Kia Carnival 2008 User Manual

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Page 1

2008 ACCESSORIES & BODY, CAB

Body (Interior & Exterior) - General - Sedona

SPECIFICATIONS

GENERAL SPECIFICATIONS

TIGHTENING TORQUE

TIGHTENING TORQUE SPECIFICATIONS

HOOD Type Rear hinged, gas lifter type

FRONT DOOR Construction Front hinged, full door

construction

Regulator system X-ARM type

Locking system Pin-fork system

REAR DOOR Construction Sliding door construction

Regulator system Wire drum type

Locking system Pin-fork system TAILGATE Type Inner hinged, gas lifter type GLASS THICKNESS Windshield glass 5 mm

Front door glass 4 mm

Rear door glass 4 mm

Rear window glass 3.5 mm

SEAT BELTS Front 3 point type with Emergency

Locking Retractor (ELR)

Rear 3 point type with Emergency

Locking Retractor (ELR)

Items N.m Kgf. m Lbf. ft

Front and rear doors Door hinge to body 33.3-41.2 3.4-4.2 24.6-30.4

Door hinge to door 21.6-26.5 2.2-2.7 15.9-19.5 Striker 6.9-10.8 0.7-1.1 5.1-8.0 Glass mounting bolt 7.8-11.8 0.8-1.2 5.8-8.7 Outside handle

mounting bolt

6.9-10.8 0.7-1.1 5.1-8.0

Rear channel mounting nut

7.8-11.8 0.8-1.2 5.8-8.7

Tailgate Tailgate hinge to

body

6.9-8.8 0.7-0.9 5.1-6.5

Tailgate hinge to tailgate

6.9-8.8 0.7-0.9 5.1-6.5

Tailgate lift mounting bolt

6.9-8.8 0.7-0.9 5.1-6.5

2008 Kia Sedona EX

2008 ACCESSORIES & BODY, CAB Body (Interior & Exterior) - General - Sedona

2008 Kia Sedona EX

2008 ACCESSORIES & BODY, CAB Body (Interior & Exterior) - General - Sedona

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SPECIAL TOOLS

SPECIAL TOOLS REFERENCE CHART

Key cylinder mounting nut

6.9-10.8 0.7-1.1 5.1-8.0

Hood Hood hinge to body 21.6-26.5 2.2-2.7 15.9-19.5

Hood hinge to hood 21.6-26.5 2.2-2.7 15.9-19.5 Hood latch to body 6.9-10.8 0.7-1.1 5.1-8.0

Seat Front seat mounting

bolts

43.1-64.7 4.4-6.6 31.8-47.7

Rear seat mounting bolts

43.1-64.7 4.4-6.6 31.8-47.7

Seat belt Front seat belt

height adjuster

39.2-53.9 4.0-5.5 28.9-39.8

Front seat belt buckle mounting bolt

39.2-53.9 4.0-5.5 28.9-39.8

Front seat belt anchor mounting bolt

39.2-53.9 4.0-5.5 28.9-39.8

Front seat belt lower anchor

39.2-53.9 4.0-5.5 28.9-39.8

Front seat belt upper anchor

39.2-53.9 4.0-5.5 28.9-39.8

Rear seat belt anchor attaching bolt

39.2-53.9 4.0-5.5 28.9-39.8

Rear seat belt retractor mounting bolt

39.2-53.9 4.0-5.5 28.9-39.8

Tool (Number and name) Illustration Use

09793-2100 Door hinge adjusting wrench

Adjustment, removal and installation Of the door hinge

09800-21000 Ornament remover

Trim removal

2008 Kia Sedona EX

2008 ACCESSORIES & BODY, CAB Body (Interior & Exterior) - General - Sedona

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09853-31000 Headliner clip remover

Removal of the headliner clips

09861-31100 Sealant cut-out tool

Cutting the sealant of the windshield (Use with 09861-31200)

09861-31200 Sealant cutting blade

Cutting the sealant of the windshield (Use with 09861-31100)

09861-31300 Sealant gun

Application of the sealant to the windshield

2008 Kia Sedona EX

2008 ACCESSORIES & BODY, CAB Body (Interior & Exterior) - General - Sedona

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TROUBLESHOOTING

TROUBLESHOOTING CHART

09681-31400 Glass holder

Removal and installation of the windshield

09681-31000 Windshield molding remover

Removal of the windshield molding

09880-4F000 Hog ring clip installer

Installation of the hog ring clip

Symptom Suspect Area Remedy

2008 Kia Sedona EX

2008 ACCESSORIES & BODY, CAB Body (Interior & Exterior) - General - Sedona

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Water leaks from sunroof Dirt accumulated in drain tube Clear dirt inside of drain

Clogged drain tube Blow air into drain to remove dirt Broken or dislocated drain tube,

defective Or cracked clip

Check tube installation and Flange contact

Deteriorated roof lid weatherstrip Replace Excessive roof lid-to-body

clearance and Improperly fitted weatherstrip

Adjust

Wind noise around sunroof Loose or deformed deflector, gaps

In body work

Retighten adjust or replace

Sunroof lid makes a noise when moving

Foreign particles lodged in guide rail

Check drive cable and guide Rails for foreign particles

Loose guide rails and lid Retighten

Motor runs but sunroof does not move or moves only partially

Foreign particles lodged in guide rail

Check drive cable and guide Rails for foreign particles

Incorrect engagement of motor pinion With drive cable

Check for loose motor installation And damaged pinion

Decrease in motor's clutch slipping force

Adjust

Increased sunroof sliding resistance Or interference of sunroof with drive cables, weatherstrip, etc. due to maladjustment of sunroof

Adjust or replace

Noise in motor (clutch slipping Noise from motor when sunroof Is fully opened or closed is not An unusual noise)

Incorrect engagement of motor pinion With drive cable

Check pinion installation and Retighten motor

Worn out or damaged motor pinion bearing

Replace motor assembly

Worn out or deformed drive cable Replace

Door glass fails to operate Up and down

Incorrect window glass installation Adjust position Damaged or faulty regulator arm

or regulator

Correct or replace

Door does not open or close completely

Incorrect door installation Adjust position Defective door check assembly Correct or replace Door hinge requires grease Apply grease

Hood does not open or close completely

Striker and latch not properly aligned

Adjust

Incorrectly installed hood Adjust Incorrect hood bumper height Adjust

Water leak through windshield end rear window

Defective seal Fill with sealant Defective flange Correct

2008 Kia Sedona EX

2008 ACCESSORIES & BODY, CAB Body (Interior & Exterior) - General - Sedona

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2008 BRAKES

Brake System - General - Sedona

SPECIFICATIONS

BRAKE SYSTEM SPECIFICATIONS

Item Specification

Master cylinder

 Type

Tandem type

 I.D. mm (in)

26.99/(1.063)

 Piston stroke mm (in)

30 (1.18)

 Fluid level warning sensor

Provided

Brake booster

 Type

8 + 9 in Tandem

 Boosting ratio

9.0: 1

Front brake (Disc)

 Type

Floating type with ventilated disc

 Disc O.D.

298 mm (11.73 in)

 Disc thickness

28 mm (1.10 in)

 Pad thickness

10.5 mm (0.41 in)

 Cylinder type

Double piston

 Cylinder I.D.

