Kia Carens 2002, Carens 2000, Carens 2001 User Manual

4.5 (28)

General Information

General Information

Model : SORENTO

2001 > 1.8L DOHC >

FUNDAMENTAL PROCEDURES

There are six primary symbols used to complement illustrations. There symbols indicate the areas to apply such materials during service.

 

Symbol

Meaning

Type

 

 

 

 

 

 

 

 

 

 

 

 

Apply oil

New engine oil or gear oil as

 

 

 

 

 

 

 

 

 

 

appropriate

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Apply brake fluid

Only brake fluid

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Apply automatic transmission fluid

Only ATF

 

 

 

 

 

 

 

 

 

 

(ATF)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Apply grease

Appropriate grease

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Apply sealant

Appropriate sealant

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Apply petroleum jelly

Appropriate petroleum jelly

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Whenever special oil or grease is required, it will be shown in the illustration.

NOTICES, CAUTIONS, AND WARNINGS

As you read through the various procedures, you will encounter Notices, Cautions and Warnings. Each one is there for a specific purpose. Notices give you added information that will assist you in completing a particular procedure. Cautions

present you from making an error that could damaged the vehicle. Warnings remind you to be especially careful in specific areas where carelessness can cause personal injury.

The following items contain general procedures you should alwys follow when working on a vehicle :

PROTECTION OF THE VEHICLE

Always cover fenders, seats, and floor areas before starting work.

Operate the engine only in a well-ventilated area to avoid carbon monoxide poisoning.

A WORD ABOUT SAFETY

The following precautions must be followed when jacking up the vehicle:

1.Block the wheels.

2.Use only the specified jacking positions.

3.Support the vehicle with safety stands.

The engine compartment must be clear of tools and people before starting the engine.

PREPARATION OF TOOLS AND MEASURING EQUIPMENT

1. All necessary tools and measuring equipment should be available before starting any work.

SPECLAL SERVICE TOOLS (SST'S)

1.Use special service tools when they are required. SST's can be found under "preparation" prior to any procedure requiring them.

REMOVAL OF PARTS

1.Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement for repair.

DISASSEMBLY

1.If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that assembly can be performed easily and efficiently.

2.Inspection of parts

When removed, each part should be carefully inspected for malfunction, deformation, damage, or other problems.

3.Arrangement of parts

All disassembled parts should be carefully arranged for assembly. Separate or identify the parts to be replaced form those that will be reused.

4.Cleaning parts for reuse

All parts to be reused should be carefully and thoroughly cleaned according to the appropriate method.

REASSEMBLY

Standard values, such as torques and certain adjustments, must be strictly observed in the assembly of all parts. When removed, the following parts should be replaced with new ones:

1.Oil seals

2.O-rings

3.Cotter pins

4.Gaskets

5.Lock washers

6.Nylon nuts

Depending on location:

1.Sealant should be applied or new gaskets used.

2.Oil should be applied to the moving components of parts.

3.Specified oil or grease should be applied at the prescribed locations (such as oil seals) before assembly.

ADJUSTMENT

1. Use appropriate gauges and/or testers when making adjustments.

RUBBER PARTS AND TUBING

1. Prevent gasoline or oil from getting on rubber parts or tubing.

ELECTRICAL TROUBLESHOOTING TOOLS

1.Test Light

The test light, as shown in the figure, uses a 12V bulb. The two lead wires should be connected to probes. The test light is used for simple voltage checks and in checking for short circuits.

When checking the engine control module (ECM), never use a bulb exceeding 3.4W.

2.Jumper Wire

The jumper wire is used for testing by shorting across switch terminals and ground connections.

Do not connect a jumper wire from the power source line to a body ground. Such a connection may cause damage to harnesses or electronic components.

3.Voltmeter

The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15V or more is used by connecting the positive (+) probe to the point where voltage is to be measured and the negative (-) probe to a body ground.

4.Ohmmeter

The ohmmeter is used to measure the resistance between two points in a circuit to check for continuity, and in diagnosis of short circuits.

Do not attempt to connect the ohmmeter to any circuit to which voltage is applied ; this may bum or otherwise damage the ohmmeter.

ELECTRICAL PARTS

1.Battery Cable

Before disconnecting connectors replacing electrical parts, disconnect the negative battery cable.

CONNECTORS

1.Removal of connector

(1)Never pull on the wiring harness when disconnecting connectors.

