuit malfunction NO signal when ignition switch turned ON
Signal below lower limit when VICS valve is not GND short,
VICS valve circuit operating Open
P1523
malfunction Signal above upper limit when VICS valve is
Battery short
operating
Cooling fan relay (Low - Signal below lower limit when each cooling fan is
P1672 GND short,
speed) circuit malfunction not operating
Open Battery
Cooling fan relay (High - Signal above upper limit when each cooling fan is
P1673 short
speed) circuit malfunction operating
GND short,
Main relay circuit Signal below lower limit
P1699 Open
malfunction
Signal above upper limit Battery short
USING THIS SECTION

1. Introduction
2. Work flow
Diagnostic Symptom Index
Symptom Diagnosis Charts

1. Description : Further describes the symptom. Confirm that the chart addresses the actual symptom before beginning
troubleshooting
2. Troubleshooting Hints : This describes the possible point of malfunction.
3. Step : This shows the order of troubleshooting. Proceed with troubleshooting as indicated.
4. Check : This describes an inspection to determine the malfunction of parts quickly.
5. Remedy : This recommends the appropriate action to take as a result (Yes/No) of the check.
DIAGNOSTIC SYMPTOM INDEX
NO. TROUBLESHOOTING ITEM DESCRIPTION
1 Will not crank or cranks slowly Refer Engine Electrical System
Engine cranks at normal speed but shows only partial
2 No combustion
combustion and will not continue to run
Cranks normally but Partial combustion Engine cranks at normal speed but shows only partial
3
will not start Engine cold combustion and will not continue to run
Partial combustion Engine start normally when cold, but will not start after running
4
after warm-up and hot soaked
Engine cranks at normal speed but requires excessive cranking
5 Always
time before starting
Cranks normally but Same condition as No.5 after running and cold; restarts normally
6 When engine is cold
hard to start after warm-up
Same condition as No.5 after running and hot soaked; starts
7 After warm-up
normally when cold
8 Always Engine stalls or vibrates excessively at idle.
9 Rough idle Before warm-up Engine stalls or vibrates excessively at idle during warm-up
(Low idle
speed/engine stalls at Engine runs normally at idle during warm-up but vibrates
10 After warm-up
idle) excessively or stalls after warm-up
11 When A/C ON Engine stalls or vibrates excessively at idle when A/C ON
Engine stalls or vibrates excessively only just after starting
12 Rough idle/engine stalls just after starting
(acceleration from idle)
13 High idle speed after warm-up Idle speed excessive after warm-up
14 Idle moves up and down/idle hunting Engine speeds up and down periodically at idle
Engine unexpectedly stops running while decelerating or after
15 Engine stalls on deceleration
deceleration
16 Engine stalls suddenly (intermittent) Engine intermittently stops running
Flat spot occurs just after accelerator depressed or mid jerking
17 Stumbles/hesitates on acceleration
occurs during acceleration
18 Surges while cruising Unexpected change in engine speed which is usually repetitive
Performance poor under load when throttle valve wide open
19 Lack of power
Maximum speed reduced
20 Poor acceleration Performance poor while accelerating
Engine runs rough while decelerating and abnormal combustion
21 Runs rough on deceleration/backfire
occurs in exhaust system
22 Knocking Abnormal combustion accompanied by audible "pinging" noise
23 Fuel odor Gasoline odor in cabin
24 High oil consumption Oil consumption excessive
Kia Data Pro Scan Tool does not indicate Diagnostic Trouble
25 MIL always ON
Code but MIL always ON
26 MIL never ON Kia Data Pro Scan Tool indicates malfunction
27 A/C does not work Blower fan operates but magnetic clutch does not operate
Driveability Definitions
Stumble : Mild jerking during acceleration.
Hesitation : Delay in increase in engine speed occurring just after the accelerator pedal is depressed.
Surge : Continuous soft jerking during cruise.
Precautions for Symptom Diagnosis

Fuel System Pressure Release
The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnectingany fuel line to reduce the chance of personal injury or fire damage to vehicle components.
Fuel is explosive. An empty fuel tank can still contain explosive gases.
Supply adequate ventilation to the work area. Do not smoke, and keep sparks and open flames away. Refer to fuel
system for fuel system pressure release procedures.
SYMPTOM DIAGNOSIS CHARTS
2 Cranks normally, but will not start (no combustion)
· Cranks normally, but no combustion
Description · Battery is OK
· Throttle valve closed while cranking
(Troubleshooting hint)
No fuel injection to engine because of fuel shortage or no ignition in all cylinders.
No spark
· Ignition control malfunction
· Malfunction of ignition system component
No fuel injection
· Malfunction of fuel pump
· Malfunction of injector
Low fuel line pressure
Low engine compression pressure
Step Check Remedy
Check for a strong blue spark plug with spark Yes Go to step 5.
1 plug wire disconnected.
Is blue spark present? No Go to next step.
Malfunction indicator light is illuminated.

Check that malfunction indicator light is Yes Check for causes. Refer to troubleshooting
2 illuminated while ignition switch is ON. with diagnostic trouble codes.
Does MIL remain ON after engine start-up?
No Go to next step.
Check ignition system.
3 Check resistance of DLI coils. Yes Go to next step.
Primary : Approx. 0.36-0.44Ω
Secondary : 10.9 - 13.3Ω
Check wiring harness between ECM and DLI
coil. No Replace ignition coils or repair wiring harness.
Is resistance within specification?
Check spark plug wires.
Yes Go to next step.
Resistance : 16kΩ/m
4
Check for damage to spark plug wires.
No Replace spark plug wires.
Check if engine starts on this condition.
Connect data link connector terminals Fuel - Check fuel pump relay or wiring harness if
pump and B+ with a jumper wire and check Yes
5 engine starts.
operational sound of fuel pump. - Go to step 7 if engine does not start.
Does fuel pump operate?
No Go to next step.
Check continuity of fuel pump (between
Check that battery voltage is applied on GRN/YEL and BLK).
Yes
6 GRN/YEL fuel pump connector when ignition - If there is continuity, replace fuel pump.
switch is ON. - If there is no continuity, repair ground circuit.
No Repair related wiring harness.
Crank engine and check operational sound of Yes Go to step 10.

7
injector No Go to next step.
Check that battery voltage is applied on Yes Go to next step.

8
injector connector when ignition is running. No Check wire between main relay and injector.
9 Check that the resistance of injector is 14.5Ω.
No Replace injector.
High pressure :
Disconnect return line from fuel filter side.
Connect the data link connector terminals Fuel Blow through line towards tank.
pump and B+ with a jumper wire and check If line is clear, try with new pressure regulator.
fuel line pressure while ignition switch is ON. If line is blocked, check for blockage in return
Fuel line pressure : 43~46 psi (294~314 kPa, line and clean or replace as necessary.
10
3.0~3.1 kg/cm²) No Low pressure :
(on condition that vacuum hose is
Block return line and check if pressure rises.
disconnected from pressure regulator)
If pressure rises, replace pressure regulator.
Is fuel line pressure within specification?
If pressure does not rise, check fuel filter at
fuel delivery module.
If it is OK, measure fuel pump max. pressure
and replace as necessary.
Check engine compression pressure. Check engine condition :
Engine compression pressure : 193 psi (1360 - Wear of piston, piston ring and cylinder wall
11 kPa, 13.6 kg/cm²) at 290 rpm - Defect of cylinder head gasket
Is engine compression pressure within No
- Deformation of cylinder head
specification? - Improper valve clearance
- Valve stuck to guide
Check condition of all spark plugs.
Spark plug gap : 0.039~0.043 in (1.0~1.1mm) Yes Go to next step.
12 Check for excessive carbon deposit and
correct contact with spark plug wires. No Clean or replace.
Are spark plugs OK?
13 Check crankshaft position sensor. Yes Go to next step.
Is crankshaft position sensor OK? Check crankshaft position sensor and related
No
wire harness.
14 Replace ECM and check for proper operation.
3 Cranks normally, but won't start (partial combustion)-When engine is cold

· Cranks normally, but partial, not continuous, combustion occurs
· Fuel present in tank
Overrich air/fuel ratio
· Clogged air cleaner element
· Malfunction of mass air flow sensor
Overlean air/fuel ratio
· Incorrect fuel injection control (correction for engine coolant temperature)
· Low fuel line pressure
· Air leakage at intake system
Step Check Remedy
1 illuminated. with diagnostic trouble codes.
Does MIL remain on after engine start-up?
No Go to next step.
Disconnect spark plug. Yes Go to next step.
2 Crank engine and check for spark at plug wire
terminal. Is spark OK? No Replace ignition coil or repair wiring harness.

High pressure :
Connect the data link connector terminals fuel Blow through line towards tank.
pump and B+ with a jumper wire and check If line is clear, try new pressure regulator.
fuel line pressure with ignition switch is ON. If line is blocked, check for blockage in return
3
If it is OK, measure fuel pump max pressure
4 Do injector operate while cranking engine? Check that battery voltage is applied on
No injector connector and check wire between
main relay and injector.
Check resistance of injector. Yes Go to next step.
5 Resistance : 14.5Ω
Is resistance within specification? No Replace injector.
Crank condition of IAC valve. Yes Go to next step.

Check for open circuit between IAC valve and
ECM. Check battery voltage is applied to Open circuit or incorrect voltage :
6 - Repair wiring harness incorrect IAC valve
BLU/YEL wire of IAC valve with engine No
running. resistance :
Is IAC valve OK? - Replace IAC valve
Check terminal voltage of MAF sensor, throttle
position sensor, ignition coils and engine
7
coolant temperature sensor.
No Repair as necessary.
Are sensors functioning properly?
8 Check if MAF sensor is OK.
No Replace MAF sensor.
Check engine coolant temperature sensor
- If normal : check wiring harness between
Check that engine starts when engine coolant Yes engine coolant temperature sensor and ECM
9 temperature sensor connector is disconnected. - If not normal : replace engine coolant
Does engine start? temperature sensor.
No Go to next step.
Check air leakage at intake system Yes Repair or replace.

10
components. No Go to next step.
Check engine compression pressure. Check engine condition.
Check condition of spark plug.
Spark plug gap : 0.039~0.043 in (1.0~1.1 mm) Yes Go to next step.
12 - Excessive carbon deposit
- Contact with high spark plug wire No Clean or replace.
Are spark plugs OK?
4 Cranks normally, but won't start (partial combustion) - After engine is warmed up
· After engine is left hot after running, cranking speed is OK
· Engine starts normally when engine is cold
· Correction for coolant temperature
· Fuel leakage at injector
Vapor lock occurs
· Fuel pressure decrease after engine stops
Step Check Remedy
Warm up engine to normal operating
temperature and stop engine. Connect data Yes Replace fuel with another brand.
link connector terminal fuel pump and B+ with
1
a jumper wire for 3 minutes while ignition
switch in ON. Then check that engine starts. No Go to step 2.
Does engine start?
Connect data link connector terminals fuel Yes Go to next step.
pump and B+ with a jumper wire and check
High pressure :
fuel line pressure while ignition switch is ON.
2 Fuel line pressure : 43~46 psi (294~314 kPa,
Blow through line towards tank.
3.0~3.1 kg/cm²) No
If line is clear, try new pressure regulator.
If line is blocked, check for blockage in return
line and clean or replace as necessary.
Low pressure :
Is fuel line pressure within specification? If pressure does not rise, check fuel filter at
Plug fuel pressure regulator outlet and check Yes Replace fuel pressure regulator.
that fuel pressure is retained while ignition
switch is OFF.
3 Fuel line pressure : 25 psi (180 kPa, 1.8 Check fuel pump pressure is kept
kg/cm²) for 15 minutes No - If normal : check fuel leakage from injector
Is fuel line pressure retention within - If not normal : replace fuel delivery module.
specification?
Check engine coolant temperature sensor.
- If normal : check wiring harness between
Check that engine starts when engine coolant Yes engine coolant temperature sensor and ECM
4 temperature sensor connector is disconnected. - If not normal : replace engine coolant
Does engine start? temperature sensor
No Go to next step.
Malfunction indicator light is illuminated. Check
Check if malfunction indicator light is Yes for causes. Refer to troubleshooting with
5 illuminated while ignition switch is ON. diagnostic trouble codes.
Is MIL remain ON after engine start-up?
No Go to next step.
6
No Check for causes.
Are sensor terminals voltage correct?
5 Cranks, normally, but hard to start - Always