Ø48 mm (Ø1.89 in)

Rear Brake (Disc)

 Type

Floating type with solid disc

 Disc O.D.

302 mm (11.89 in)

 Disc thickness

12 mm (0.47 in)

 Pad thickness

10 mm (0.39 in)

 Cylinder type

Single piston

 Cylinder I.D

Ø42.9 mm (Ø1.69 in)

Parking Brake

 Type

DIH (Drum in hat)

 Actuation

Foot brake

 Drum

Ø190 mm (Ø7.48 in)

O.D=Outer Diameter I.D=Inner Diameter

2008 Kia Sedona

2008 BRAKES Brake System - General - Sedona

2008 Kia Sedona

2008 BRAKES Brake System - General - Sedona

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SPECIFICATION (ABS) ANTI-LOCK BRAKE SYSTEM SPECIFICATIONS

SPECIFICATION (ESC)

ELECTRONIC STABILITY CONTROL SPECIFICATIONS

NOTE: ABS: Anti-Lock Brake System

ESC: Electronic Stability Control

Part Item Standard value Remark

HECU (Hydraulic and Electronic Control Unit)

System 4 channel 4 sensor

(Solenoid)

•ABS system: ABS & EBD control

Type Motor, valve relay

integrated type Operating voltage 8 V-16 V (DC) Operating temperature -40 to 120°C (-40 to

248°F)

Warning lamp

Operating voltage 12 V •ABS W/LABS

failure

•Brake W/L: Parking, brake oil, EBD failure

Current consumption 80 mA

Active wheel speed sensor

Supply voltage DC 4.5-2.0 V Operating temperature -40-150 °C Output current low 5.9-8.4 mA Typ.7 mA Output current High 11.8-16.8 mA Typ.14 mA Frequency range 1-2500 HZ

Air gap

Front 0.15-1.5 mm Typ.0.7 mm

Rear 0.2-1.2 mm Typ.0.7 mm Tone wheel 48 teeth Output duty 30-70 %

Part Item Standard Value Remark

HECU (Hydraulic and Electronic Control Unit)

System 4 channel 4 sensor

(Solenoid)

•Total control (ABS, EBD, TCS, ESC)

Type Motor, valve relay

integrated type Operating voltage 8 V-16 V (DC) Operating temperature -40 to120°C (-40 to

248°F)

Warning lamp

Operating voltage 12 V •ESC Operating

Lamp

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2008 BRAKES Brake System - General - Sedona

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SERVICE STANDARD

SERVICE STANDARD SPECIFICATIONS

TIGHTENING TORQUE

ESC Warning Lamp

Current consumption 80 mA

Active wheel speed sensor

Supply voltage DC 4.5-20 V Operating temperature -40-150 °C Output current low 5.9-8.4 mA Output current high 11.8-16.8 mA Tone wheel 48 teeth Frequency range 1-2500 HZ

Air gap

Front 0.15-1.5 mm Type. 0.7 mm Rear 0.2-1.2 mm Type. 0.7 mm

Steering Wheel Angle Sensor

Operating Voltage 8V-16 V Current Consumption Max 150 mA Operating Angular velocity Max ± 780 °/sec

Yaw-rate & Lateral G sensor

Operating Voltage 8 V-16 V Current Consumption Max. 120 mA Output Voltage high 4.35 V-4.65 V Type. 4.5 V Output Voltage low 0.35-0.65 V Type. 0.5 V Yaw Sensor Operating Range ±100 ° /s G Sensor Operating Range ±1.8 G Reference voltage output 2.464-2.536 V Type. 2.5 V

Items Standard value

Brake pedal height 192.4 mm (7.57 in) Brake pedal full stroke 122 mm (4.8 in) Adjust Brake pedal full stroke 60 mm (2.36 in) Brake pedal free play 3-8 mm (0.11-0.31 in) Stop lamp switch outer case to pedal stopper

clearance

1.0-1.5 mm (0.04-0.06 in)

Booster push rod to master cylinder piston clearance 0.6-1.7 mm (0.02-0.07 in) (at 500 mm.Hg) Parking brake pedal stroke when pedal assembly is

depressed with 294N (30kgf, 661b force)

145 mm (5.71 in) above

Front disc brake pad thickness 10.5 mm (0.41 in) Front disc thickness 28 mm (1.10 in) Rear disc brake pad thickness 10 mm (0.394 in) Rear disc brake disc thickness 12 mm (0.47 in) Rear parking brake liner thickness 4 mm (0.16 in)

2008 Kia Sedona

2008 BRAKES Brake System - General - Sedona

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TIGHTENING TORQUE SPECIFICATIONS

LUBRICANT LUBRICANT SPECIFICATIONS

SPECIAL TOOL

SPECIAL TOOLS DESCRIPTION

Items N.m kgf.m lb-ft

Master cylinder to booster mounting nut 8-12 0.8-1.2 5.8-8.7 Brake booster mounting nut 13-16 1.3-1.6 9.4-11.6 Bleeder screw 7-13 0.7-1.3 5.06-9.4 Brake tube nut, brake hose 13-17 1.3-1.7 9.4-12.3 Caliper guide rod bolt (Front) 22-32 2.2-3.2 15.9-23.1 Caliper guide rod bolt (Rear) 22-32 2.2-3.2 15.9-23.1 Caliper assembly to knuckle (Front) 85-100 8.5-10 61.5-72.3 Caliper assembly to knuckle (Rear) 50-60 5.0-6.0 36.2-43.4 Brake hose to front caliper 25-30 2.5-3.0 18.1-21.7 Brake pedal assembly bracket mounting nut 10-15 1.0-1.5 7.2-10.8 Brake pedal mounting nut 13-16 1.3-1.6 9.4-11.6 Stop lamp switch mounting nut 8-10 0.8-1.0 5.8-7.2 Active wheel speed sensor mounting bolt on the brake plate 7-10 0.7-1.0 5.1-7.2 HECU mounting bracket bolt 17-26 1.7-2.6 12.3-18.8 HECU mounting nut 6-10 0.6-1.0 4.3-7.2 Yaw rate & lateral acceleration sensor bolt 5-8 0.5-0.8 3.6-5.8

Item Recommended lubricant Quantity

Brake fluid DOT 3 or DOT 4 As required Brake pedal bushing and brake pedal bolt Chassis grease As required Parking brake shoe and backing plate contact surfaces Bearing grease As required Caliper guide rod and boot RX - 2 grease 0.8-1.3 g Rear caliper guide rod and boot Rubber grease 0.8-1.3 g

Tool (Number and Name) Illustration Use

09581-11000 Piston expander

Spreading the front disc brake piston

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2008 BRAKES Brake System - General - Sedona

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TROUBLESHOOTING

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the like cause of the problem. Check each part in order. If necessary, replace these parts