(2) Connectors can be removed by pressing or pulling the lock lever..

2.Locking a connector

Listen for a click when locking connectors. This sound indicates that they are securely locked.

3.Inspection

(1)When a tester is being used to check for continuity or to measure voltage, insert the tester probe from the wire harness side.

(2)Check the terminals of waterproof connectors from the connector side, because they cannot be accessed from the wire harness side.

Use a fine wire to prevent damage to the terminal.

Do not damage the terminal when inserting the tester lead.

Terminals

1.Inspection

Pull lightly on individual wires to ensure that they are secured in the terminal.

2.Replacement or terminals

Use the appropriate tools to remove the terminal as shown.

When installing the terminal, be sure to insert it until it locks securely.

(1)Female

Insert a thin piece of metal from the terminal side of the connector, and with the terminal locking tab pressed down, pull the terminal out from the connector.

(2)Male

Insert a thin piece of metal from the terminal side of the connector, and with the terminal locking tab pressed down, pull the terminal out from the connector.

3.Sensors, switches, and relays

Always handle sensors, switches, and relays carefully. Do not drop them or accidently strike them against other parts.

4.Wiring color codes.

Two-color wires are indicated by two color code symbols. The first code symbol indicates the base color of the wire, and the second the color of the stripe on the base color.

Code

Color

Code

Color

 

 

 

 

BLK

Black

ORN

Orange

 

 

 

 

BRN

Brown

PNK

Pink

 

 

 

 

GRN

Green

RED

Red

 

 

 

 

GRY

Gray

VIO

Violet

 

 

 

 

BLU

Blue

WHT

White

 

 

 

 

LT BLU

Light Blue

YEL

Yellow

 

 

 

 

LT GRN

Light Green

LT GRY

Light gray

 

 

 

 

JACK AND SAFETY STAND POSITIONS

1.Front end

(1)Jack position :

At the front subframe

2.Safety stand positions :

(1)On both sides of the side sills

3. Rear end

(1)Jack position :

At the center of the rear crossmember

4.Safety stand positions :

(1)On both sides of the side sills

VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS

1.Front end / Rear end Side sills (both sides)

2.Rear end

Side sills (both sides)

TOWING

Proper towing equipment is necessary to prevent damage to the vehicle.

Always observe laws and regulations applicable to vehicles in tow. As a general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies.

With either automatic or manual transmission :

1.Set the ignition switch in the ACC position.

2.Place the selector lever or shift lever in N (Neutral).

3.Release the parking brake.

Do not tow the vehicle backward with driving wheels on the ground. This may cause internal damage to the transmission.

Do not use the hook loops under the front and rear of the vehicle for towing purposes. These hook loops are designed ONLY for transport tie-down. If tie-down hook loops are used for towing, the front/rear bumper will be damaged.

VIN locations

• Vin locations

Vehicle identification number arrangement

ENGLISH/METRIC CONVERSION TABLE

MULTIPLY

BY

TO GET

 

 

 

 

 

LENGTH

 

inch (")

 

25.4

millimeters (mm)

foot (ft.)

 

0.3048

meters (m)

yard (yd.)

 

0.9144

meters

mile

 

1.609

kilometers (km)

 

 

 

 

 

 

AREA

 

inch² (in²)

 

645.2

millimeters² (mm²)

 

 

6.45

centimeters² (cm²)

Foot² (ft²)

 

0.0929

meters² (m²)

yard² (yd³)

 

0.8361

meters² (m²)

 

 

 

 

inch³(in³)

 

VOLUME

 

 

16387

mm³

 

 

 

 

16.387

cm³

quart (qt.)

 

0.0164

liters (l)

 

0.9464

liters

gallon (gal.)

 

 

3.7854

liters

yard³ (yd³)

 

 

0.7646

meters³(m³)

 

 

 

 

 

 

 

 

MASS

 

pound (lb.)

 

0.4536

kilograms (kg)

ton

 

907.18

kilograms(kg)

 

 

 

 

 

 

FORCE

 

kilogram (kg)

 

9.807

newtons (n)

ounce (oz.)