· Cranks normally, but cranking time up to starting is excessively long
· Engine is normal while engine is idling (Refer to "Rough ldling" if not in good idling condition)
· Incorrect fuel injection control (correction for engine coolant temperature)
· Air leakage at intake system
· Malfunction of manifold absolute pressure sensor
Spark plugs not in good condition
Step Check Remedy
Check if malfunction indicator light is Yes Check for causes. Refer to troubleshooting
Does the MIL remain ON after engine start-up?
No Go to next step.
Check intake manifold vacuum while engine is
idling.
2
Vacuum : more than 18.9 inHg (480 mmHg)
No Check air leakage at intake system.
Is intake manifold vacuum within specification?
Check cleanness of air cleaner element. Yes Go to next step.
3
Is air cleaner element OK? No Check air leakage at intake system.
Check if engine starts easily when throttle Check carbon deposit on throttle valve and go
Yes
4 valve is held one quarter open. to step 6.
Does engine start easily? No Go to next step.
High pressure :
Check fuel line pressure while engine is idling. If line is clear, try new pressure regulator.
Fuel line pressure : 43~46 psi (294~314 kPa, If line is blocked, check for blockage in return
3.0~3.1 kg/cm²) line and clean or replace as necessary.
5
(on condition that vacuum hose is No Low pressure :
Check condition of IAC valve. Check for open
circuit between IAC valve & ECM. Measure Yes Go to next step.
6 Battery voltage is applied to BLU/YEL wire
engine running. No Check for causes.
Is IAC valve OK?
Connect data link connector terminals Fuel Check fuel pump relay.
Pump and B+ with a jumper wire and check Yes - If normal, repair or replace wiring harness.
7 - If not normal, replace relay.
that engine starts.
Does engine start? No Go to next step.
Yes Clean or replace.
8 Check if map sensor is OK.
No Go to next step.
Check engine compression pressure Check engine condition.
Check spark plug condition.
Spark plug gap : 0.039~0.043 in (1.0~1.1mm). Yes Go to next step.
10 Check for excessive carbon deposit and
correct contact with spark plug wires. Are No Clean or replace.
spark plugs OK?
6 Cranks normally, but hard to start - When engine is cold

· Cranks normally, but cranking time up to starting is excessively long
· Battery is OK
Description
· Restart is normal after engine warmed up
· Engine is normal while engine is idling (Refer to "Rough Idling" if not in good idling condition)
· Contaminated air cleaner element
· Malfunction of injection control (Correction for engine coolant temperature)
Step Check Remedy
Check if malfunction indicator light is Yes Check for causes. Refer to Troubleshooting
No Go to next step.
2
Are sensor OK?
Check if engine starts easily when throttle Check carbon deposit on throttle valve and go
Yes
3 valve quarter open. to step 6.
Does engine start easily? No Go to next step.
Check vacuum in intake manifold while engine Yes Go to next step.
is idling.
4 Check air leakage at intake air system
Vacuum : more than 18.9 inHg (480 mmHg) No
Is intake manifold vacuum within specification? component.

5
Is air cleaner element OK? No Replace air cleaner element.
High pressure :
Connect the data link connector terminals Fuel Blow through line towards tank.
pump and B+ with a jumper wire and check If line is clear, try new pressure regulator.
fuel line pressure while ignition switch is ON. If line is blocked, check for blockage in return
6
Replace ECM and check for proper operation. Yes Road test and return vehicle to customer.
7
Is system operating correctly? No Replace fuel another brand.
7 Cranks normally, but hard do start-After engine is warmed up

· After engine is left hot after running, cranks normally, but cranking time up to starting is excessively long
· Battery is OK
Description
· Starts normally when engine is cold
· Engine is normal while engine is idling (Refer to "Rough ldling" if not in good idling condition)
Overrich air/fuel ration
· Malfunction of fuel ratio calculation
· Fuel leakage from injector
Vapor lock
Step Check Remedy
No Go to next step.
Check terminal voltage of mass airflow sensor,
throttle position sensor, ignition coils and
2
engine coolant temperature sensor.
Are sensors OK?
After engine idling and turn ignition switch Plug outlet of fuel pressure regulator and turn
OFF. ignition switch OFF. Then check that fuel line
Check that fuel line pressure is retained. Pressure is retained.
3 Fuel line pressure : more than 25 psi (180 kPa, - If normal : replace fuel pressure regulator
1.8 kg/cm²) for 15 minutes No
- If not normal : check fuel pump pressure
Is fuel line pressure retention within kept.
specification? If fuel pump is normal, check fuel leakage from
injector.
temperature and stop engine. Connect data Yes Replace fuel with another brand.
link connector terminals fuel pump and B+ with
4 a jumper wire for 3 minutes while ignition
switch is ON. Then check that engine starts
easily. No Go to next step.
Does engine start easily?
5
Is system operating correctly? No Replace fuel with another brand.
8 Rough idling / Engine stops while idling - always

Description · Engine starts normally, but engine stops or vibrates while idling.
· Air leakage
· Malfunction if fuel injection control
Clogging or malfunction of one or more injector
Malfunction of malfunction of one or more injector
Malfunction of IAC valve or related wiring
Malfunction of spark plug
Malfunction of throttle position sensor or related wiring
Step Check Remedy
No Go to next step.
2
Are sensors OK?
Check operating sound of injector while engine Yes Go to step 5.
3 idling.
Are injectors operating? No Go to next step.
Check that voltage is applied to injector Yes Go to next step.
connectors while engine is running (approx.
4 Check the wiring harness between ECM and
12V). No
Is voltage within specification? injector.
Check the resistance of injector. Yes Go to next step.

Ignition ON, throttle closed, measure voltage Yes Go to next step.

6 of throttle position sensor (0.4~0.8V). Replace throttle position sensor or repair
Is voltage within specification? No
wiring harness.
No Replace MAF sensor.
Check engine compression pressure.
Engine compression pressure : 193 psi (1360 Check engine condition.
8 kPa, 13.6 kg/cm²) - 290 rpm - Wear of piston, piston ring and cylinder wall
Is engine compression pressure within No - Defect of cylinder head gasket
specification? - Deformation of cylinder head
9 Rough idling / engine stops while engine is idling - engine cold

Description · Engine speed is slow, engine stops or vibrates while warming up engine.
Insufficient intake air.
· Malfunction of IAC valve
Malfunction of fuel injection control.
· Malfunction of fuel injection control devices
(correction for engine coolant temperature)
Step Check Remedy
No Go to next step.
Check intake manifold vacuum at dynamic
chamber while engine is idling.
2
Vacuum : 18.9 inHg (480 mmHg) at idle
No Check for air leakage in intake system.

3
throttle position sensor, ignition coils, engine
4
Are sensors OK?
Check resistance of engine coolant
temperature sensor.
- At -4°F(-20°C) : 14.6 to 17.8 kΩ
5
- At 68°F(20°C) : 2.2 to 2.7 kΩ Replace the engine coolant temperature
- At 176°F(80°C) : 0.29 to 0.35 kΩ No
sensor.
6
10 Rough idling / engine stops while engine is idling - After engine is warmed up
Description · Engine operation is normal while warming up engine, but engine stops or vibrates after warming up.
Malfunction of IAC valve
· Air leakage
Malfunction of ignition system
· Malfunction of fuel injection control
(correction for coolant temperature)
Step Check Remedy
No Go to next step.
2
Are sensors OK?
Check vacuum of intake manifold. Yes Go to next step.

3 Vacuum : more than 18.9 inHg (480 mmHg) at Check for air leakage at intake system
idle No
component.

4
Is air cleaner element OK? No Replace air cleaner.
High pressure :
5
Disconnect engine coolant temperature sensor Replace the engine coolant temperature
connector and check that engine condition Yes
6 sensor.
improves.
Does engine condition improve? No Go to next step.
7 is idling.
Are injectors operating? No Go to next step.
8 Check resistance of injector Yes Go to step 10.

Resistance : 14.5 Ω

Engine compression pressure : 193 psi (1360 Yes Go to next step.
9 kPa, 13.6 kg/cm²) at 290 rpm
Is engine compression pressure within No Check engine
specification?
11 Rough idling / Engine stops while engine is idling - When A/C is in operation
· Engine stops or vibrates excessively when A/C is operating.
Description
· Idling condition is normal when A/C is turned OFF.
Malfunction of IAC control system
Malfunction of A/C operational switch
Step Check Remedy
No Go to next step.
Check air conditioner cut relay is ON/OFF Yes Go to next step.

2 when air conditioner switch is ON/OFF. Malfunction of air conditioner switch or air
Are A/C cut relay and A/C switch OK? No
conditioner cut relay.
Is there continuity between C25, C29, C51 and Yes Go to next step.
3 C251-29 of ECM.
Does continuity exist? No Repair wiring harness.
12 Abnormal idling / engine stops immediately after starting

· Starting is normal, but engine vibrates excessively or stops immediately after starting (when accelerating
Description from idling condition)
· Idling condition is normal on other conditions.
Malfunction of IAC system
Air leakage at intake system
Malfunction of manifold absolute pressure sensor
Step Check Remedy
No Go to next step.
No Repair MAF sensor or related wiring harness.
Check that voltage of throttle position sensor Yes Go to next step.

3 terminal is 0.4~0.8V and does not vary. Replace throttle position sensor or wiring
harness.
Check for air leakage at intake system and
4 vacuum of dynamic chamber while engine is Yes Go to next step.
idling.
Vacuum : more than 18.9inHg (480 mmHg) No Check intake system and dynamic chamber.
13 High idle speed after engine warmed up

Description · Excessively high idle speed after engine warmed up
Excessive intake air flow
Throttle valve not closed completely
Malfunction of idle speed control
· IAC valve stuck
· IAC valve connector disconnected
· Incorrect input signal from coolant temperature sensor
Step Check Remedy
Check that throttle valve is closed completely
1 when accelerator pedal is released. Check correct installation and free operation of
Is throttle valve closed? No throttle linkage. If not normal, clean or adjust
linkage.
No Go to next step.
Disconnect engine coolant temperature sensor
Yes Replace engine coolant temperature sensor.
connector and check if engine condition
3
improves.
No Go to next step.
Does engine condition improves?
Replace throttle position sensor or wiring
Check that voltage of throttle position sensor Yes
4 harness.
terminal is 0.4~0.8V and does not vary.
No Go to next step.
Check ECM terminal voltage.
- IAC valve control Yes Go to next step.
5 - A/C request input
- Park/neutral input No Replace as necessary.
Are voltage correct?
14 Variation of idle speed / Idle hunting

Description · Periodic engine speed increase and decrease while engine is idling
Malfunction of throttle position sensor system
Air leakage
Fuel injection is irregular
Step Check Remedy
No Go to next step.
Check that voltage of throttle position sensor Yes Go to next step.
2 terminal is 0.4~0.8V and does not vary. Replace throttle position sensor or wiring
harness.
Check air cleaner element. Yes Go to next step.

3
Disconnect high tension cord and check equal Yes Go to next step.
4
engine speed decrease in all cylinders. No Go to step 7.
Check ECM terminal voltage.
· IAC valve control Yes Go to next step.
5 · A/C request input
· Park/neutral input No Check for causes.
Are voltage correct?
No Replace the MAF sensor.
7 is idling.
Are injectors OK? No Go to next step.
Check that approx. battery voltage is applied Yes Go to next step.

8 to injector connector terminals. Check the wiring harness between ECM and
injector.
Check resistance of injector. Yes Go to next step.
Check spark plugs for proper operation. Yes Go to next step.

10
Are spark plugs OK? No Clean or replace.
Engine compression pressure : 193 psi (1360 Yes Go to next step.
11 kPa, 13.6 kg/cm²) at 290 rpm
Is engine compression pressure within No Check for cause.
specification?
Check for fuel leakage from injectors. Yes Replace the injector.
12
Do injectors leak? No Go to next step.
15 Engine stalls on deceleration

· Engine stops unexpectedly during or after deceleration
Description
· Idling condition is normal
Engine speed decreases abruptly when accelerator pedal is released, which can cause connectors to come loose.
Malfunction of idle air control
Malfunction of fuel cut control
Step Check Remedy
Check that malfunction indicator light is Yes Check for causes. Refer to Troubleshooting
1 illuminated while ignition switch is ON. with Diagnostic Trouble Codes.
No Go to next step.
2 Check throttle position sensor, IAC valve Yes Go to next step.
terminal voltage and related wiring harness. Repair the wiring harness or replace defective
Are sensors OK? No
component.
Check ECM terminal voltages for C46, C47, Yes Go to next step.
3 C19, C10 and C20.
Are voltage within specification? No Check for cause and repair as necessary.
Check contact condition of the following

connectors : Yes Go to next step.
- Throttle position sensor, mass airflow
4
pressure sensor, ignition coils, injector,
crankshaft position sensor, ECM. No Repair or replace.
Are terminal connections OK?
16 Engine stalls suddenly (intermittent), sudden engine stop

· Engine stops suddenly and intermittently
Description
· Engine is normal until engine stops
Intermittently loosened electrical contact.
Step Check Remedy
No Go to next step.
Check contact condition of the following
connectors : Yes Go to next step.
- Throttle position sensor, mass air flow
2
sensor, ignition coils, injector, crankshaft
position sensor ECM. No Repair or replace as necessary.
Are connections OK?
Measure crankshaft position sensor and Yes Go to next step.
3 manifold absolute pressure sensor signals.
Are sensor signals OK? No Repair or replace.
4 C19, C10 and C20.
Are voltages OK? No Check for cause and repair as necessary.
17 Stumble / Hesitation on acceleration

· Vehicle seems to stop for a time immediately after pressing accelerator or rattles a little during
Description
acceleration
Lean air/fuel ration on acceleration
· Air leakage
· Malfunction of fuel injection control
Step Check Remedy
Check that malfunction indicator light is Malfunction indicator light is illuminated. Check
1 illuminated while ignition switch is ON. Yes for causes. Refer to troubleshooting with
Does the MIL remain ON after engine start-up? diagnostic trouble codes.
No Go to next step.
idling.
2 Check air leakage at air intake system and
Is intake manifold vacuum within specification? repair.