TROUBLESHOOTING CHART

Symptom Suspect Area Reference

Lower pedal or spongy pedal 1. Brake system (Fluid leaks) repair

2. Brake system (Air in) air-bleed

3. Piston seals (Worn or damaged) replace

4. Rear brake shoe clearance (Out of adjustment)

adjust

5. Master cylinder (Inoperative) replace

Brake drag 1. Brake pedal freeplay

(Minimum)

adjust

2. Parking brake lever travel (Out of adjustment)

adjust

3. Parking brake wire (Sticking) repair

4. Rear brake shoe clearance (Out of adjustment)

adjust

5. Pad or lining (Cracked or distorted)

replace

6. Piston (Stuck) replace

7. Piston (Frozen) replace

8. Anchor or Return spring (Inoperative)

replace

9. Booster system (Vacuum leaks) repair

10. Master cylinder (Inoperative) replace

Brake pull 1. Piston (Sticking) replace

2. Pad or lining (Oily) replace

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2008 BRAKES Brake System - General - Sedona

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3. Piston (Frozen) replace

4. Disc (Scored) replace

5. Pad or lining (Cracked or distorted)

replace

Hard pedal but brake inefficient 1. Brake system (Fluid leaks) repair

2. Brake system (Air in) air-bleed

3. Pad or lining (Worn) replace

4. Pad or lining (Cracked or distorted)

replace

5. Rear brake shoe clearance (Out of adjustment)

adjust

6. Pad or lining (Oily) adjust

7. Pad or lining (Glazed) replace

8. Disc (Scored) replace

9. Booster system (Vacuum leaks) repair

Noise from brake 1. Pad or lining (Cracked or

distorted)

replace

2. Installation bolt (Loosen) adjust

3. Disc (Scored) replace

4. Sliding pin (Worn) replace

5. Pad or lining (Dirty) clean

6. Pad or lining (Glazed) replace

7. Anchor or Return spring (Inoperative)

replace

8. Brake pad shim (Damage) replace

9. Shoe hold-down spring (Damage)

replace

Brake fades 1. master cylinder replace

Brake vibration, pulsation

1. brake booster replace

2. pedal free play adjust

3. master cylinder replace

4. caliper replace

5. master cylinder cap seal replace

6. damaged brake lines replace

Brake Chatter

Brake chatter is usually caused by loose or worn components, or glazed or burnt linings. Rotors with hard spots can also contribute to brake chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining.

2008 Kia Sedona

2008 BRAKES Brake System - General - Sedona

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2008 ELECTRICAL

Charging System - Sedona

DESCRIPTION

The charging system includes a battery, an generator with a built-in regulator, and the charging indicator light and wire.

The Generator has built-in diodes, each rectifying AC current to DC current.

Therefore, DC current appears at generator "B" terminal. In addition, the charging voltage of this generator is regulated by the battery voltage detection system.

The main components of the generator are the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley. The brush holder contains a built-in electronic voltage regulator.

Fig. 1: Identifying Generator Components Courtesy of KIA MOTORS AMERICA, INC.

ON-VEHICLE INSPECTION

CHECK BATTERY VOLTAGE

1. If 20 minutes have not passed since the en

ine was stopped, turn the ignition switch ON and turn on the

CAUTION:

 Check that the battery cables are connected to the correct terminals.  Disconnect the battery cables when the battery is given a quick

charge.

 Never disconnect the battery while the engine is running.

2008 Kia Sedona

2008 ELECTRICAL Charging System - Sedona

2008 Kia Sedona

2008 ELECTRICAL Charging System - Sedona

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electrical system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.

2. Turn the ignition switch OFF and turn off the electrical systems.

3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.

Standard voltage: 12.5-12.9V at 20°C (68°F)

If the voltage is less than specification, charge the battery.

CHECK THE BATTERY TERMINALS AND FUSES

1. Check that the battery terminals are not loose or corroded.

2. Check the fuses for continuity.

INSPECT DRIVE BELT

Visually check the belt for excessive wear, frayed cords etc.

If any defect has been found, replace the drive belt.

Fig. 2: Identifying Defective Drive Belt Courtesy of KIA MOTORS AMERICA, INC.

VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES

1. Check that the wiring is in good condition.

2. Check that there is no abnormal noise from the alternator while the engine is running.

CHECK BATTERY WARNING LIGHT CIRCUIT

1. Warm up the engine and then turn it off.

NOTE: Cracks on the rib side of a belt are considered acceptable. If the belt has

chunks missing from the ribs, it should be replaced.

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2. Turn off all accessories.

3. Turn the ignition switch "ON". Check that the battery warning light is lit.

4. Start the engine. Check that the light is lit.

If the light does not go off as specified, troubleshoot the discharge light circuit.

INSPECT CHARGING SYSTEM

VOLTAGE DROP TEST OF GENERATOR OUTPUT WIRE

This test determines whether or not the wiring between the generator "B" terminal and the battery (+) terminal is good by the voltage drop method.

PREPARATION

1. Turn the ignition switch to "OFF".

2. Disconnect the output wire from the generator "B" terminal. Connect the (+) lead wire of ammeter to the "B" terminal of generator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire o

voltmeter to the "B" terminal of generator and the (-) lead wire of voltmeter to the (+) terminal of battery.

Fig. 3: Charging System Circuit Diagram Courtesy of KIA MOTORS AMERICA, INC.

TEST

1. Start the engine.

2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.

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And then, read the voltmeter at this time.

RESULT

1. The voltmeter may indicate the standard value.

Standard value: 0.2V max

2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case check the wiring from the alternator "B" terminal to the battery (+) terminal. Check for loose connections, color change due to an overheated harness, etc. Correct them before testing again.

3. Upon completion of the test, set the engine speed at idle.

Turn off the headlamps, blower motor and the ignition switch.

OUTPUT CURRENT TEST

This test determines whether or not the generator gives an output current that is equivalent to the normal output.

PREPARATION

1. Prior to the test, check the following items and correct as necessary.

Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is described in BATTERY.

The battery that is used to test the output current should be one that has been partially discharged. With a fully charged battery, the test may not be conducted correctly due to an insufficient load.

Check the tension of the generator drive belt. The belt tension check method is described in INSPECT DRIVE BELT.

2. Turn off the ignition switch.

3. Disconnect the battery ground cable.

4. Disconnect the generator output wire from the alternator "B" terminal.

5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be sure to connect the (-) lead wire of the ammeter to the disconnected output wire.

6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B" terminal and (-) lead wire to a good ground.

7. Attach an engine tachometer and connect the battery ground cable.

8. Leave the engine hood open.

NOTE: Tighten each connection securely, as a heavy current will flow. Do not rely

on clips.

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Fig. 4: Output Current Circuit Diagram Courtesy of KIA MOTORS AMERICA, INC.

TEST

1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the open circuit in the wire between alternator "B" terminal and battery (-) terminal or poor grounding is suspected.

2. Start the engine and turn on the headlamps.

3. Set the headlamps to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 RPM and read the maximum output current value indicated by the ammeter.

RESULT

1. The ammeter reading must be higher than the limit value. If it is lower but the generator output wire is in good condition, remove the generator from the vehicle and test it.

Limit value: 91A min. (130A alternator)

NOTE: After the engine start up, the charging current quickly drops.

Therefore, the above operation must be done quickly to read the maximum current value correctly.

NOTE:

 The nominal output current value is shown on the nameplate affixed

to the generator body. The output current value changes with the electrical load and the

temperature of the generator itself. The nominal output current may not be obtained if the temperature of

the generator itself or ambient temperature is too high.