 

0.2780

newtons

pound (lb)

 

4.448

newtons

 

 

 

 

 

 

ACCELERATION

 

foot/second² (ft/sec²)

 

0.3048

meter/sec² (m/s²)

inch/second² (in/sec²)

 

0.0254

meter/sec² (m/s²)

 

 

 

 

 

 

TORQUE

 

pound-inch (lb-in)

 

0.11298

newton-meters (N·m)

pound-foot (lb-ft)

 

1.355 8

newton-meters (N·m)

 

 

 

 

 

 

POWER

kilowatts (kW)

horsepower (hp)

 

0.746

 

 

 

 

 

 

 

 

PRESSURE

 

pounds/inch² (psi)

 

6.895

kilopascals (kPa)

 

 

 

 

 

 

ENERGY

 

foot-pound

 

1.355 8

joules (J)

kilowatt-hour

 

3,600,000

joules (J)

 

 

 

 

 

 

FUEL PERFORMANCE

 

miles/gallon (mpg)

 

0.4251

kilometers/liter (km/l)

 

 

 

 

 

 

VELOCITY

 

miles/hour (mph)

 

1.6093

kilometers/hour

 

 

 

 

 

 

TEMPERATURE

 

 

 

 

 

to convert fahrenheit temperature to Celsius

C

5/9 (F-32)

 

 

temperature, use formula :

 

F

9/5 C (+32)

 

 

 

 

 

 

UNITS

 

 

 

 

 

 

 

ft-lb or in-lb (N·m)

Torque

 

 

 

 

 

rpm

Rotational speed

 

 

 

 

 

A

Amperes

 

 

 

 

 

 

V

Volts

 

 

 

 

 

 

Ω

Ohms (resistance)

 

 

 

psi (kPa)

Pressure

 

 

 

inHg (mmHg)

Pressure (usually negative/vacuum)

 

 

 

W

Watts (electrical power)

 

 

 

US qt (liters)

Volume

 

 

 

in (mm)

Length

 

 

 

ABBEREVIATIONS

 

 

 

 

 

ABDC

 

After bottom dead center

 

 

 

ABS

 

Anti-lock braking system

 

 

 

A/C

 

Air conditioner

 

 

 

ACC

 

Accessories

 

 

 

A/T

 

Automatic transaxle

 

 

 

ATDC

 

After top dead center

 

 

 

ATF

 

Automatic transmission fluid

 

 

 

BBDC

 

Before bottom dead center

 

 

 

BTDC

 

Before top dead center

 

 

 

CMP

 

Camshaft position sensor

 

 

 

DIS

 

Distributorless ignition system

 

 

 

DLC

 

Data link connector

 

 

 

DOHC

 

Dual overhead camshaft

 

 

 

EBD

 

Electronic brake-force distribution

 

 

 

ECM

 

Engine control module

 

 

 

ECT

 

Engine coolant temperature

 

 

 

E/L

 

Electrical load

 

 

 

EX

 

Exhaust

 

 

 

GND

 

Ground

 

 

 

HLA

 

Hydraulic lash adjuster

 

 

 

HO S

 

Heated oxygen sensor

 

 

 

IAT

 

Intake air temperature

 

 

 

IGN

 

Ignition

 

 

 

IN

 

Intake

 

 

 

INT

 

Intermittent

 

 

 

IAC

 

Idle air control

 

 

 

LH

 

Left hand

 

 

 

M

 

Motor

 

 

 

MAF

 

Mass air flow

 

 

 

MIL

 

Malfunction indicator lamp

 

 

 

M/S

 

Manual steering

 

 

 

M/T

 

Manual transaxle

 

 

 

OBD

 

On-board diagnosis

 

 

 

OFF

 

Switch off

 

 

 

ON

Switch on

 

 

PCV

Positive crankcase ventilation

 

 

P/S

Power steering

 

 

PRC

Pressure regulator control

 

 

P/W

Power window

 

 

RH

Right hand

 

 

SFI

Sequential fuel injection system

 

 

SST

Special service tool

 

 

SW

Switch

 

 

TCS

Traction control unit

 

 

TDC

Top dead center

 

 

TNS

Tail number side

 

 

TPS

Throttle position sensor

 

 

TWC

Three way catalyst

 

 

WU-TWC

Warm-up three-way catalyst

 

 

Scheduled maintenance services

Follow schedule if the vehicle is mainly operated where none of the following conditions apply.

Repeated short-distance driving.

Driving in dusty conditions.

Driving with extended use of brakes.

Driving in areas where road salt or other corrosive materials are used.