3
Check if MAF sensor is OK. Yes Go to next step.

4
Is MAF sensor OK? No Replace MAP sensor.
Check engine coolant temperature sensor.
5 Replace the engine coolant temperature
Is ECT sensors OK? No
sensor.
Check throttle position sensor.
Voltage between terminals : Yes Go to next step.
6 Idling condition : 0.4~0.8V
Throttle valve full open : 4.0~4.4V No Replace the throttle position sensor.
Is TP sensor OK?
Disconnect injector connector one by one
while engine is idling, and check equal engine Yes Go to next step.
7 speed decrease for each cylinder.
Does engine speed decrease equally for all No Check injector. Refer to Fuel System.
cylinders?
Check correct installation and free operation of Yes Go to next step.

8 throttle linkage. Adjust or replace joint or damaged linkage and
Is throttle linkage OK? No
adjust deflection of throttle cable.
High pressure :
9
Check air passage and vacuum hose Yes Go to next step.
10 installation.
Are vacuum hoses OK? No Repair as necessary.
Check exhaust system clogging. Yes Repair or replace necessary.

11
Is exhaust system clogged? No Go to next step.
18 Surging while cruising

Description · Repeated engine speed variation occurs at all times
Misfire
Intermittent electrical connection
Lean air/fuel ratio
Step Check Remedy
Malfunction indicator is illuminated. Check for
Check that malfunction indicator light is Yes causes. Refer to troubleshooting with
No Go to next step.
idling.
2 Check air leakage at air intake system and
Is intake manifold vacuum within specification? repair.

Is TP sensor OK?
Disconnect front heated oxygen sensor Yes Go to next step.
4 connector and check for proper operation.
Is HO2S OK? No Replace front heated oxygen sensor.
Check that vehicle speed sensor signal input Yes Go to next step.
5
to ECM D22. Is correct. Is signal correct? No Repair wiring harness or vehicle speed sensor.
Check ECM terminal voltages for C19, C10 Yes Go to next step.
6 and C20.
Are voltages OK? No Check for causes and repair.
Check correct installation and free operation of Yes Go to next step.

7 throttle linkage. Adjust or replace joint or damaged linkage and
Is throttle linkage OK? No
adjust deflection of throttle cable.

8
High pressure :
9
Check exhaust system clogging. Yes Repair as necessary.

10
Is exhaust system clogged? No Go to next step.
19 Lack of power
· Lack of power at full throttle
Description · Lower maximum vehicle speed
· Idling speed is normal
Insufficient intake air
· Throttle valve does not open fully
· Clogged intake air system
Lean air/fuel ratio
· Fuel line pressure decrease.
· Malfunction of fuel injection.
Malfunction of ignition
Step Check Remedy
Check the following items.
- Clutch slippage Yes Go to next step.
- Brake dragging
1
- Lack of tire air pressure
- Improper tire size No Repair as necessary.
Are these systems OK?
Is throttle valve open full when depressing Yes Go to step 5.

2
accelerator pedal fully? No Go to next step.
Check correct installation of throttle cable. Yes Go to next step.

3
Is throttle cable OK? No Repair or adjust throttle cable.
Check correct operation of throttle body. Yes Go to next step.

4
Is throttle body OK? No Repair or replace throttle body.
Check that malfunction indicator light is Yes Check for causes. Refer to trouble shooting
No Go to next step.
Replace camshaft position sensor or repair
Check the camshaft position sensor. Yes
6 related wire harness.
Is CMP sensor OK?
No Go to next step.
Check the camshaft position sensor.
Is TP sensor OK?
Check vacuum in intake manifold while engine
is idling.
8
No Repair intake system or dynamic chamber.
Disconnect injector connector one by one
while engine is idling, and check equal engine Yes Go to next step.
9 speed decrease for each cylinder.
Does engine speed decrease equally for each No Check injector. Refer to fuel system.
cylinder?

10
11 Keep engine idling and turn ignition switch Yes Go to next step.
Plug outlet of pressure regulator and turn
OFF. ignition switch OFF. Then check fuel line
Check that fuel line pressure is retained. pressure is retained.
Fuel line pressure : more than 25 psi (180 kPa, No - If normal : replace pressure regulator
1.8 kg/cm²) for 15 minutes - If not normal : check fuel pump
Is fuel pressure retention within specification? If fuel pump is normal, check fuel leakage from
injector.
Does fuel line pressure increase when Yes Go to next step.
accelerating abruptly?
12 Check fuel line and fuel filter clogging and
Fuel line pressure : 48 psi (330 kPa, 3.3 No
kg/cm²) repair if as normal.
Check the MAF sensor. Yes Go to next step.

13
Is MAP sensor OK? No Replace MAF sensor.
- Check resistance of DLI coil Yes Go to next step.
Primary : 0.36~0.44Ω
14 secondary : 10.9~13.3Ω
- Check wiring harness between DLI coil and
ECM No Replace ignition coils or repair wiring harness.
Is ignition system OK?
Check spark plug wires. Yes Go to next step.

15
Are spark plug wires OK? No Replace spark plug wires.
Check spark plug. Yes Go to next step.

16
Are spark plugs OK? No Clean or replace.
- Valve guide stuck
Replace ECM and check for proper operation. Yes Road test and return vehicle tp customer.
18
20 Poor acceleration/Lack of power

· Lack of power on acceleration
· Lack of power at full throttle
Description
· Lower maximum vehicle speed
· Idling speed is normal
Factors except engine malfunction
· Clutch slippage
· Brake dragging
· Lack of tire air pressure
· Improper tire size
· Overload
Insufficient intake air
· Throttle valve does not open fully
· Intake system clogging
Step Check Remedy
Are the following factors OK?
- Clutch slippage Yes Go to next step.
- Brake dragging
1 - Lack of tire air pressure
- Improper tire size
- Overload No Repair as necessary.
Are the items OK?
Is throttle valve open full when depressing Yes Go to step 5.

2

3
Is throttle cable OK? No Repair or adjust throttle cable.
Check correct operation of throttle body. Yes Go to next step.

4
Is throttle body OK? No Repair or replace throttle body
No Go to next step.
Check camshaft position sensor and Yes Go to next step.

6 connector. Replace camshaft position sensor or repair
Is CMP sensor OK? No
related wire harness.
Throttle valve fully open : 4.0~4.4V No Replace throttle position sensor.
Is TP sensor OK?
is idling.
8 Check air leakage into intake system and
Is intake manifold vacuum within specification? repair as necessary.
Disconnect injector connector one by one Yes Go to next step.

9 while engine is idling. Is there an equal engine
speed decrease for each cylinder? No Check injectors. Refer to fuel system.
Check cleanness of air cleaner element. Yes Go next step.

10
High pressure :
Disconnect return line from fuel side.
Fuel line pressure : 46~51 psi (320~350 kPa, if line is blocked, check for blockage in return
11
12 Does fuel line pressure increase when Yes Go to next step.
accelerating abruptly.
Fuel line pressure : 48 psi (330 kPa, 3.3 Check fuel line and fuel filter clogging and
No
kg/cm²) repair as necessary.
Check the MAF sensor. Yes Go to next step.

13
Is MAF sensor OK? No Replace MAF sensor.
Check resistance of DLI coils. Yes Go to next step.
Primary : 0.039~0.043 Ω
14 secondary : 10.9~13.3 Ω
Check wiring harness between DLI coils and
ECM. No Replace ignition coils or repair wiring harness.
Is ignition system OK?
Check spark plug wires. Yes Go to next step.

15
Are spark plug wires OK? No Replace spark plug wires.
Check spark plug
- Spark plug gap : 0.034~0.043 in (1.0~1.1 Yes Go to next step.
mm)
16
- Excessive carbon deposit
- Contact with high tension cord No Clean or replace as necessary.
Are spark plug OK?
18
21 Rough engine running on deceleration / backfire

· Rough engine running on deceleration and backfire
Description
· Transmission is normal
· Air cleaner element clogged
· Malfunction of fuel injection system(fuel cut control)
· Malfunction of throttle position sensor
Step Check Remedy
Check that malfunction indicator light is Yes Check for causes. Refer to Troubleshooting
No Go to next step.
Check vacuum in intake manifold while engine
is idling.
2
No Check air leakage at air intake system.

3
Is air cleaner element OK? No Replace air cleaner element
4 B10, B19 and B-20.
Are terminal voltages OK? No Replace air cleaner element.
Check fuel injection system. Yes Go to next step.

5
Is fuel injection system OK? No Repair injection system as necessary.
Check mass air flow sensor. Yes Go to next step.

6
Is MAF sensor OK? No Replace MAF sensor.
- Voltage between terminals
- When idling : 0.4-0.8V
- When opening throttle valve fully : 4.0~4.4V
7
- Check that idling voltage returns to specified
value when releasing after pulling accelerator
No Replace the throttle position sensor.
cable.
Is TP sensor OK?
Check throttle body contamination. Yes Clean or replace as necessary.

8
Is throttle body contaminated? No Go to next step.
Check fuel leakage from injector. Yes Clean or replace as necessary.

9
Do fuel injectors leak? No Go to step 10.
22 Knocking
Description · Abnormal combustion occurs, accompanied by audible "pinging" noise
Improper ignition timing
Carbon deposit in cylinder
Engine Overheat
· Incorrect fuel injection
· Fuel line pressure decrease on acceleration
Step Check Remedy
Check that malfunction indicator light is Yes for causes. Refer to troubleshooting with
1 illuminated while ignition switch is ON. diagnostic trouble code.
No Go to next step.
Is throttle valve open fully when depressing Yes Go to step 5.

2

3
Is throttle cable OK? No Repair of replace throttle cable.
Check correct installation of throttle body. Yes Go to next step.

4
Is throttle body OK? No Repair or replace throttle body.
6 Check camshaft position sensor. Yes Go to next step.
Is CMP sensor OK? Check camshaft position sensor and related
No
wire harness.
High pressure :
Check fuel line pressure while engine is idling If line is clear, try with new pressure regulator.
Fuel line pressure : 43 ~46 psi (294~314 kPa, If line is blocked, check for blockage in return
7
Check cooling system. Yes Go to nest step.

8
Is cooling system OK? No Repair or replace.
9
23 Fuel odor
Description · Fuel odor in passenger compartment
Loose connection of fuel system of evaporative gas control system
Malfunction of evaporative gas control system
Step Check Remedy
Check damage or leakage of fuel system or Yes Repair or replace
1 evaporative gas control system.
Are system leaking or damaged? No Go to next step.

Check that malfunction indicator light is Yes for causes. Refer to troubleshooting with
No Go to next step.
Warn up engine fully. After disconnecting
vacuum hose from evaporative emissions Yes Go to step 6.
3 canister to purge solenoid valve, check
vacuum is applied to it. No Go to next step.
Is vacuum applied?
Check operational sound of EVAP canister Yes Check vacuum goes clogging.
4 purge solenoid valve is normal.
Is EVAP canister purge valve OK? No Go to next step.
Check that vacuum is applied to vacuum hose Yes Check ECM terminal voltage.
5 after applying battery voltage to EVAP canister
purge valve. Is vacuum applied? No Replace EVAP canister purge valve.
24 High oil consumption

Description · High oil consumption
Malfunction of PCV valve
Malfunction of engine (oil leakage)
Step Check Remedy
Check damage, removal, clogging or sticking Yes Go to next step.
1 of PCV hose, or ventilation hose fittings.
Is PVC system OK? No Repair or replace as necessary.
Check engine condition :

- Wear of piston ring groove
Yes
- Malfunction of piston ring
Check that there is air pressure or oil in - Wear of piston or cylinder
2 ventilation hose. Check engine condition
Is ventilation hose OK? - Oil leakage
No -Wear of valve seal
-Wear of valve stem
-Wear of valve guide
25 MIL on continuously
· Kia power scan (Kia data pro scan tool)does not display diagnostic trouble code, but MIL light on
Description
continuously
Short circuit of wiring harness
Malfunction of ECM
Step Check Remedy
Disconnect wire (GRN/RED from ECM and Yes Replace the ECM.
1 check that MIL remains illuminated. Is MIL
illuminated? No Check short circuit from meter set to ECM.
26 MIL does not light illuminate

Description · Kia power scan displays malfunction code, but MIL does mot illuminate
Bulb is blown
Open circuit
Malfunction of ECM
Step Check Remedy
Check MKL bulb is OK. Yes Go to next step.