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2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.

3. Disconnect the battery ground cable.

4. Remove the ammeter and voltmeter and the engine tachometer.

5. Connect the generator output wire to the generator "B" terminal.

6. Connect the battery ground cable.

REGULATED VOLTAGE TEST

The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.

PREPARATION

1. Prior to the test, check the following items and correct if necessary.

Check that the battery installed on the vehicle is fully charged. The battery checking method is described in BATTERY.

Check the alternator drive belt tension. The belt tension check method is described in INSPECT DRIVE BELT.

2. Turn ignition switch to "OFF".

3. Disconnect the battery ground cable.

4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the voltmeter to the "B" terminal of the alternator. Connect the (-) lead to good ground or the battery (-) terminal.

5. Disconnect the alternator output wire from the alternator "B" terminal.

6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Connect the (-) lead wire of the ammeter to the disconnected output wire.

7. Attach the engine tachometer and connect the battery ground cable.

In such a case, reduce the temperature before testing again.

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Fig. 5: Output Current Circuit Diagram Courtesy of KIA MOTORS AMERICA, INC.

TEST

1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.

Voltage: Battery voltage

If it reads 0V, there is an open circuit in the wire between the generator "B" terminal and the battery and the battery (-) terminal.

2. Start the engine. Keep all lights and accessories off.

3. Run the engine at a speed of about 2,500 RPM and read the voltmeter when the generator output current drops to 10A or less

RESULT

1. If the voltmeter reading agrees with the value listed in the regulating voltage table below, the voltage regulator is functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.

REGULATING VOLTAGE TABLE REGULATING VOLTAGE CHART

2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.

3. Disconnect the battery ground cable.

Voltage regulator ambient temperature °C (°F)Regulating voltage (V)

-30 (-22) 14.2-15.3 25 (77) 14.2-14.8

135 (275) 13.3-14.8

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4. Remove the voltmeter and ammeter and the engine tachometer.

5. Connect the generator output wire to the generator "B" terminal.

6. Connect the battery ground cable.

ALTERNATOR

REMOVAL

1. Disconnect the battery negative terminal first, then the positive terminal.

2. Disconnect the alternator connector, and remove the cable from alternator "B" terminal.

3. Remove the drive belt.

4. Pull out the through bolts and then remove the alternator (A).

Fig. 6: Locating Generator Courtesy of KIA MOTORS AMERICA, INC.

5. Installation is the reverse of removal.

COMPONENT

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Fig. 7: Exploded View Of Generator Courtesy of KIA MOTORS AMERICA, INC.

DISASSEMBLY

1. Remove the

enerator cover (A) using a screwdriver (B).

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Fig. 8: Identifying Generator Cover Courtesy of KIA MOTORS AMERICA, INC.

2. Remove the slip ring guide (A).

3. Loosen the mounting bolts (B) and disconnect the brush holder assembly (C).

Fig. 9: Identifying Slip Ring Guide And Mounting Bolts Courtesy of KIA MOTORS AMERICA, INC.

4. Remove the rectifier (A) with 4 screw.

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Fig. 10: Identifying Rectifier Courtesy of KIA MOTORS AMERICA, INC.

5. Remove the nut, pulley (A) and spacer.

Fig. 11: Identifying Pulley Courtesy of KIA MOTORS AMERICA, INC.

6. Loosen the 4 nuts (A).

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Fig. 12: Identifying Bolts Courtesy of KIA MOTORS AMERICA, INC.

7. Disconnect the rotor (A) and cover (B).

Fig. 13: Identifying Rotor And Cover Courtesy of KIA MOTORS AMERICA, INC.

8. Reassembly is the reverse order of disassembly.

INSPECTION

INSPECT ROTOR

1. Check that there is continuity between the slip rings (A).

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Fig. 14: Identifying Slip Rings, Rotor And Rotor Shaft Courtesy of KIA MOTORS AMERICA, INC.

2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (C).

3. If the rotor fails either continuity check, replace the generator.

INSPECT STATOR

1. Check that there is continuity between each pair of leads (A).

Fig. 15: Identifying Leads Courtesy of KIA MOTORS AMERICA, INC.

2. Check that there is no continuity between each lead and the coil core.

3. If the coil fails either continuity check, replace the alternator.

BATTERY

DESCRIPTION

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1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell caps.

2. Water never needs to be added to the maintenance-free battery.

3. The battery is completely sealed, except for small vent holes in the cover.

Fig. 16: View Of Battery Courtesy of KIA MOTORS AMERICA, INC.

INSPECTION

BATTERY DIAGNOSTIC TEST (1)

CHECKING FLOW

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Fig. 17: Battery Diagnostic Test Flow Diagram Courtesy of KIA MOTORS AMERICA, INC.

LOAD TEST

1. Perform the following steps to complete the load test procedure for maintenance free batteries.

2. Connect the load tester clamps to the terminals and proceed with the test as follow:

1. If the battery has been on charge, remove the surface charge by connecting a 300 ampere load for 15 seconds.

2. Connect the voltmeter and apply the specified load.

3. Read the voltage after the load has been applied for 15 seconds.

4. Disconnect the load.

5. Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that shown in BATTERY TEST VOLTAGE

BATTERY TEST VOLTAGE

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BATTERY DIAGNOSTIC TEST (2)

1. Make sure the ignition switch and all accessories are in the OFF position.

2. Disconnect the battery cables (negative first).

3. Remove the battery from the vehicle.

Fig. 18: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC.

4. Inspect the battery tray for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe off with a cloth moistened with baking soda and water.

Voltage Temperature

9.6V 20°C (68.0°F) and above

9.5V 16°C (60.8°F)

9.4V 10°C (50.0°F)

9.3V 4°C (39.2°F)

9.1V -1°C (30.2°F)

8.9V -7°C (19.4°F)

8.7V -12°C (10.4°F)

8.5V -18°C (-0.4°F)

NOTE:

 If the voltage is greater than shown in BATTERY TEST VOLTAGE, the

battery is good.

 If the voltage is less than shown in BATTERY TEST VOLTAGE,

replace the battery.

CAUTION: Care should be taken in the event the battery case is cracked or

leaking, to protect your skin from the electrolyte. Heavy rubber gloves (not the household type) should be wore when removing the battery.

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5. Clean the top of the battery with the same solution as described above.

6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.

7. Clean the battery posts with a suitable battery post tool.

8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed cables and broken terminal clamps.

9. Install the battery in the vehicle.

10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the posts.

11. Tighten the terminal nuts securely.

12. Coat all connections with light mineral grease after tightening.

Fig. 19: View Of Battery Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: When batteries are being charged, an explosive gas forms beneath

the cover of each cell. Do not smoke near batteries being charged or which have recently been charged. Do not break live circuit at the terminals of batteries being charged. A spark will occur when the circuit is broken. Keep open flames away from battery.

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CRASH PAD

COMPONENTS

Fig. 7: Identifying Crash Pad Components Courtesy of KIA MOTORS AMERICA, INC.

REPLACEMENT

CLUSTER FASCIA PANEL REPLACEMENT

NOTE:

 When prying with a flat-tipped screwdriver, wrap it with protective tape,

and apply protective tape around the related parts, to prevent damage.