Driving on rough and/or muddy roads.

Extended periods of idling and/or low-speed operation.

Driving for prolonged periods in cold temperatures and/or extremely humid climates.

Maintenance Schedule (Except for Europe)

Kia Carens 2002, Carens 2000, Carens 2001 User Manual

Engine Electrical System

Engine Electrical System

General Information

2001 > 1.8L DOHC >

GENERAL DESCRIPTION

Ignition system overview

The Dual Overhead Cam(DOHC) Engine Ignition System is now a Distributorless Ignition System(DLI) type. This system is similar to the one currently used on Sephia/Shuma vehicles. The key components of this system are :

2 Separate Coil Packs

A Crankshaft Position Sensor that provides engine RPM information to the ECM.

An Ignition Control Module built into the ECM.

A Canshaft Position Sensor that provides engine firing order information to the ECM

Spark Plug Wires and Spark Plugs

Ignition system function

In a conventional ignition system, the ignition coil produces a high voltage current and the disributor thenrelays this current at the required time, to each spark plug. In the disctributirless ignition system, two sensors the camshaft position sensor and the crankshaft position sensor, tell the Engine Control Module (ECM) which cylinder is ready to fire.

The ECM then sends an ignition signal to an electronic ignition coil. This ignition coil then produces and sends a high voltage current to the proper spark plug.

Electronic spark advance system

Ignition Timing is determined and set within the ECM based on signals from various sensors and switches.

Optimum performance is gained with this system. The ECM varies ignition timing according to engine speed, intake air amountm coolant temperature and other conditions.

Timing specification at idle is : 8 ± 5° BTDC

Timing is not adjustable.

Ignition system components

The mechanical, rotating high-voltage distrivutor mechanism has been replaced by static electronically controlled components. These components are described below.

Ignition coil

1.Two ignition coil are used in this system. The engine locates them directly above the #2 and #4 spark plugs. The coil resistance is dentical for these two coils and there is no maintenance required for them.

If determined to be faulty, they must be replaced.

High-tension leads

The high-tension leads connect the two ignition coils to the spark plugs. Their function is basically the same as on the previous system. Because of their shorter length, the DLI high-tension leads enhance the ignition systems delivered voltage. In addition, they reduce the wave interference from one high tension wire to another.

Spark plugs

The spark plugs provide the air gap necessary to produce an arc from the electrical energy coming in from the ignition coil. This arc then ignites the fuel/air mixture in the cylinder, producing power.

2001 > 1.8L DOHC >

DIAGNOSIS

Problem

Possible Cause

Action

 

 

 

Engine light is "ON"

Engine control module detects fault

Check engine module. Repair as

in system

required

 

 

 

 

Engine runs rough

Spark plug failure

Check, clean or replace plugs

 

 

 

 

High-tension lead arcing to ground

Replace high-tension leads

 

 

 

 

Ignition coil(s) faulty

Check/replace ignition coil

 

 

 

 

CMP sensor faulty

Check/replace sensor

 

 

 

 

CKP sensor faulty

Check/replace sensor

 

 

 

Engibe fails to start, starter

Fuse failure

Check/replace IGN fuse

turning

 

 

Low battery current

Check charging system

 

 

 

 

 

Ignition coil(s) failure

Check/replace coil(s)

 

 

 

 

CMP sensor failure

Check/replace sensor

 

 

 

 

CKP sensor failure

Check/replace sensor

 

 

 

2001 > 1.8L DOHC >

SPECIFICATIONS

Fastener tightening specifications

 

Item

 

 

 

 

Ignition coil bolt

 

5~7.2 lb-ft (7~10N·m, 0.7~10kg-m)

 

 

 

Spark plugs

 

18~22lb-ft (25-30N·m, 2.5~3.0kg-m)

 

 

 

SPECIFICATIONS

General specifications

 

 

Item

 

 

TBD

 

 

 

 

 

 

 

Engine idle speed

 

 

 

 

800 ± 50 rpm

 

 

 

 

 

 

 

 

Ignition coil

 

 

Type

 

 

Dual coil

 

 

 

 

 

 

 

 

 

 

Primary coil resistance

0.45~0.55Ω at 68°F (20°C)

 

 

 

 

 

 

 

 

 

 

Secondary coil resistance

13~15kΩ at 68°F (20°C)

 

 