1
Is bulb OK? No Replace bulb.
Ground ECM wire (GRN/RED) with a jumper Yes Go to next step.
2 wire and check if MIL illuminates.
Does MIL illuminate? No Repair wiring harness from ECM to meter set.
Check ECM connections. Yes Replace ECM.

3
Are ECM connections OK? No Repair or replace ECM connector.
27 Air conditioner does not operate

Description · Blower motor operates, but magnetic clutch not engaged
Short or open circuit of wiring harness
Malfunction of air conditioner relay, air conditioner switch, magnetic switch
Malfunction of ECM
Step Check Remedy
Check voltage of ECM terminal C51. Yes Go to next step.

1
Is voltage OK? No Check for causes.
Check voltage of ECM terminal D25. Yes Check air condition system.
2
Is voltage OK? No Replace ECM.
General diagnosis
Problem Possible cause Action
Engine cranks but will not Replace fuel pressure
start regulator
Fuel pressure problem
Replace leaking injector
Replace injector O-ring
Head to start (cold engine) Replace
Idle air control valve not working
Replace throttle body
Defective throttle position sensor
Replace regulator, check
Fuel pressure too low
fuel line leakage
Engine coolant temperature sensor open circuit or out of
Repair harness
range
Replace sensor
Rough idle (cold engine) Replace injector
Fuel injector flow
Clean and adjust throttle
Throttle plate stuck open
plate
Adjust throttle cable
Throttle position sensor malfunction
Replace TP sensor
Idle air control valve inoperative
Replace
Air inteke duct disconnected between
Reconnect air duct
MAF sensor and throttle body
Leaking injector
Replace
Leaking injector O-ring seals
Replace
Stalling or hesitation (hot or
Throttle position sensor malfunction Replace TP sensor
cold engine)
Check pressure regulator of
Head start (hot engine) Incorrect fuel pressure
fuel pump
Stalls on quick stops or
Mass air flow sensor open circuit or out of range Replace TP sensor
deceleration
Check pressure regulator or
Hard start (hot engine) Incorrect fuel pressure
fuel pump
Replace MAF sensor
Stalls on quick stops or
Mass air flow sensor open circuit or out of range Check electrical circuit (see
deceleration
wiring Diagram)
Poor performance/loss of Clogged injectors Check injector flow rate
power Air filter clogged Replace
Fuel gauge shows empty at Check wiring, connectors
all fuel levels of fill and sender assembly.
Loose or dirty wiring connections or short to ground wiring
Repair clean or tighten as
needed.
Leaking sender float Replace sender.
Install float. Make sure float
Missing sender float
is secured on sender arm.
Test for correct resistance
Short circuit in sender assembly values and replace as
needed.
Inspect fuel tank and sender
Sender assembly arm movement obstructed for cause. Correct or replace
faulty component
Fuel gauge will nnot read full Check part number. If
Wrong sender installed
when tank is full incorrect, install correct part.
Sender arm movement obstructed (float rod bent) for cause. Correct or replace
faulty component.
Leaking float Install new sender.
Sender or gauge calibration value and replace
component as needed.
Check fuel tank fill vent for
kinks or obstructions.
Fuel tank not filling to rated capacity Correct as required and fill
tank to verify proper
capacity.
Fuel gauge shows full at all Check wiring, connections
fuel levels Loose or dirty wiring connections or open circuit in wiring and sender terminals. Repair
or clean if required.
Open circuit in sending unit values and replace if
required.
for cause. Gently bend float
Sender arm movement obstructed
arm away from obstruction
or replace component.
Fuel gauge reads incorrectly, Fuel sender mounting angle
but all fuel system may have changed or the
Fuel tank damage
components are running sender unit may be
properly. damaged.
2000 > 2.5L GASOLIN(K5) >
ECM terminal voltage
Terminal Signal Connected to Test condition Voltage

Key ON/Engine OFF B+
A-1 Ignition input Ignition switch
Idle B+
A-3 Diagnosis K-line Data link connector
Idle B+
A-4 Electric load ground Ground Constant <0.5V
A-5 Power 1 ground Ground Constant <0.5V
A-6 Power 2 ground Ground Constant <0.5V
A-7 Battery back up Battery Constant <0.5V
A-8 Power input Main relay
Idle B+
A-9 Power input Main relay
Idle B+
HO2S heater control Key ON/Engine OFF B+

B-1 HO2S (BANK 1)
(BANK 1) Idle 0~B+
HO2S shield (BANK
B-8 HO2S Constant <1V
1)
HO2S shield (BANK
B-9 HO2S Constant <1V
2)
HO2S input (BANK Key ON/Engine OFF B+

B-13 HO2S (BANK 1)
2) Idle 0~B+
Key ON/Engine OFF <0.5V
HO2S input (BANK
B-14 HO2S (BANK 1) Idle (air/fuel closed-loop
1) 0~1V
control)
HO2S input (BANK
B-15 HO2S (BANK 2) Idle (air/fuel closed-loop
2) 0~1V
control)
Engine coolant
Transaxle control Key ON (engine coolant
B-17 temperature signal <1.5V
module temp<168°F (70°C))
output
HO2S ground
B-20 Ground Constant <1V
(BANK 1)
HO2S ground
B-21 Ground Constant <1V
(BANK 2)
Key OFF B+
B-23 Main relay control Main relay
Key ON <1V
Key ON/Engine OFF <1V
C-1 MAF sensor input MAF sensor
Idle (after warm-up) 0.6~0.8V
C-8 CKP sensor input CKP sensor Key ON/Engine OFF <0.5V
2~3V (rectangular
Idle
wave)
Throttle position
C-10 Reference voltage Key ON 5V
sensor
Key ON (Placing transmission
<1V
Transaxle range in P/N range)
C-13 Park/Neutral input
switch Key ON (Placing transmission
B+
in other range)
C-17 MAF sensor ground Ground constant <1V
Key ON (accelerator pedal
0.4~0.8V
Throttle position released)
C-19 TP sensor
(TP) sensor input Key ON (accelerator pedal fully
4~4.4V
depressed)
C-20 TP sensor ground Ground constant <1V
C-21 CKP sensor ground Ground constant <1V
Intake Air
Key ON (intake air temperature
C-22 Temperature (IAT) IAT sensor Approx. 3.7V
at 68°F (20°C))
sensor input
C-23 IAT sensor ground Ground constant <1V
Engine coolant
Key ON (Engine coolant
C-24 temperature (ECT) ECT sensor Approx. 1.4V
temperature at 176°F (80°C))
sensor input
C-25 ECT sensor ground Ground constant <1V
Transaxle control
C-26 Torque signal output Idle 8~10V
module
C-33 Fuel injector control Fuel injector #1
Idle B+
Idle B+
C-35 Fuel injector control Fuel injector #5 Idle B+
Idle B+
Idle B+
Idle B+
Idle (EVAP canister purge
EVAP canister purge EVAP canister purge 10~12V (duty signal)
C-42 solenoid operating)
solenoid control solenoid valve
Idle (EVAP canister purge
B+
solenoid not operating)
C-45 Variable intake VICS valve Key ON/Engine OFF B+
system control VICS valve operating <1V
(VICS) valve control VICS valve not operating B+
Idle air control (IAC) Key ON/Engine OFF B+
C-46 valve control IAC valve
(closing coil) Idle 4~6V (duty signal)
Idle air control (IAC) Key ON/Engine OFF <1V

C-47 valve control IAC valve
(opening coil) Idle 8~10V (duty signal)
Key ON, A/C operating <1V

C-51 A/C request input A/C switch
Key ON, A/C not operating Approx. 9.8V
Key ON/Engine OFF 0V or 5V
D-7 CMP sensor input CKP sensor 4.5~4.7V
Idle
(rectangular wave)
D-8 CMP sensor ground Ground Constant <0.5V
Key ON, Fuel pump relay
<1V
Fuel pump relay operating
D-10 Fuel pump relay
control Key ON, Fuel pump relay not
B+
operating
Key ON (accelerator pedal
10~11V
TP sensor signal Transaxle control released)
D-13
output module Key ON (accelerator pedal fully
2~3V
depressed)
Engine RPM signal Instrument cluster
D-17 5~6V (rectangular
output (meter set) Idle
wave)
Key On, Cooling fan (low
<1V
Cooling fan relay Cooling fan relay speed) operating
D-18
control (low speed) (low speed) Key ON. Cooling fan (low
B+
speed) not operating
Malfunction indicator
D-20 MIL control Idle (no DTC present) B+
light
Idle (DTC present) <0.5V
Vehicle stop 0V/5V
Vehicle speed
D-22 instrument cluster 2~3V (rectangular
sensor input Vehicle rolling
wave)
A/C compressor Key ON, A/C operating <1V
A/C dual pressure
D-25 clutch operation
switch Key ON, A/C not operating Approx. 9.8V
input
Key ON, A/C operating <1V
D-29 A/C cut relay control A/C cut relay
Key ON, A/C not operating B+
Cooling fan relay cooling coil (high Key ON, Cooling fan (low
D-40 <1V
control (high speed) speed) speed) operating
Key ON, Cooling fan (low
B+
speed) not operating
Ignition coil (cyl. no. Key ON/Engine OFF B+

E-1 Ignition coil control
2&5) Idle B+

3&6) Idle B+

1&4) Idle B+
E-5 Ignition coil ground Ground constant <1V
Fuel System
Fuel System
Fuel Delivery System

2000 > 2.5L GASOLIN(K5) >
Releasing fuel system pressure
THE FUEL SYSTEM REMAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE
FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE THE CHANCE
OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONENTS.
1. Start engine.
2. Disconnect fuel pump connector located under center floor carpet.
3. Let engine stall, then turn OFF ignition switch
4. Reconnect fuel pump connector.
Fuel line handling
FUEL IS EXPLOSIVE. WHEN WORKING ON FUEL SYSTEM MAKE SURE TO SUPPLY ADEQUATE
VENTILATION TO THE WORK AREA. DO NOT SMOKE, AND KEEP SPARKS AND OPEN FLAMES
AWAY.
1. When disconnection fuel hose quick connectors, use shop towels to absorb fuel, pretecting equipment and
personnel.
Priming the fuel system

After fuel pressure has been released, system must be primed to avoid excessive cranking to restart the
engine. Follow steps below :
1. Connect data link connector terminals FUEL PUMP and B+ with a jumper wire.
2. Turn ignition switch ON for no longer than 10 seconds to pressurize system and check for fuel leaks.
(Jumper wire gets hot if it is left in for longer than 10 seconds.)
3. Turn ignition switch OFF and remove jumper wire.
Fuel pressure hold inspection

1. Disconnect negative battery terminal.
THE FUEL SYSTEM REMAINS UNDER PRESSURE WHEN THE ENGINE IS NOT RUNNING.
RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE
THE CHANCE OF PERSONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONENTS.
2. Release fuel system pressure. Refer to "Releasing fuel system pressure".

3. Raise a vehicle.
4. Install SST (0K2A1 141 001A) to fuel filter as descried below.
5. Connect negative battery terminal.

6. Connect data link connector terminals FUEL PUMP and B+ with jumper wire.
7. Turn ignition switch ON for 10 seconds to operate fuel pump.

9. Inspect fuel pressure after 15 minutes.
Fuel pressure : More than 25 psi (180 kPa, 1.8 kg/cm²)
10. If not as specified, check the following components :

do following inspections :
A. Fuel pump
B. Pressure regulator
C. Injectors
Fuel line pressure inspection

1. Disconnect negative battery cable.
2. Release fuel system pressure. Refer to "Releasing Fuel System Pressure".
3. Raise a vehicle.
4. Install SST (0K2A1 131 001A) to fuel filter as shown.
5. Connect negative battery cable.