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1. Tilt the steering column down.

2. Remove the screws, and detach the clips.

3. After disconnecting the connector (A), remove the cluster fascia panel (B).

Fig. 8: Identifying Connector And Cluster Fascia Panel Courtesy of KIA MOTORS AMERICA, INC.

4. Installation is the reverse of removal.

CENTER FASCIA PANEL REPLACEMENT

1. Detach the clips, then remove the center fascia panel (A).

 Put on gloves to protect your hands.

NOTE:

 Make sure the connector is plugged in properly.

NOTE:

 When prying with a flat-tipped screwdriver, wrap it with protective tape,

and apply protective tape around the related parts, to prevent damage.

 Put on gloves to protect your hands.

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Fig. 9: Identifying Center Fascia Panel And Clip Courtesy of KIA MOTORS AMERICA, INC.

2. Installation is the reverse the removal.

LOWER PANEL REPLACEMENT

1. Remove the crash pad side cover. See COVER REPLACEMENT.

2. Remove the fuse box cover (A).

Fig. 10: Identifying Fuse Box Cover Courtesy of KIA MOTORS AMERICA, INC.

3. After loosenin

the crash pad lower panel mounting screws, then remove the lower panel (B).

NOTE:

 Make sure the connector is plugged in properly.

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4. Remove the parking brake lever (C).

Fig. 11: Identifying Lower Panel, Parking Brake Lever And Fastener Locations Courtesy of KIA MOTORS AMERICA, INC.

5. Disconnect the connector (A).

Fig. 12: Identifying Connector Courtesy of KIA MOTORS AMERICA, INC.

6. Installation is the reverse of removal.

HEATER CONTROL UNIT REPLACEMENT

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1. Remove the center fascia panel. See REPLACEMENT.

2. Remove the console upper cover (A).

3. Disconnect the connector (B).

Fig. 13: Identifying Center Cover And Connector Courtesy of KIA MOTORS AMERICA, INC.

4. Loosen the air vent mounting screw, then remove the air vent (A).

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Fig. 14: Identifying Air Vent And Fastener Locations Courtesy of KIA MOTORS AMERICA, INC.

5. After loosening the heater control unit mounting screws, then remove the heater control unit (A).

Fig. 15: Identifying Heater Control Unit And Screw Courtesy of KIA MOTORS AMERICA, INC.

6. Installation is the reverse of removal.

Fig. 16: Identifying Connector (1 Of 2) Courtesy of KIA MOTORS AMERICA, INC.

NOTE:

 Make sure the connector (A) is plugged in properly.

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Fig. 17: Identifying Connector (2 Of 2) Courtesy of KIA MOTORS AMERICA, INC.

CLUSTER REPLACEMENT

1. Remove the cluster fascia panel. See REPLACEMENT.

2. Loosen the screws.

Fig. 18: Identifying Cluster Panel And Screw Courtesy of KIA MOTORS AMERICA, INC.

3. Disconnect the cluster connectors (A), then remove the cluster (B).

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Fig. 19: Identifying Cluster Connectors And Cluster Courtesy of KIA MOTORS AMERICA, INC.

4. Installation is the reverse of removal.

AUDIO ASSEMBLY REPLACEMENT

1. Remove the center fascia panel. See REPLACEMENT.

2. Loosen the screws.

Fig. 20: Identifying Center Fascia Panel And Screw Courtesy of KIA MOTORS AMERICA, INC.

NOTE:

 Make sure the connector are plugged in properly.

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3. Disconnect the connector (A), then remove the audio assembly (B).

Fig. 21: Identifying Connector And Audio Assembly Courtesy of KIA MOTORS AMERICA, INC.

4. Installation is the reverse of removal.

AIR VENT REPLACEMENT

1. Remove the side cover. See COVER REPLACEMENT.

2. Loosen the mounting screws, then remove the air vent (A).

NOTE:

 Make sure the connector are plugged in properly.

NOTE:

 When prying with a flat-tipped screwdriver, wrap it with protective tape,

and apply protective tape around the related parts, to prevent damage.

 Put on gloves to protect your hands.

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Fig. 22: Identifying Air Vent Courtesy of KIA MOTORS AMERICA, INC.

3. Installation is the reverse of removal.

GLOVE BOX REPLACEMENT

1. Disconnect the damper (B) from the glove box (A).

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Fig. 23: Identifying Damper And Glove Box Courtesy of KIA MOTORS AMERICA, INC.

2. Remove the glove box (A) from the lift (B).

Fig. 24: Identifying Glove Box And Lift Courtesy of KIA MOTORS AMERICA, INC.

3. Disconnect the pine (A), then remove the glove box (B).

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Fig. 25: Identifying Pine And Glove Box Courtesy of KIA MOTORS AMERICA, INC.

4. Installation is the reverse of removal.

COVER REPLACEMENT

1. Remove the crash pad side cover (A), crash pad center under cover (B).

1. Crash pad side cover.

NOTE:

 When prying with a flat-tipped screwdriver, wrap it with protective tape,

and apply protective tape around the related parts, to prevent damage.

 Put on gloves to protect your hands.

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Fig. 26: Identifying Crash Pad Side Cover And Clip Courtesy of KIA MOTORS AMERICA, INC.

2. Front crash pad center under cover, LH.

Fig. 27: Identifying Center Under Cover And Clip Courtesy of KIA MOTORS AMERICA, INC.

3. Front crash pad center under cover, RH.

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Fig. 28: Identifying Front Crash Pad Center Under Cover And Clip Courtesy of KIA MOTORS AMERICA, INC.

2. Installation is the reverse of removal.

SHROUD REPLACEMENT

1. Loosen the screws.

2. Disconnect the connector, then remove the shroud assembly (A).

Fig. 29: Identifying Shroud Assembly And Screw Courtesy of KIA MOTORS AMERICA, INC.

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3. Installation is the reverse of removal.

LOWER CRASH PAD PANEL REPLACEMENT

1. Remove the glove box. See GLOVE BOX REPLACEMENT.

2. Remove the side air vent. See AUDIO ASSEMBLY REPLACEMENT.

3. Remove the DVD cover (A).

Fig. 30: Identifying DVD Cover Courtesy of KIA MOTORS AMERICA, INC.

4. Loosen the mounting screws, remove the DVD (A).

Fig. 31: Identifying DVD And Screw

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Courtesy of KIA MOTORS AMERICA, INC.

5. Disconnect the connector (A).

Fig. 32: Identifying Connector Courtesy of KIA MOTORS AMERICA, INC.

6. After loosening the upper glove box mounting screws, then remove the upper glove box (A).

Fig. 33: Identifying Upper Glove Box And Fastener Locations Courtesy of KIA MOTORS AMERICA, INC.

7. Loosen the panel mounting bolts and screws.

8. After disconnecting the connector, remove the panel (A).

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Fig. 34: Identifying Panel And Fastener Locations Courtesy of KIA MOTORS AMERICA, INC.