 

 

 

 

 

High-tension lead

 

 

 

 

16kΩ per 3.28feet (1m)

 

 

 

 

 

 

 

Spark plug gap

 

 

 

 

0.027~0.031in (0.7~0.8mm)

 

 

 

 

 

 

 

 

Spark plug type

 

 

 

 

 

BKR6E

 

 

 

 

 

 

 

 

Starter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine/Trans

 

 

TBD

 

 

 

 

 

 

 

 

 

Item

 

M/T

 

A/T

 

 

 

 

 

 

 

Starter

 

Type

 

Direct

 

Gear reduction

 

 

 

 

 

 

 

 

 

Output

 

12V - 0.9kW

 

12V - 1.2kW

 

 

 

 

 

 

 

 

 

Brush length

Standard

0.67in (17mm)

 

0.49in (12mm)

 

 

 

 

 

 

 

 

 

 

 

 

Minimum

0.45in (11.5mm)

 

0.28in (7mm)

 

 

 

 

 

 

 

 

Engine Electrical System

Engine Electrical System

Ignition System

Engine Electrical System

Engine Electrical System

Ignition System - Ignition Coil

2001 > 1.8L DOHC >

INSPECTION

Voltage check

1.Disconnect negative battery cable.

2.Disconnect ignition coil connector.

3.Turn ignition switch to "ON".

4.Measure voltage at red and blue wires at ignition coil connector. Voltage : approximately 12volts

5.If not voltage check main fuse, ignition switch and wire harness.

Resistance check

1.Using an ohmmeter check resistance of primary coil. Connect one lead of ohmmeter to positive (+) terminal and other lead to each negative (-) terminal. If not within specification, replace coil.

Remember that unit has two coil assemblies, so both must be checked. Primary coil resistance : 0.45~0.55Ω @ 68°F (20°C)

2.Using an ohmmeter, check resistance of the secondary coil. If not within specification, replace coil. Remember that you must check resistance of both top and bottom secondary coil. If one is out of specification replace the whole unit.

Secondary coil resistance : 13~15Ω @ 68°F (20°C)

REMOVAL

1.Disconnect battery cable.

2.Disconnect high-tension leads.

3.Disconnect ignition coil connector.

4.Remove four ignition coil mounting bolts.

5.Remove ignition coils.

INSTALLATION

1.Position two coils above No. 2 and No. 4 spark plugs, and firmly push down to connect.

2.Insert and tighten four ignition coil mountinh bolts. Tightening torque : 14~19lb-ft (19~25N·m, 1.9~2.6kg-m)

3.Reconnect ignition coil connectors.

4.Reattach high tension leads. Lead are marked for correct connection.

5.Reconnect battery cable.

Engine Electrical System

Engine Electrical System

Ignition System - Spark Plug

2001 > 1.8L DOHC >

REMOVAL

Do not attempt any maintenance on spark plugs if engine is hot.

1.Disconnect negative battery terminal.

2.Carefulley remove high-tension leads.

3.Use compressed air to blow any dirt or debris from around spark plug hole.

4.Check that spark plug fits squarely spark plug socket and remove spark plug.

INSTALLATION

1.Install spark plug into cylinder head.

Tightening torque : 18~22lb-ft (25~30N·m, 2.5~3.0kg-m)

2.Reconnect high-tension leads.

3.Reconnect negative battery cable.

INSPECTION

1.Reconnect negative battery cable.

2.Connect spark plug to high-tension lead.

3.Hold spark plug with insulated pliers 0.2 to 0.39 inch (5~10mm) from a ground.

DO NOT TOUCH VEHICLE BODY DURING FOLLOWING INSTRUCTIONS.

4.While holdung spark plug, have a second person crank engine. Verify that a strong blue spark jumps from spark plug to ground.

5.If there is no spark or the spark is weak, check for, and implement correction :

A.Carbon deposits. Clean out or replace plug.

B.Oil fouling. Correct oil problem, replace plug.

C.Worn or burnt electrode. If present, replace plug.

D.Broken or burned ceramic insulator. If present replace plug.

E.Damaged spark plug ring. If so, replace ring.

F.Improper spark plug gap. Regap if possible, otherwise replace plug. Gap : 0.027~0.031in (07~0.8mm)

Engine Electrical System

Engine Electrical System

Ignition System - Spark Plug Cable

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