8. Inspect the fuel line pressure.
Fuel line pressure : 33~38 psi (240~270 kPa, 2.4~2.7 kg/cm²)
Pressure too high :

A. Check for restricted fuel return line
B. If line is clean, replace pressure regulator pressure too low :
C. Block return line and check if pressure rises
D. If pressure does rise, replace pressure regulator.
E. If pressure does not rise, replace pressure regulator.
F. If pressure does not rise, measure fuel pump maximum pressure.
2000 > 2.5L GASOLIN(K5) >
Fuel tank
1) BEFORE PERFORMING THE FOLLOWING OPERATION, RELEASE THE FUEL PRESSURE FROM THE
FUEL SYSTEM TO REDUCE THE POSSIBILITY OF INJURY OR FIRE.
2) WHEN REMOVING THE FUEL TANK, KEEP SPARKS, CIGARETTES, AND OPEN FLAMES AWAY FROM IT.
3) BEFORE REPAIR THE FUEL TANK, CLEAN IT THOROUGHLY WITH STEMA TO REMOVE ALL EXPLOSIVE
GAS.
Drain the fuel from the fuel tank before removing the tank.
Fuel System
Fuel System
Fuel Delivery System - Fuel Pump

2000 > 2.5L GASOLIN(K5) >
Inspection
Fuel pump inspection
THE FUEL SYSTEM REMAINS UNDER PESSURE WHEN THE ENGINE IS NOT RUNNING. RELEASE
FUEL SYSTEM PRESSURE BEFORE DISCONNECTING ANY FUEL LINE TO REDUCE THE CHANCE
OF PRESONAL INJURY OR FIRE DAMAGE TO VEHICLE COMPONENTS.
Fuel pump operation

2. Remove fuel filler cap.

3. Turn ignition switch "ON".
4. Determine if fuel pump is running by listening for sound of it at fuel filler inlet.
5. Install fuel filler cap.
6. If no sound was heard, measure voltage between fuel pump connector wire (GRN/YEL) to chassis ground.
Voltage : Approx. 12V
7. If voltage is not correct, check fuel pump relay and related wiring harness.
8. If you do not measure 12V, check for continuity between fuel pump connector terminal wires (GRN/YEL)
and (BLK).
9. If there is continuity, replace fuel pump.
10. If there is no continuity, repair ground circuit.
Fuel pump maximum pressure

Perform pump operation inspection if regulated pressure is not as specified.
3. Raise a vehicle.
4. Connect SST (0K2A1 131 001A) to fuel filter and close the valve in line to fuel filter as shown.
RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING ANY FUEL LINE TO REDUCE
6. Connect data link connect terminals FUEL PUMP and B+ with jumper wire.

8. Measure fuel pump maximum pressure.
Fuel pump maximum pressure : 65~85 psi (450~588 kPa, 4.5~6.0 kg-m)
9. If not within specification, replace fuel pump.

Fuel System
Fuel System
Fuel Delivery System - Injector

2000 > 2.5L GASOLIN(K5) >
Inspection
Check operation
1. Warm up engine and let engine idle.
2. Listen for sound of each injector running by using sound scope or screwdriver.
FUEL IS EXPLOSIVE. WHEN WORKING ON FUEL SYSTEM, MAKE SURE TO SUPPLY ADEQUATE
VENTILATION TO THE WORK AREA. DO NOT SMOKE, AND KEEP SPARKS AND OPEN FLAMES
AWAY.
Make sure the fuel injectors are firmly seated on the fuel rail to prevent movement and possible
damage.
3. If no sound is heard, measure injector resistance.

4. If injector is OK, check wiring to injector and voltages of ECM connector C terminal 33, 34, 35, 36, 37, 38.
5. If removal of injector system is needed, replace injector.
Fuel leakage test

1. Remove injectors together with fuel rail.
2. Verify that injector retaining clips are secured onto injectors.
5. Tilt injectors about 60 degrees and verify that no fuel leaks from the injector nozzles.
6. If fuel leaks, replace injector.
7. Turn ignition switch "OFF" and remove jumper wire.
Volume test
1. Remove injectors together with fuel rail.
2. Verify that injector retaining clips are secured onto injectors.
3. Reconnect injector connectors.
4. Apply a battery voltage to injector as shown figure.
5. Inspect injector volume with graduated container.
Injector volume : 48~54 ml/15 seconds
6. If not as specified, replace injectors.

When reassembling fuel rail and injectors :
• Use new injector O-rings
• Apply a small amount of clean engine oil to each O-ring before installing
Injector resistance
1. Disconnect injector harness.
2. Measure resistance of each injector.
Resistance : 14.5Ω at 68°F (20°C)
3. If not within specification, replace injector.

Fuel System
Fuel System
Fuel Delivery System - Fuel Pressure Regulator

2000 > 2.5L GASOLIN(K5) >
Inspection
Fuel line pressure inspection
1. Disconnect negative battery cable.
2. Release fuel system pressure. Refer to "Releasing Fuel System Pressure".
3. Raise a vehicle.
4. Install SST (0K2A1 131 001A) to fuel filter as shown.
5. Connect negative battery cable.

6. Start the engine and run engine at idle.
7. Disconnect vacuum hose from pressure regulator.
8. Inspect the fuel line pressure.
Fuel line pressure : 43~46 psi (294~314 kPa, 3.0~3.1 kg/cm²)
Pressure too high :

A. Check for restricted fuel return line
B. If line is clean, replace pressure regulator
Pressure too low :
A. Block return line and check if pressure rises
B. If pressure does rise, replace pressure regulator.
C. If pressure does not rise, measure fuel pump maximum pressure.
Fuel pressure hold inspection

RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTINGANY FUEL LINE TO REDUCE

3. Raise a vehicle.
4. Install SST (0K2A1 131 001A) to fuel filter as descried below.
7. turn ignition switch ON for 10 seconds to operate fuel pump.
9. Inspect fuel pressure after 15 minutes.
Fuel pressure : More than 25 psi (180 kPa, 1.8 kg/cm²_
10. If not as specified, check the following components :

do following inspections :
A. Fuel pump
B. Pressure regulator
C. Injectors
Fuel System
Fuel System
Troubleshooting

2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0100 Mass airflow (MAF) sensor circuit malfunction

Circuit description
A mass airflow (AMF) sensor is located on
the air cleaner assembly and the throttle
body. The MAF sensor measures the mass
of intake air entering engine through it.
ECM uses this information to determine
the injection duration and ignition timing.
A large amount of intake air represents
acceleration or high load conditions while a
small mount of intake air
representsdeceleration or idle. The mass
of intake air should be 11~16kg/h at warm
idle, increase suddenly at acceleration and
be stable during constant engine speed.
Fault type and fault condition

DTC Fault type Fault condition
P0100 GND short / Open • Intake air mass is lower than 3 kg/h when throttle angle is
high than 4.2° after engine starting except the fuel cut-off
operation.
Battery short • Intake air mass is higher than 700 kg/h when engine is
running after engine starting.
Limp home (fail-safe) function

• In case of MAF sensor failure, the limp home value of the sensor is computed according to engine speed,
throttle angle, and the mass airflow through the IAC valve.
• EVAP emission control function is controlled in minimum operation mode.
• The following adaptation functions are prohibited.
1. Adaptive air/fuel ratio correction : adaptation values are set to neutral.
2. Idle speed adaptation
• The diagnosis of fuel system is prohibited.
DTC No.P0100 flow (MAF) sensor circuit malfunction

Related items • Open or short between MAF sensor voltage supply line and main relay
• Open or short between MAF sensor signal line and ECM
• MAF sensor malfunction
Step Inspection Action

Start engine and allow engine to idle until
1 engine reaches operating temperature. Yes Go to step 2.
Measure voltage between MAF sensor
connector B14-B and GND (0.6~0.8V). No Go to step 5.
Is voltage within specification?
Ignition OFF, disconnect MAF sensor
connector. Yes Go to step 4.
Ignition ON, engine OFF, measure voltage
2
between sensor harness connector B14-C
and ECM connector C17 (approx. 12V). No Go to step 3.
Short or open between MAF sensor
Measure voltage between MAF sensor Yes connector and ECM sensor GND 17.
harness connector B14-C and chassis Repair wire as necessary.
3
GND (approx. 12V). Open or short between MAF sensor
Is voltage within specification? No connector B14-C and main relay.
Repair wire as necessary.
Check for wire connection between MAF Yes Repair connection as necessary.
4 sensor connector B14-C and relay.
Was a poor connection found? No Replace MAF sensor.
Check following condition for wire

connections between ECM and MAF Find short between MAF signal, B14-B and
sensor Yes ECM connector C1.
5 - Open Repair wire as necessary.
- Short to GND
- Short to MAF GND
Is MAF signal wire open and short? No Replace MAF sensor.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0110 Intake air temperature (IAT) sensor circuit malfunction

Circuit description
A intake air temperature (IAT) sensor is
threaded into the dynamic chamber. The
IAT sensor is a thermistor which
changesits resistance with changes in
temperature. The ECM supply a reference
voltage (5V) to the IAT sensor and
monitors output voltages produced by the
resistance changes due to the intake air
temperature changes. As the intake air
gets warmer,the sensor resistance
decreases and the output voltage is
decreased.
As the intake air gets cooler, the sensor
resistance increases and the output
voltage is increased.

• IAT sensor signal is higher than approx. 244°F(118°C)
GND short
approx. 60 seconds after engine start.
P0110
• IAT sensor signal is lower than approx. -36°F (-38°C) approx.
Battery short, Open
60 seconds a

• In case of no ECT sensor fault, the substitute valve of intake air temperature is assumed 32°F(0°C) when
the engine coolant is below 158°F(70°C), and assumed Approx. 68°F(20°C) when the engine coolant it
above 158°F(70°C).
• In case of ECT sensor fault, the intake air temperature is assumed Approx. 68°F(20°C).
1. Adaptive air/fuel ratio correction
• The diagnosis functions of EVAP system and fuel system are prohibited.
DTC No. P0110 Intake air temperature (IAT) sensor circuit malfunction
Related items • Open or Short between IAT sensor signal and ECM
• Open or Short between IAT sensor GND and ECM
• IAT sensor malfunction

1 Ignition OFF & disconnect IAT sensor Yes Go to step 2.
connector.
Ignition ON, measure voltage between sensor Open or short between sensor
harness connector B12-A (to ECM) and GND connector B12-A and ECM connector
No
(approx. 5V). C22.
Is voltage within specification? Repair as necessary.
Yes Go to step 3.
Ignition OFF, measure resistance between
ECT sensor harness connector (to ECM) Open or short between sensor
2 connector B12-B and ECM connector
B12-B and GND (0Ω). No
Is resistance within specification? C23.
Repair as necessary.
Measure resistance between sensor connector
B12 terminal 1 and 2. Poor terminal contact due to oxidation,
Yes bent or misplaced terminal.
3 Repair as necessary.
No Replace IAT sensor.

2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0115 Engine coolant temperature (ECT) sensor circuit malfunction

Circuit description
An engine coolant temperature (ECT)
sensor in threaded into the thermostat
housing. The ECT sensor is a thermistor
whichchanges its resistance with changes
in temperature. The ECM supplies a
reference voltage (5V) to the ECT sensor
and monitors output voltage produced by
the resistance changes due to engine
coolant temperature changes. As the
coolant gets warmer, the sensor resistance
decreases and the output voltage is
decreased. As the coolant gets cooler, the
sensor resistance increases and the output
voltage is increased. The ECM detects the
output voltage of engine coolant
temperature andincrease the fuel injector
duration when engine is cold.

• ECT sensor signal is higher than approx. 284°F (140°C)
GND short
Approx. 60 seconds after engine starting.
P0115
• ECT sensor signal is lower than approx. -36°F (-38°C)
Battery short/Open
Approx. 60 seconds after engine starting.

• If no valid coolant temperature value has determined after ignition switch turned ON, the substitute value
of coolant temperature is assumed the same value of intake temperature when the IAC sensor is not
faulty, and assumed as 68°F(20°C) when the IAT sensor is faulty.
• If valid coolant temperature value existed before the fault is detected, the substitute value of coolant
temperature is the last valid coolant temperature value. Then, this value is increased by a specified value
(according to intake air mass) until Approx. 212°F(100°C).
• The cooling fan is operating at high speed.
• The EVAP canister purge system is controlled in minimum mode. operation
• The following adaptation is prohibited.
1. Adaptive air/fuel ratio correction (adaptive valve is set to neutral)
• The diagnosis of fuel system is prohibited.
DTC No. P0115 Engine coolant temperature (ECT) sensor circuit malfunction
Related items • Open or Short between ECT sensor signal and ECM
• Open or Short between ECT sensor GND and ECM
• ECT sensor malfunction

Ignition OFF & disconnect ECT sensor Yes Go to step 2.
connector.
Ignition ON, measure voltage between sensor Open or short between sensor
1 connector B13-A and ECM connector
harness connector B13-A (to ECM) and GND No
(approx. 5V). C24.
Yes Go to step 3.
Ignition OFF, measure resistance between
ECT sensor harness connector (to ECM) Open or short between sensor
2 connector B13-B and ECM connector
B13-B and GND (0Ω). No
Is resistance within specification? C25.
Measure resistance between sensor connector
B13 terminal 1 and 2. Poor terminal contact due to oxidation,
Yes bent or misplaced terminal.
No Replace ECT sensor.