9. Installation is the reverse of removal.

CRASH PAD REPLACEMENT

1. Remove the following items.

 Front seat. See FRONT SEAT .  Cluster fascia panel, cluster. See CLUSTER REPLACEMENT.  Audio assembly. See AUDIO ASSEMBLY REPLACEMENT.  Glove box. See GLOVE BOX REPLACEMENT.  Side cover, center under cover. See COVER REPLACEMENT.  Front pillar trim. See FRONT PILLAR TRIM.

2. Remove the photo sensor (C), speaker connector (B).

3. Disconnect the passenger's air bag connector (A). Loosen the bolt and nut, then remove the crash pad (D).

4. Installation is the reverse of removal.

NOTE:

 When prying with a flat-tipped screwdriver, wrap it with protective tape,

and apply protective tape around the related parts, to prevent damage.

 Put on gloves to protect your hands.

NOTE:

 Make sure the crash pad fits onto the guide pins correctly.  Before tightening the bolts, make sure the crash pad wire harnesses

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Fig. 35: Identifying Crash Pad Fastener Locations Courtesy of KIA MOTORS AMERICA, INC.

COWL CROSSBAR ASSEMBLY REPLACEMENT

1. Remove the crash pad. See CRASH PAD REPLACEMENT.

2. Remove the connectors.

are not pinched.

 Make sure the connectors are plugged in properly, and the antenna

lead is connected properly.

 Enter the anti-theft code for the radio, then enter.

NOTE:

 When prying with a flat-tipped screwdriver, wrap it with protective tape,

and apply protective tape around the related parts, to prevent damage.

 Put on gloves to protect your hands.

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3. Loosen the bolts and nuts, then remove cowl crossbar assembly (A).

4. Installation is the reverse of removal.

Fig. 36: Identifying Cowl Crossbar Fastener Locations Courtesy of KIA MOTORS AMERICA, INC.

NOTE:

 Make sure the crash pad fits onto the guide pins correctly.  Before tightening the bolts, make sure the crash pad wire harnesses

are not pinched.

 Make sure the connectors are plugged in properly, and the antenna

lead is connected properly.

 Enter the anti-theft code for the radio, then enter the customer's radio

station presets.

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2008 ACCESSORIES & BODY, CAB

Horns - Sedona

COMPONENT LOCATION

Fig. 1: Horn System Component Locations Courtesy of KIA MOTORS AMERICA, INC.

HORN

REPLACEMENT

1. Remove the bolt from the high pitch horn and the low pitch horn and disconnect the horn connector, then remove the horn.

2. Installation is the reverse of removal.

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Fig. 2: Identifying Horn Courtesy of KIA MOTORS AMERICA, INC.

ADJUSTMENT

Operate the horn, and adjust the tone to a suitable level by turning the adjusting screw.

Fig. 3: Adjusting Horn Courtesy of KIA MOTORS AMERICA, INC.

INSPECTION

Test the horn by connecting battery voltage to the terminal 1, and ground terminal 2.

The horn should make a sound. If the horn fails to make a sound, replace it.

NOTE: After adjustment, apply a small amount of paint around the screw head to keep

it from loosening.

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2008 HVAC

HVAC General - Sedona

SPECIFICATION

AIR CONDITIONER AIR CONDITIONER SPECIFICATION

BLOWER UNIT BLOWER UNIT CHART

HEATER AND EVAPORATOR UNIT HEATER AND EVAPORATOR UNIT CHART

Item

Specification

3.8L

Compressor

Type Fixed type (Swash plate)

Oil type & Capacity FD46XG (PAG), 210 ± 10cc

Pulley type 6PK-TYPE

Displacement 214cc/rev Condenser Heat rejection 19,500 ± 5% kcal/hr APT (A/C pressure transducer) The method to measure the

pressure

Vout = 0.00878835* pa +

0.37081095

Expansion valve Type Block (L-TYPE) Refrigerant

Type R-134a

Capacity [oz. (g)] 31.7 ± 0.88 (900 ± 25)

Item Specification

Fresh and recirculation Operating method Actuator

Blower

Type Sirocco

Speed step Auto + 8 speed (Automatic)

1-8 speed (Manual)

Speed control Power Mosfet

Air filter Type Particle filter

Item Specification

Heater

Type Pin & Tube type

Heating capacity 4,700 ± 5% kcal/hr

Mode operating method Actuator

Temperature operating method Actuator

Evaporator

Temperature control type Evaporator temperature sensor

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TROUBLESHOOTING

PROBLEM SYMPTOMS TABLE

Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant charge, air flow or compressor.

Use the Troubleshooting table to help you find the cause of the problem. See TROUBLESHOOTING CHART. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.

After correcting the malfunction, check the complete system to ensure that performance is satisfactory.

STANDARD: TROUBLESHOOTING CHART

A/C ON/OFF °C (°F)]

ON: 2.6 ± 0.5 (36.7 ± 0.9)

OFF: 1.1 ± 0.5 (34.0 ± 0.9)

Symptom Suspect Area

No blower operation

1. Blower fuse

2. Blower relay

3. Blower motor

4. Power Mosfet

5. Blower speed control switch

6. Wire harness

No air temperature control

1. Engine coolant capacity

2. Heater control assembly

No compressor operation

1. Refrigerant capacity

2. A/C Fuse

3. Magnetic clutch

4. Compressor

5. A/C pressure transducer

6. A/C switch

7. Evaporator temperature sensor

8. Wire harness

No cool air comes out

1. Refrigerant capacity

2. Refrigerant pressure

3. Drive belt

4. Magnetic clutch

5. Compressor

6. A/C pressure transducer

7. Evaporator temperature sensor

8. A/C switch

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SPECIAL TOOLS

SPECIAL TOOLS CHART

9. Heater control assembly

10. Wire harness

Insufficient cooling

1.Refrigerant capacity

2. Drive belt

3. Magnetic clutch

4. Compressor

5. Condenser

6. Expansion valve

7. Evaporator

8. Refrigerant lines

9. A/C pressure transducer

10. Heater control assembly

No engine idle-up when A/C switch ON

1. Engine ECM

2. Wire harness

No air inlet control 1. Heater control assembly No mode control

1. Heater control assembly

2. Mode actuator

No cooling fan operation

1. Cooling fan fuse

2. Fan motor

3. Engine ECM

4. Wire harness

Tool (Number and name) Illustration Use

09977-29000 Disc & hub assembly bolt remover

Removal and installation of the

disc & hub assembly bolt

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2008 ACCESSORIES & BODY, CAB

Power Door Mirrors - Sedona

COMPONENT LOCATION

Fig. 1: Power Door Mirror Component Locations Courtesy of KIA MOTORS AMERICA, INC.

POWER DOOR MIRROR ACTUATOR

INSPECTION

1. Remove the front door quadrant inner cover (A). Take care not to damage fixing clips. Refer to FRONT DOOR .

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Fig. 2: Identifying Front Door Quadrant Inner Cover Courtesy of KIA MOTORS AMERICA, INC.

2. Disconnect the power door mirror connector from the harness.

3. Verify that the mirror operates properly. See Fig. 4.

Fig. 3: Identifying Power Door Mirror Actuator Connector Terminals Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 4: Testing Power Mirror Actuator Courtesy of KIA MOTORS AMERICA, INC.

MIRROR HEATER

Fig. 5: Testing Mirror Heater Courtesy of KIA MOTORS AMERICA, INC.