2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0120 Throttle position (TP) sensor circuit malfunction

Circuit description
A throttle position (TP) sensor is mounted
on the throttle body and detects the
opening of throttle valve. The ECM
determines operation conditions such as
idle (closed throttle), part load, acceleration
/ deceleration, and wide open throttlefrom
TP sensor.
The ECM supplies a reference voltage
(5V) to TP sensor and output voltage
increase directly with the opening of
throttle valve.
The output voltage will vary from 0.4~0.8
volt at closed throttle to 4.0~4.4 volt at
wide open throttle.

• TP sensor voltage is lower than 0.1V when ignition switch is
GND
turned ON.
P0120
• TP sensor voltage is higher than 4.86V when ignition switch
Battery short
is turned ON.

• In case of the TP sensor failure, the throttle angle is assumed depending on the engine speed and intake
air mass.
• In case of simultaneous TP sensor and MAF sensor failures, the throttle angle is maintained 25.3°.
1. Adaptive air/fuel ratio correction
3. TP sensor adaptation
• The following diagnosis are prohibited
1. MAF sensor
2. Fuel system
DTC No. P0120 Throttle position (TP) sensor circuit malfunction

Related items • Open or Short between TP sensor 5 volt reference and ECM
• Open or Short between TP sensor signal and ECM
• Open or Short between TP sensor GND and ECM
• TP Sensor Malfunction

Ignition OFF & disconnect TP sensor Yes Go to step 2.
connector.
Ignition ON, measure voltage between
1 Open or short between sensor connector
sensor harness connector B25-B (to ECM)
No B25-B and ECM connector C-10.
and GND (approx. 5V).
Ignition OFF, measure resistance between Yes Go to step 3.

TP sensor harness connector B25-A (to Open or short between sensor connector
2
ECM) and GND (0Ω). No B25-A and ECM connector C20. Repair as
Is resistance within specification? necessary.
Reconnect TP sensor connector. Ignition Yes Go to step 4.
ON, measure voltage between sensor
3 connector B25-C and GND (0.4~0.8V) with Open or short between sensor connector
throttle closed. Is voltage with No B25-C and ECM connector C19. Repair as
specification? necessary.
Press accelerator pedal fully and measure Yes Replace TP sensor.

voltage between sensor connector B25-C Poor terminal contact due to oxidation,
4
and GND (4.0~4.4V). No bent or misplaced terminal. Repair as
Is voltage within specification? necessary.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0130 Heated oxygen (HO2S) sensor circuit malfunction (Bank 1)

Circuit description
A heated oxygen sensor (HO2S) is
mounted in the front exhaust pipe and
detects the oxygen content in the exhaust
gas.
As the air/fuel ration is lean, the sensor
should output al low voltage (lower
450mV). As the air / fuel ratio is rich, the
sensor should output a high voltage
(higher than 450mV). The HO2S acts as
rich/lean switch and sends this information
to the ECM.
Based on this signal, the ECM
increases/decreases the fuel injection
duration when air fuel ratio is lean/rich. The
HO2Scontains a heater which reduces its
warning-up time so that it can control
feedback immediately upon engine start
up. The fuel pump relay supplies a battery
voltage to the heater. The ECM provides
ground circuit for activating the heater.

Battery short • HO2S voltage is higher than 1V after HO2S heater operating.
P0130 (Bank 1) • HO2S voltage is lower than 0.06V after HO2S heater
GND short
operating.
DTC No. P0130 Heated O₂sensor (HO2S) circuit malfunction (Bank 1)

Related items • Open or short circuit in oxygen sensor heater circuit
• Oxygen sensor malfunction

Ignition OFF, disconnect HO2S connector. Yes Go to step 2.
Measure resistance between sensor
1 harness connector B05-b (to ECM) and Open between HO2S connector B05-b and
GND (0Ω). No ECM connector B20.
Is resistance within specification? Repair as necessary.
Ignition ON, measure voltage between Short to battery voltage between HO2S
HO2S harness connector B05-a (to ECM) Yes connector B05-a and ECM connector B14.
and GND.
Is measured voltage above 1V? No Go to step 3.
Ignition OFF, measure resistance between Short to GND between HO2S connector
HO2S harness connector B05-a (to ECM) Yes B05-a and ECM connector B14.
and GND.
Is measured resistance 0Ω? No Go to step 4.
Measure resistance between HO2S Yes Go to step 5.

harness connector B05-a (to ECM) and Open between HO2S connector B05-a and
4
ECM connector B-14 (0Ω). No ECM connector B14.
Reconnect HO2S connector.
Inspect for terminal contact failure.
temperature for more than 10 minutes. Yes
Using SST (0K2A1 189 AA0), monitor
5
HO2S signal.
Does the HO2S (Bank 1) signal switch
lean to rich or rich to lean over 3 times for No Repair HO2S (Bank 1).
10 seconds?
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0135 HO2S heater circuit malfunction (Bank 1)

Circuit description
When the engine starts, the HO2S heater
is pre-heated for the time (1) depending
upon engine coolant at start and the intake
air mass. The HO2S heater during
pre-heating is duty-controlled according to
the battery voltage, engine speed,
andintake air mass.
After the pre-heating time is expired, the
HO2S heater is fully heated for a specified
time (Approx. 6 sec). Then the HO2S
heater is again duty-controlled based on
battery voltage, intake air mass, engine
speed, and HO2S voltage.
The HO2S contains a heater wh reduces
its warning-up time so that it can control
up.
Main relay supply a battery voltage to the
heater. The ECM provides ground circuit
for activating the heater.

Open • NO signal when ignition switch is turned ON
P0135 (Bank 1) GND short • Signal below lower limit when ignition switch is turned ON.
Battery short • Signal above upper limit when ignition switch is turned ON.
DTC No. P0135 O2 sensor heater circuit malfunction(Bank 1)

Related items • Open or short circuit oxygen sensor heater circuit
• Wrong oxygen sensor heater resistance

Ignition OFF, disconnect HO2S (Bank 1)
1
sensor harness connector B05-C and GND
(approx. 12V). No Go to step 6.
IS voltage within specification?
Ignition ON & engine OFF, measure Short to battery voltage between sensor
voltage between sensor harness connector Yes connector B05-d and ECM connector B1.
B05-d (to ECM) and GND (12V).
Is voltage within specification? No Go to step 3.
Ignition OFF, measure resistance between Short to GND between sensor connector
sensor harness connector B05-d (to ECM) Yes B05-d and ECM connector B1.
and GND (0Ω).
Is resistance within specification? No Go to step 4.
Disconnect ECM connector. Measure Yes Go to step 5.

resistance between sensor harness Repair wiring between HO2 sensor
4 connector B05-d and ECM harness harness connector B05-d and ECM
connector B1 (0Ω). No
connector B1, confirm repair and road test
Is resistance within specification? vehicle.
Ignition OFF, measure resistance between Yes Replace ECM.
sensor connector B05 terminals c and d
5 Replace HO2S sensor (Bank 1), confirm
(approx. 6Ω at 73°F (23°C)). No
Is resistance within specification? repair and road test vehicle.
Repair wiring between harness connector

Check "O2 SEN" (10A) fuse OK. Yes B02-B and HO2S connector B05-C.
6 Confirm repair and road test vehicle.
Is "O2 SEN" (10A) fuse OK?
No Replace fuse as necessary.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0150 Heated oxygen (HO2S) sensor circuit malfunction (Bank 2)

Circuit description
A heated oxygen sensor (HO2S) is
mounted in the front exhaust pipe and
detects the oxygen content in the exhaust
gas.
As the air/fuel ration is lean, the sensor
should output al low voltage (lower
450mV). As the air / fuel ratio is rich, the
sensor should output a high voltage
(higher than 450mV). The HO2S acts as
rich/lean switch and sends this information
to the ECM.
Based on this signal, the ECM
increases/decreases the fuel injection
duration when air fuel ratio is lean/rich. The
HO2Scontains a heater which reduces its
warning-up time so that it can control
up. The fuel pump relay supplies a battery
voltage to the heater. The ECM provides
ground circuit for activating the heater.

Battery short • HO2S voltage is higher than 1V after HO2S heater operating.
P0150 (Bank 2) • HO2S voltage is lower than 0.06V after HO2S heater
GND short
operating.
DTC No. P0150 Heated O₂sensor (HO2S) circuit malfunction (Bank 2)

Related items • Open or short circuit in oxygen sensor heater circuit
• Oxygen sensor malfunction

Ignition OFF, disconnect HO2S connector. Yes Go to step 2.
1 harness connector B04-b (to ECM) and Open between HO2S connector B04-b and
GND (0Ω). No ECM connector B21.
Ignition ON, measure voltage between Short to battery voltage between HO2S
HO2S harness connector B04-a (to ECM) Yes connector B04-a and ECM connector B15.
and GND.
Is measured voltage above 1V? No Go to step 3.
Ignition OFF, measure resistance between Short to GND between HO2S connector
HO2S harness connector B04-a (to ECM) Yes B04-a and ECM connector B15.
and GND.
Measure resistance between HO2S Yes Go to step 5.

harness connector B04-a (to ECM) and Open between HO2S connector B05-a and
4
ECM connector B-15 (0Ω). No ECM connector B15.
Reconnect HO2S connector.
Inspect for terminal contact failure.
temperature for more than 10 minutes. Yes
Using SST (0K2A1 189 AA0), monitor
5
HO2S signal.
Does the HO2S (Bank 2) signal switch
lean to rich or rich to lean over 3 times for No Repair HO2S (Bank 2).
10 seconds?
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0155 HO2S heater circuit malfunction (Bank 2)

Circuit description
When the engine starts, the HO2S heater
is pre-heated for the time (1) depending
upon engine coolant at start and the intake
air mass. The HO2S heater during
pre-heating is duty-controlled according to
the battery voltage, engine speed,
andintake air mass.
After the pre-heating time is expired, the
HO2S heater is fully heated for a specified
time (Approx. 6 sec). Then the HO2S
heater is again duty-controlled based on
battery voltage, intake air mass, engine
speed, and HO2S voltage.
The HO2S contains a heater which
reduces its warning-up time so that it can
control feedback immediately upon engine
start up.
Main relay supply a battery voltage to the
heater. The ECM provides ground circuit
for activating the heater.

Open • NO signal when ignition switch is turned ON
P0155 (Bank 2) GND short • Signal below lower limit when ignition switch is turned ON.
Battery short • Signal above upper limit when ignition switch is turned ON.
DTC No. P0155 O2 sensor heater circuit malfunction(Bank 2)

Related items • Open or short circuit oxygen sensor heater circuit
• Wrong oxygen sensor heater resistance

Ignition OFF, disconnect HO2S (Bank 2)
1
sensor harness connector B04-C and GND
(approx. 12V). No Go to step 6.
IS voltage within specification?
Ignition ON & engine OFF, measure Short to battery voltage between sensor
voltage between sensor harness connector Yes connector B05-d and ECM connector B13.
B05-d (to ECM) and GND (12V).
sensor harness connector B05-d (to ECM) Yes B05-d and ECM connector B13.
and GND (0Ω).
Disconnect ECM connector. Measure Yes Go to step 5.

resistance between sensor harness Repair wiring between HO2 sensor
4 connector B05-d and ECM harness harness connector B05-d and ECM
connector B13 (0Ω). No
connector B13, confirm repair and road
Is resistance within specification? test vehicle.
Ignition OFF, measure resistance between Yes Replace ECM.
sensor connector B05 terminals c and d
5 Replace HO2S sensor (Bank 1), confirm
(approx. 6Ω at 73°F (23°C)). No
Is resistance within specification? repair and road test vehicle.
Repair wiring between harness connector

Check "O2 SEN" (10A) fuse OK. Yes B02-B and HO2S connector B04-C.
6 Confirm repair and road test vehicle.
Is "O2 SEN" (10A) fuse OK?
No Replace fuse as necessary.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0201 Cylinder 1 injector circuit malfunction

Circuit description
Based on information from various

sensors, the ECM measures the amount of
time the injector is open for each spray and
outputs this as a signal to control the
injectors. The main relay provides battery
voltage to the injectors. The ECM controls
each injector by grounding the control
circuit. When ECM energizes the injector
circuit, the circuit voltage shouldbe low.
When ECM de-energizes the injector
circuit, the circuit voltage should be high. If
the circuit detects a voltage out of what is
expected, this cause the DTC to set.