FOLDING MIRROR

Fig. 6: Identifying Folding Mirror Position Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 7: Testing Folding Mirror Courtesy of KIA MOTORS AMERICA, INC.

OUTSIDE FOLDING MIRROR SWITCH

REPLACEMENT

1. Disconnect the negative (-) battery terminal.

2. Remove the front door trim panel. Refer to FRONT DOOR .

3. Remove the power window main switch mounting screws (3 each) (A) after disconnecting the switch connector (12-pin) from the switch.

Fig. 8: Identifying Power Window Main Switch And Mounting Screws Courtesy of KIA MOTORS AMERICA, INC.

4. Remove the switch from the front door trim panel.

5. Installation is the reverse of removal.

INSPECTION

1. Disconnect the 12-pin connector from the switch.

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Fig. 9: Identifying Outside Folding Mirror Switch 12-Pin Connector Courtesy of KIA MOTORS AMERICA, INC.

2. Check for continuity between the terminals in each switch position. See Fig. 10.

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Fig. 10: Testing Outside Folding Mirror Switch Courtesy of KIA MOTORS AMERICA, INC.

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2008 ACCESSORIES & BODY, CAB

Power Sliding Door System - Sedona

COMPONENT LOCATION

Fig. 1: Power Sliding Door System Component Locations Courtesy of KIA MOTORS AMERICA, INC.

DESCRIPTION

Power sliding door is an electro-mechanical system designed to provide power opening and closing of a vehicle's sliding door through the push of a button of the transmitter key or the main control buttons on the

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overhead console or the sub control buttons on the center pillar trim or inside/outside door handle switch.

The power sliding door will reverse direction of travel if resistance to movement is detected while the door is being closed. If resistance to movement is detected while the power sliding door is being opened, the door will stop moving.

1. DRIVE UNIT

Drive unit (A) consists of a DC motor, optical sensor, clutch, cables and pulleys and wire harness. The clutch and motor portion of the assembly provides the power and torque required to open or close the sliding door. The clutch assembly is used to connect or disconnect the motor so that the Sliding Door may be moved manually, if desired.

Fig. 2: Identifying Drive Unit Courtesy of KIA MOTORS AMERICA, INC.

2. POWER SLIDING DOOR CONTROL MODULE (PSDM)

The PSD System uses a power sliding door control module (microprocessor controller) to operate the drive unit. Signals are received from the vehicle and used to start or stop power open or close operations. The PSDM cannot be ad

usted or repaired and if found to be faulty, must be replaced.

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Fig. 3: Identifying Power Sliding Door Control Module Courtesy of KIA MOTORS AMERICA, INC.

3. SLIDING DOOR CHIME (C)

When the power sliding door detect the resistance or abnormal operation, the chime will sound.

Fig. 4: Identifying Sliding Door Chime Courtesy of KIA MOTORS AMERICA, INC.

4. ANTI-PINCH STRIP (D)

Secondary Obstacle Detection is provided by means of a contact type strip. Strip is composed of two conductive zones separated by an air gap. When strip is compressed, conductive zones make contact, activating the switch signal.

Copper wire is extruded through conductive material to prevent resistive buildup. Terminating resistor is molded into end of strip to detect failures of strip.

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Fig. 5: Identifying Anti-Pinch Strip Courtesy of KIA MOTORS AMERICA, INC.

5. OVERHEAD CONSOLE AND REMOTE CONTROL SWITCH (A)

The power sliding doors can be opened and closed automatically with the RKE and the main control button on the overhead console.

Fig. 6: Identifying Overhead Console And Remote Control Switch Courtesy of KIA MOTORS AMERICA, INC.

6. DOOR LATCH (B)

The door latch contains a detent switch [C] used to detect the latch state and report the latch state to the power slidin

door module.

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Fig. 7: Identifying Door Latch Courtesy of KIA MOTORS AMERICA, INC.

7. KEYLESS ENTRY (A)

Power sliding doors can be opened and closed by pressing the button on the RKE more than 0.5 sec. Open operation shall be reserved when an additional open/close signal is received during power opening.

Fig. 8: Identifying Keyless Entry Transmitter Courtesy of KIA MOTORS AMERICA, INC.

8. INSIDE/OUTSIDE DOOR HANDLE SWITCH

Power sliding door can be opened and closed manually/automatically from inside or outside vehicle.

Outside door handle switch (A)

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Fig. 9: Identifying Outside Door Handle Switch Courtesy of KIA MOTORS AMERICA, INC.

Inside door handle switch (B)

Fig. 10: Identifying Inside Door Handle Switch Courtesy of KIA MOTORS AMERICA, INC.

OPERATION

POWER SLIDING DOOR OPEN/CLOSE

1. The right/left sliding door is opened and closed automatically if the main switch (A) is pressed on the overhead console.

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Fig. 11: Identifying Main Switch Courtesy of KIA MOTORS AMERICA, INC.

2. When the power ON/OFF button (PWR) (B) is ON, the power sliding door and power tailgate can be opened and closed automatically by using trim switch.

3. When the sliding door window is open (more than 3 in/80 mm), the power sliding door will not power open fully but will open to the 3/4 position and the chime will sound 3 times.

4. General rules for chime functions

 Chime shall operate when a power operation cannot be performed as requested except handle pull:

1 Time (Duration 0.5 second on)

 Chime shall operate when an obstacle has been detected: 3 Time (0.5 sec on, 0.5 sec off)  Chime shall operate if PSD has not reached primary latch position after a power cinch cycle: 3

Time (0.5 sec on, 0.5 sec off)

POWER SLIDING DOOR OPERATING CONDITION

1. The sliding door will not power open when vehicle is moving above 3 mph (5 km/h) or the gearshift lever is not in P (Park) for automatic transaxle.

2. The power sliding door will not open with the transmitter or the main control button when all power sliding doors are locked and closed.

3. The power sliding door will detect the resistance, then stop movement or move to the full open position to allow the object to be cleared.

4. The left sliding door cannot be opened when the fuel filler lid is open.

5. If the automatic stop and reversal feature operates continuously more than twice during one opening or closing operation, the power sliding door may stop at that position. At this time, close the doors manually and operate the door automatically again.

WARNING: Do not leave the power sliding door at half-opened position. Close

the window and then open the door fully. Half-opened door is held and then released after 10 minutes. The chime sounds 3 times to indicate the door is released. If the vehicle is stopped on a downward slope, it may move and cause an injury.

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6. The power sliding door can be opened by pulling the outside door handle while the door is unlocked and child safety lock is engaged.

CHILD SAFETY LOCKS

To prevent children from opening the power sliding doors from the inside, the child safety locks (A) should be used whenever children are in the vehicle.

Fig. 12: Identifying Child Safety Locks Courtesy of KIA MOTORS AMERICA, INC.

NOTE:

 If the fuel filler lid is opened when the left sliding door is not closed

completely, the door may be opened. Close the left sliding door before refueling to prevent possible damage to the door or the fuel filler lid.

 Sudden starting or accelerating the vehicle while the door is closing

could cause it to open the door and result in a serious injury or damage to cargo.

CAUTION:

 The door could suddenly close by itself and cause a serious

injury especially when stopping on a downhill grade.