Battery short • Signal above upper limit when engine speed is above 25rpm.
P0201 Open • No signal when engine speed is above 25rpm.
GND short • Signal below lower limit when engine speed is above 25rpm.
DTC No. P0201 Cylinder 1 injector circuit malfunction

Related items • Open or Short between injector control and ECM
• Open or Short between injector voltage supply and Main Relay
• Cylinder 1 Injector Malfunction

Ignition OFF & disconnect cylinder 1 Yes Go to step 2.
connector.
1 Open or short between injector connector
injector harness connector B18-A and
No B18-A and main relay.
GND (11V~13V).
Reconnect cylinder 1 connector. Yes Go to step 3.

Measure voltage between injector Open or short between injector connector
2
connector B18-B and GND (11~13V). No B18-B and ECM connector C33.
Is voltage within specification. Repair as necessary.
Ignition OFF, disconnect cylinder 1 Short to battery between injector connector
3 connector. Yes B18-B and ECM connector C33.
Measure voltage between harness Repair as necessary.
connector B18-B (to ECM) and GND.
Is measured voltage 11~13V? No Go to step 4.
Measure resistance between cylinder 1 Poor terminal contact due to oxidation,

injector connector B18 terminals 1 and 2 Yes bent or misplaced terminal. Repair as
4 necessary.
(14.5Ω at 68°F(20°C)). Is resistance within
specification? No Replace cylinder 1 injector.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING

Circuit description

the circuit detects a voltageout of what is



connector.
GND (11V~13V).

2
connector B19-B and GND (11~13V). No B19-B and ECM connector C38

4 necessary.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING

Circuit description




connector.
GND (11V~13V).

2

4 necessary.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING

Circuit description




connector.
GND (11V~13V).

2

4 necessary.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING

Circuit description




connector.
injector harness connector B22-B and
GND (11V~13V).
Measure voltage between injector Yes Go to step 3.

connector B22-B (to ECM) and GND Open or short between injector connector
2
(11~13V). No B22-B and ECM connector C35.

4 necessary.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING

Circuit description




connector.
GND (11V~13V).

2

injector connector C34 terminals 1 and 2 Yes bent or misplaced terminal. Repair as
4 necessary.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0230 Fuel pump relay circuit malfunction

Circuit description
When the ignition switch is turned ON, the ECM activates the
fuel pump for 4 seconds if the CKP sensor signal is not
delivered to the ECM. IF ECM detects the CKP sensor signal,
the fuel pump remains ON. When the ignition switch is turned
OFF, the ECM turns fuel pump OFF.

• Signal below lower limit when fuel pump relay is not
Open/GND short
P0230 operating.
Battery short • Signal above upper limit when fuel pump is operating.
DTC No. P0230 Fuel pump relay circuit malfunction

Related items • Fuel pump relay malfunction
• Open or short in circuit.

Yes Go to step 2.
Wait 10 seconds after ignition ON,
measure voltage between ECM connector Open or short to GND between fuse relay
1 box connector B-02 and ECM connector
D10 and GND (11~13V). No
Is voltage within specification? D-10
Short to battery fuse relay box connector
Start engine and measure voltage between Yes B-02 and ECM connector D-10.
2 ECM connector D10 and GND. Repair as necessary.
Is measured voltage 12-14V?
No Go to step 3.
Ignition OFF, disconnect fuel pump relay Poor terminal contact at ECM connector
connector. Yes D-10 or fuse relay box connector B-02.
3 Inspect fuel pump relay for continuity. Repair as necessary.
Refer to fuel pump relay inspection.
Is fuel pump relay OK? No Replace fuel pump relay.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0335 Crankshaft position (CKP) sensor circuit malfunction

Circuit description
A Crankshaft position (CKP) sensor is on
the front of transmission case adjacent to
the flywheel.
The CKP sensor is an inductive sensor
that generates Ac voltage using a sensor
and a toothed wheel mounted on the
crankshaft.
When the teeth in the wheel passes
through the sensor’s magnetic filed, they
generate a voltage signal in the pick-up
coil of sensor. The wheel has 60 teeth with
two missing teeth and 60 voltage pulses
are induced during one crankshaft
revolution. For example, the frequency of
voltage pulses in 1 rpm is 1Hz.
The ECM calculates the frequency of
sensor to compute engine rpm. Using the
signal differences caused by two missing
teeth, the ECM identifies which cylinder is
on top dead center.

NO signal NO CKP sensor signal
P0335 Valid crankshaft slot detected but synchronization not successful
Invalid signal
Number of crankshaft slots is not correct (<56 slots or >60 slots)
DTC No. P0335 Crankshaft position (CKP) sensor malfunction

Related items • Open or Short between CKP sensor signal (+) and ECM
• Open or Short between CKP sensor signal (-) and ECM
• CKP Sensor Malfunction

Ignition ON, disconnect CKP sensor Yes Go to step 2.
connector.
1 Measure voltage between sensor harness Open or short between sensor connector
connector B16-A and GND (11~13V). No B16-A and main relay.
Ignition OFF, disconnect ECM connector. Yes Go to step 3.

harness connector B16-B and ECM
No B16-B and ECM connector C8. Repair as
harness connector C08 (0Ω).
necessary.
Measure resistance between sensor Yes Go to step 4.

harness connector B16-C and ECM Open or short between sensor connector
3
harness connector C21 (0Ω). No B16-C and ECM connector C21.
Reconnect ECM connector and measure Short between sensor connector B16-B
resistance between sensor harness Yes and connector B16-C.
4 connector B16-B and harness connector Repair as necessary.
B16-C (0Ω) (to ECM). Is measured
resistance specified value? No Go to step 5.
Ignition ON, measure voltage between Short to battery voltage in connector

sensor harness connector B16-B (to ECM) Yes C131-2.
and GND (11~13V). Is measured voltage
within specified value? No Go to step 6.
Measure gap between CKP sensor and Yes Replace CKP sensor.
target wheel 0.012~0.0509 in (0.3~1.7
6 Check target wheel for proper installation.
mm). No
Is gap within specification? Adjust target wheel gap.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0340 malfunction

Circuit description
A camshaft position (CMP) sensor is

mounted at the rear of the cylinder head.
The CMP sensor sends a signal to ECM
when the number one cylinder is at top
dead center.
The CMP sensor consists of hall effect
device and magnet.
When the magnetic field of the hall effect
device is interrupted by a dowel pin of
camshaft, sensor voltage outputs 0V. If
not, the sensor voltage outputs 5V.

NO signal NO CMP sensor signal when CKP sensor is not faulty
P0340 CMP sensor is detected out of window range of CKP sensor
Invalid signal
when CKP sensor is not faulty
DTC No. P0340 Camshaft position (CMP) sensor circuit malfunction

Related items • Open or Short between CMP sensor signal (+) and ECM
• Open or Short between CMP sensor signal (-) and ECM
• CMP sensor malfunction

Ignition OFF, disconnect CMP sensor Yes Go to step 2.
connector.
CMP sensor harness connector B15-A and
No B15-A and main relay. Repair as
GND (11~13V).
necessary.
Is voltage within specification.
Ignition OFF, measure resistance between Yes Go to step 3.

CMP sensor harness connector B15-C (to Open between sensor connector B15-C
2
ECM) and GND (0Ω). No and ECM connector D8. Repair as
Is resistance within specification. necessary.
sensor harness connector B15-B (to ECM) Yes B15-B and ECM connector D7.
and GND (0Ω).
Disconnect ECM connector. Yes Go to step 5.
Measure resistance between CMP sensor
4 harness connector B15-B(to ECM) and Open between sensor connector B15-B
ECM harness connector D7 (0Ω). No and ECM connector D7.
Reconnect ECM connector. Ignition ON, Short to battery voltage between sensor
measure voltage between CMP sensor Yes connector B15-B and ECM connector D7.
5 harness connector B15-B (to ECM) and Repair as necessary.
GND (11~13V). Is voltage with
specification? No Go to step 6.
Disconnect CMP sensor installed at Yes Replace CMP sensor.
cylinder head and check cylinder #1
6 Remove camshaft and install cylinder #1
detection pin. No
Is pin correctly installed in camshaft? detection pin at camshaft.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P0500 Vehicle speed sensor range/Performance

Circuit description
A vehicle speed sensor is located on transmission housing and generates 4 pulse signals per revolution at
drive shaft.
The frequency of signal is proportional to the speed of vehicle. This signal is converted into square wave in
instrumentcluster and sent to ECM. The ECM determine vehicle speed based on the frequency of the signal.

• No vehicle speed sensor signal during 4 seconds when
P0500 No signal engine is higher than approx. 2688 rpm and intake air is
higher than 272 mg/TDC.
DTC No. P0500 Vehicle speed sensor range/Performance

Related items • Open circuit in vehicle speed sensor wiring
• Short to battery voltage or short to GND in vehicle speed sensor wiring
Ignition OFF, disconnect ECM connector. Short to GND between instrument cluster
Measure resistance between harness Yes connector 2D and ECM connector D-22.
connector D-22 and GND.
Short to battery voltage between
Connect ECM connector, ignition ON, instrument cluster connector 2D and ECM
measure voltage between connector D-22 Yes
2 connector D22.
and GND (11~13V). Repair as necessary.
No Go to step 3.
Yes Replace instrument cluster.
Is there continuity between connector ECM Open circuit between connector 2D and
3
D-22 and instrument cluster terminal 2D. No ECM connector D-22.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC No. P1166 Feed back system (Bank 1)

Check connection of oxygen sensor circuit.
Check the same code number after - If normal, check for DTC P0130 or
1
performing after repair procedure. No P0150.
- If not normal, repair or replace the
connector.
Go to next step.
Yes
Air/Fuel mixture is rich
Connect power scan to DLC and check the
2 related DTC (No. P1166 or No. P1167). Go to step 5.
Is the fault type of that "rich"?
No
Air/Fuel mixture is lean or misfire
occurs.

Check the fuel line pressure while engine When pressure is high
is idling. Check clogging or restriction of fuel return
3
Fuel line pressure : 33~38 psi (240~260 No hose.
kPa, 2.4~2.7 kg/cm²) - If normal, replace the pressure regulator.
- If not normal, repair or replace.
Yes Replace injector.
Check the fuel leakage or the clog from Check the ECT sensor.
4 - If normal, replace the oxygen sensor.
injector. No
- Replace the water ect sensor if not
normal.
Remove high tension cord while engine is Yes Go to next step.
5 idling and check equal engine speed
decrease at all cylinders. No Go to step 8.

When pressure is low
Check the fuel line pressure regulator hose Check the fuel line pressure with fuel
disconnected while engine is idling. return hose plugged.
Fuel line pressure : 42~43 psi (294~304 - Check pressure regulator if pressure
6
kPa, 3.0~3.1 kg/cm²) No increases abruptly.
(on condition that vacuum hose is - Check clogging between fuel pump and
disconnected from pressure regulator) pressure regulator if pressure increases
slowly. If not clogged, check maximum
pressure of fuel pump.
Check the air flow at intake system
Yes Replace the oxygen sensor.
components.
7
- Check the connection of vacuum hose.
No Repair or replace.
- Vacuum : above 480 mmHg
Check the cylinder which misfired at step Yes Repair or replace the ignition system.
8
5. No Go to next step.
Check the injector operational sound at Check for approx. 12V at injector
9 cylinder where troubles were detected at connector terminal wire.
step 5. No
- Replace the injector if yes.
- Check short or open circuit otherwise.
Replace the injector of cylinder where
troubles were detected at step 5. Check
10
the same code number after performing
No Disconnect the defective injector.
after-repair procedure.
11 Replace the ECM and check better condition.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC No. P1167 Feed back system (Bank 2)

Check connection of oxygen sensor circuit.
Check the same code number after - If normal, check for DTC P0130 or
1
performing after repair procedure. No P0150.
- If not normal, repair or replace the
connector.
Go to next step.
Yes
Air/Fuel mixture is rich
Connect power scan to DLC and check the
2 related DTC (No. P1166 or No. P1167). Go to step 5.
Is the fault type of that "rich"?
No
Air/Fuel mixture is lean or misfire
occurs.

Check the fuel line pressure while engine When pressure is high
is idling. Check clogging or restriction of fuel return
3
Fuel line pressure : 33~38 psi (240~260 No hose.
kPa, 2.4~2.7 kg/cm²) - If normal, replace the pressure regulator.
- If not normal, repair or replace.
Yes Replace injector.
Check the fuel leakage or the clog from Check the ECT sensor.
4 - If normal, replace the oxygen sensor.
injector. No
- Replace the water ect sensor if not
normal.
Remove high tension cord while engine is Yes Go to next step.
5 idling and check equal engine speed
decrease at all cylinders. No Go to step 8.

When pressure is low
Check the fuel line pressure regulator hose Check the fuel line pressure with fuel
disconnected while engine is idling. return hose plugged.
Fuel line pressure : 42~43 psi (294~304 - Check pressure regulator if pressure
6
kPa, 3.0~3.1 kg/cm²) No increases abruptly.
(on condition that vacuum hose is - Check clogging between fuel pump and
disconnected from pressure regulator) pressure regulator if pressure increases
slowly. If not clogged, check maximum
pressure of fuel pump.
Check the air flow at intake system
Yes Replace the oxygen sensor.
components.
7
- Check the connection of vacuum hose.
No Repair or replace.
- Vacuum : above 480 mmHg
Check the cylinder which misfired at step Yes Repair or replace the ignition system.
8
5. No Go to next step.
Check the injector operational sound at Check for approx. 12V at injector
9 cylinder where troubles were detected at connector terminal wire.
step 5. No
- Replace the injector if yes.
- Check short or open circuit otherwise.
Replace the injector of cylinder where
troubles were detected at step 5. Check
10
the same code number after performing
No Disconnect the defective injector.
after-repair procedure.
11 Replace the ECM and check better condition.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P1505 IAC valve (Opening coil) circuit malfunction

Circuit description
The IAC valve is this installed on the
throttle body and controls the intake airflow
that is bypassed around the throttle plate.
The function of IAC valve is to maintain
idle speed according to various engine
loads and conditions, but also to provide
additional air during starting. Moreover, it
performs an electronic dashpot during
deceleration. The IAC valve consists of
opening coil, closing soil, and permanent.
Based on the information from various
sensors, the ECM controls both coils by
grounding their control circuit. According to
the control signals from the ECM, the valve
rotor rotates to controlthe bypass airflow
into engine.

Signal below lower when ignition
switch turned ON.
GND short
P1505 Signal above upper limit when
Battery short
(Opening coil) ignition switch turned ON.
Open
No signal when ignition switch
turned ON.
DTC No. P1505 IAC valve (Opening coil) circuit malfunction

Related items • Open circuit in IAC valve wiring
• IAC valve malfunction
• Short to battery voltage or short to ground in IAC valve circuit.

Ignition OFF, disconnect IAC valve
Short to battery voltage in connector
connector.
Yes B11-C.
between harness connector B11-C (to
ECM) and GND.
Is measured voltage approx. 12V? No Go to step 2.
Ignition OFF, measure resistance between Short to ground in connector B11-C.

IAC valve harness connector B11-1C (to Yes
ECM) and GND.
Check for continuity between harness
3 connector B11-C and ECM harness Open between connector B11-C and ECM
connector C47. No. connector C47.
Does continuity exist? Repair as necessary.
Ignition ON, engine OFF, measure voltage Yes Go to step 5.

between IAC valve harness connector Open or short between connector B11-B
4
B11-B and GND (approx. 12V). No and Main Relay.
Check for proper connections at connector Yes Go to step 6.
5 B11-B and Main Relay.
Are connections correct? No Repair connection as necessary.
Measure resistance between IAC valve Visually inspect for terminal contact failure
connector B11 terminals B and C Yes (oxidized, deformed or misplaced, etc).
(16.5~18.5Ω at 68°F(20°C)).
Is resistance within specification? No Replace IAC valve.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P1507 IAC valve (Closing coil) circuit malfunction

Circuit description
The IAC valve is this installed on the
throttle body and controls the intake airflow
that is bypassed around the throttle plate.
The function of IAC valve is to maintain
idle speed according to various engine
loads and conditions, but also to provide
additional air during starting. Moreover, it
performs an electronic dashpot during
deceleration. The IAC valve consists of
opening coil, closing soil, and permanent.
Based on the information from various
sensors, the ECM controls both coils by
grounding their control circuit. According to
the control signals from the ECM, the valve
rotor rotates to controlthe bypass airflow
into engine.

Signal below lower when ignition
switch turned ON.
GND short
P1507 Signal above upper limit when
Battery short
(Closing coil) ignition switch turned ON.
Open
No signal when ignition switch
turned ON.
DTC No. P1507 IAC valve (Closing coil) circuit malfunction

Related items • Open circuit in IAC valve wiring
• IAC valve malfunction
• Short to battery voltage or short to ground in IAC valve circuit.

Ignition OFF, disconnect IAC valve
connector.
Yes B11-A.
between harness connector B11-A (to
ECM) and GND.
Ignition OFF, measure resistance between Short to ground in connector B11-A.

IAC valve harness connector B11-A (to Yes
ECM) and GND.
3 connector B11-A and ECM harness Open between connector B11-A and ECM
connector C46. No. connector C46.
Does continuity exist? Repair as necessary.

between IAC valve harness connector Open or short between connector B11-B
4
B11-B and GND (approx. 12V). No and Main Relay.
5 B11-B and Main Relay.
Measure resistance between IAC valve Visually inspect for terminal contact failure
connector B11 terminals A and B Yes (oxidized, deformed or misplaced, etc).
(14.5~16.5Ω at 68°F(20°C)).
Is resistance within specification? No Replace IAC valve.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
Variable intake control system (VICS) valve circuit

DTC P1523
malfunction
Circuit description
A variable intake control system (VICS) is

designed to very the inertia supercharging
effect in order to improve engine
performances and the torque. When the
engine speed is between 3600~5400rpm,
the VICS valve is ON, the shutter valve is
opened, and large volume of dynamic
chamber is used.
When the engine speed is out of
3600-5400 rpm, the VICS valve is OFF, the
shutter valve is closed, and small volume
of dynamic chamber is used.

Open/GND short • Signal below lower limit when VICS valve is not operating.
P1523
Battery short • Signal above upper limit when VICS valve is operating.
DTC No. P1523 VICS valve circuit malfunction

Related items • Open circuit in VICS valve wiring
• VICS valve malfunction
• Short to battery voltage or short to ground in VICS canister valve circuit

Ignition OFF, disconnect VICS valve
connector.
Yes B17-B.
between harness connector B17-B (to
ECM) and GND.
Ignition OFF, measure resistance between Short to ground in connector B17-B.

VICS valve harness connector B17-B (to Yes
ECM) and GND.
3 Open between connector B17-B and ECM
connector B17-B and ECM harness
No connector C45.
connector C45.
Does continuity exist?

between VICS valve harness connector Open or short between connector B17-A
4
B17-A and GND (approx. 12V). No and Main Relay.
5 B17-A and Main relay.
Measure resistance between VICS valve Visually inspect for terminal contact failure
connector B17 terminals A and B Yes (oxidized, deformed or misplaced, etc.)
(13.8±3.5Ω at 68°F (20°C)).
Is resistance within specification? No Replace VICS valve.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P1672 Cooling fan relay circuit malfunction (Low speed)

Circuit description
A electric cooling fan is controlled by the ECM

to prevent engine overheat. The cooling fan
operates at two speeds (LOW/HIGH)
depending on various inputs from the vehicle
speed sensor, the air conditioner switch, and
the engine coolant temperature sensor as next
to shown figure. Three relays controls the fan
operation as following table.

• Signal below lower limit when each cooling fan is not
Open/GND short
P1672 (Low speed) operating.
Battery short • Signal above upper limit when each cooling fan is operating.
DTC No. P1672 Cooling fan relay circuit malfunction (Low speed)
Related items • Cooling fan malfunction
• Open or short in circuit

Ignition ON, measure voltage at ECM Yes Go to step 2.
1 connector D-18 and GND (approx. 12V).
Ignition OFF, disconnect cooling fan relay. Poor terminal contact at ECM connector
Measure resistance between cooling fan Yes D18.
2 relay connector D28 terminal A and D (60Ω Inspect and repair as necessary.
at 68°F (20°C)).
Is resistance within specification? No Replace cooling fan relay.
Short to GND between connector D28-D
Ignition OFF, disconnect cooling fan relay. Yes and ECM connector D18.
Measure resistance between connector Repair as necessary.
3
D28-D (to ECM) and GND.
Is measured resistance 0Ω? Open between connector D28-D and ECM
No
connector D18. Repair as need.
2000 > 2.5L GASOLIN(K5) >
TROUBLESHOOTING
DTC P1673 Cooling fan relay circuit malfunction (High speed)

Circuit description
A electric cooling fan is controlled by the ECM

to prevent engine overheat. The cooling fan
operates at two speeds (LOW/HIGH)
depending on various inputs from the vehicle
speed sensor, the air conditioner switch, and
the engine coolant temperature sensor as next
to shown figure. Three relays controls the fan
operation as following table.

• Signal below lower limit when each cooling fan is not
Open/GND short
P1673 (High speed) operating.
Battery short • Signal above upper limit when each cooling fan is operating.
DTC No. P1673 Cooling fan relay circuit malfunction (High speed)
Related items • Cooling fan malfunction
• Open or short in circuit

Ignition ON, measure voltage at ECM Yes Go to step 2.
1 connector D-40 and GND (approx. 12V).
Ignition OFF, disconnect cooling fan relay. Poor terminal contact at ECM connector
Measure resistance between cooling fan Yes D-40.
2 relay connector D29 terminal A and D (60Ω Inspect and repair as necessary.
at 68°F (20°C)).
Is resistance within specification? No Replace cooling fan relay.
Short to GND between connector C196-5
Ignition OFF, disconnect cooling fan relay. Yes and ECM connector D-40.
Measure resistance between connector Repair as necessary.
3
D29-D (to ECM) and GND.
Is measured resistance 0Ω? Open between connector D29 and ECM
No
connector D-40. Repair as need.

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Fuel System

Model : Carnival / Sedona

Special service tools

Tool (Name and number) Illustration Use

0K2A1 131 001A

0K2A1 189 B0B/0K2A1 189

Special service tools

Tool (Name and number) Illustration Use

0K2A1 189 B0B/0K2A1 189

Ignition timing : BTDC 12°±5° (at idle speed)

Ignition timing is not adjustable.

6. If timing is not within the specified range, replace the ECM.

5. Check that idle speed is within specified range.

Idle speed (transaxle in "NEUTRAL") : 725±50 rpm

6. Disconnect tachometer from DLC or spark plug wire.

Idle air control Resistance (at Opening 16.5~18.5

Model : Carnival / Sedona

1. Disconnect mass air flow sensor connector.

Tightening torque : 69~96.3 lb-in (7.8~10.8 N·m, 0.8~1 kg-m)

3. Reconnect air intake hose to the mass air flow sensor.

Model : Carnival / Sedona

Engine coolant temperature sensor is located near thermostat.

1. Disconnect engine coolant temperature sensor connector.

Tightening torque : 18-22 lb-ft (25-29 N·m, 2.5~2.9 kg-m)

2. Connect engine coolant temperature sensor connector.

Water temperature °F(°C) Resistance (KΩ)

Model : Carnival / Sedona

Specification : 2 kΩ ± 0.4 kΩ (with throttle valve closed)

4. If resistance is not as specified, replace the throttle position sensor.

Measuring condition Voltage (V)

Model : Carnival / Sedona

4. Increase and decrease engine speed quickly several times.

6. If not as specified, inspect :

Inspection of front & rear heated oxygen sensor heaters

Specification : Approx. 6Ω (68°F (20°C)).

4. If not as specified, replace heated oxygen sensor.

Tightening torque : 22~36 lb-ft (30~49 N·m, 3~5 kg-m)

5. Reconnect heated oxygen sensor connector.

Tightening torque : 22~36 lb-ft (30~49 N·m, 3~5 kg-m)

2. Reconnect heated oxygen sensor connector.

Model : Carnival / Sedona

Terminals B+ applied B+ not applied

7. If not as specified, replace main relay.

Model : Carnival / Sedona

B+ : Battery positive voltage

Terminal 85-86 Terminal 87-30

Model : Carnival / Sedona

Component description table

Component Function Remark

Diagnostic trouble codes

Clearing diagnostic trouble codes

Data link connector 20 pin layout

Engine control system components

Diagnostic trouble codes diagnosis

Cyl. no.1 injector circuit

USING THIS SECTION

Symptom Diagnosis Charts

Precautions for Symptom Diagnosis

Malfunction indicator light is illuminated.

Crank engine and check operational sound of Yes Go to step 10.