 To prevent the battery from being discharged, do not leave the

power sliding door and power tailgate at open position for a long time.

WARNING:

 Let the rear passengers get on or off the vehicle after the door

is open fully. Sudden closing could cause a serious injury.

 To prevent power sliding door system damage, don't use

excessive force to open/close the door during operation.

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POWER OPERATION

The PSD system shall not open the Sliding Door when the vehicle is moving.

The PSD system shall operate through the full range of Sliding Door travel.

The PSD system shall learn the position of each travel extreme: full open and full closed. PSD SYSTEM OPERATION CHART

WARNING: Be careful, when the child safety lock is used in an accident, that the

passengers are not held in vehicle.

Vehicle

Motion

Door Position

Zone

ON/OFF

Door Lock

Status

Operation

RKE Key

Fob Note 2

PSD main

switch

PSD sub

switch

Door handle

switch

-: No action •: Close O: Open X: Stop

Not

Moving

1 or 2

OFF Any O o - X

Not Locked O O O O

Locked O O

X (Chime 1

3 or 4

OFF Any • •

X (Chime 1

ON Any • • • •

Closing

OFF Any O O X X

ON Any O O O O

Opening 1 or

ON/OFF Any X X X X

Opening 3 or

OFF Any • • X X

ON Any • • • •

Moving

1 or 2 ON/OFF Any -

X (Chime 1 T)X (Chime 1

3 or 4

OFF Any - •

X (Chime 1

•

ON Any - • • •

Closing ON/OFF Any - X X X

Opening 1 or

ON/OFF Any - X X X

Opening 3 or

OFF Any - • X X

ON Any - • • •

Any

1 or 2 ON

Any

Manual Move in open/close direction

Any

3 or 4 ON

Any

Manual Move in open/close direction

Any

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1. Vehicle condition

Moving

 (IGN=OFF and Vehicle Speed > 5 km/h) or (IGN= ON and (Vehicle Speed > 5 km/h or PIN - not

PIN))

Not moving

 (IGN=OFF and Vehicle Speed < 5 km/h) or (IGN= ON and (Vehicle Speed < 5 km/h and TRANS -

P/N))

2. DOOR TRAVEL - ZONES

The door travel is divided into four zones starting at the full closed and latched position.

Dimensions are at the rear edge of the door and are approximate.

Zone 1 - Latching - 0 to 10 mm (primary and secondary latch positions).

Zone 2 - Near latching position including curved track portion -10 to 300 mm.

Zone 3 - Straight track - 300 mm to hold open latch.

Zone 4 - Hold Open - door in hold open latch.

POWER SLIDING DOOR OPERATION

1. Vehicle condition

Stopping condition

 When the ignition switch is in the OFF or ACC position, vehicle is stopped or moving below 5

km/h.

 When the ignition switch is in the ON position, vehicle is stopped or moving below 5 km/h (the

gearshift lever is in N (Neutral) for manual transaxle, P (Park) for automatic transaxle).

Driving condition

 When the ignition switch is in the OFF or ACC position, vehicle is moving above 5 km/h.  When the ignition switch is in the ON position, vehicle is moving above 5 km/h or the gearshift

lever is not in N (Neutral) for manual transaxle, P (Park) for automatic transaxle.

2. Door position

Any OFF Any Manual Move

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If the power sliding door is operated while the door is in slightly-opened position (less than 300mm), the door is automatically opened fully. If the power sliding door is operated while the door is in slightlyopened position (more than 300mm), the door is automatically closed completely.

3. If the door handle is pulled from inside or outside while the door is locked or child safety lock is engaged, the power sliding door is not opened.

TROUBLESHOOTING

Check the following items prior to performing Power Sliding Door System service.

1. Manual movement

Make sure the sliding door moves manually. Place the ON/OFF switch on the overhead console in the OFF position. Move the door manually and check for proper door fit and latch effort. Check for interference with other body parts such as latch striker, trim, and weather seals.

2. Battery voltage

Make sure the battery is fully charged. The PSD system is an electronic device and requires a minimum battery voltage to operate. The PSDM (Power sliding door module) monitors the battery voltage present at the PSDM input battery input and will not permit operation if the battery voltage is out of range.

3. Fuses

Two fuses protect the battery supply to the PSDM (Power sliding door module), one for Power, and one for logic. Check that the fuses are intact

4. Repeat Operations

Make sure the customer has not been operating the PSD repeatedly while the vehicle is turned off. The battery will be discharged and the PSDM (Power sliding door module) will not permit operation.

5. Vehicle on Steep Grade

Make sure the customer has not been operating the PSD system when the vehicle is parked on a steep grade (greater than 30%). The system will operate but the force of gravity and normal flex of the vehicle body may affect proper operation.

6. Obstacle Detection

The obstacle detection force is not adjustable. Factors that may affect the force are vehicle grade, battery voltage, or dirt in sliding door tracks.

7. Outside handle response time

When the vehicle has been parked and OFF, there ma

be a delay before power operation starts after the

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outside handle is pulled. This is normal because the PSDM (Power sliding door module) must wake up and check for proper conditions before starting a power open operation.

8. The sliding doors are not identical. Open and close times and obstacle detection efforts may vary when comparing the two doors. This is normal and is caused by vehicle build conditions such as door fit and rolling resistance.

9. Scan tool Diagnostic tool

Connect Scan tool to the K-line and check status of system.

POWER SLIDING DOOR SYSTEM DIAGNOSIS POWER SLIDING DOOR SYSTEM DIAGNOSIS CHART

CONDITION

POSSIBLE

CAUSES

CORRECTION

Sliding Door opens unexpectedly

Accidental activation or failure of open/close command switch

Check for shorted or defective switch

Failure of latch assembly

Check wiring connections Check for diagnostic trouble codes

Failure of Power Sliding Door or Body Control module

Disconnect then reconnect battery or fuse to reset module and function sliding door. If no function exists, check for loose wire connections. See ENGINE ELECTRICAL SYSTEM - GENERAL for detailed procedures

Sliding Door will not power open or close

Not in Park or false indication

Check switch status with SCAN tool

Battery voltage at PSDM is too low

Check for proper voltage at the PSDM. Charge battery

Blown fuse Check for blown fuse BCM or sliding door

control module critical fault codes

Check for diagnostic trouble codes

Failure of latch assembly

Check wire connections and for blown fuse Check for foreign matter preventing the operation of

latch assembly

Failure of motor assembly

Test motor assembly

Binding or sticking of components

Establish location of binding and replace necessary components

Wiring problems (system or vehicle)

Troubleshoot using electrical schematics Refer to appropriate SYSTEM WIRING DIAGRAMS article.

Troubleshoot using electrical schematics

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Power loss during Sliding Door operation

Wiring problems (system or vehicle)

Refer to appropriate SYSTEM WIRING DIAGRAMS article.

Battery voltage at PSDM is too low < 9.5V to start operation and < 8.0V to continue operation

Check for proper voltage at the PSDM. Charge battery

Failure of Power Sliding Door or Body Control Module

Check for diagnostic trouble codes

Failure of motor assembly

Test motor assembly

Sliding Door does not close to primary latch position

Door mis-alignment

Check latch and striker alignment Check rollers and track alignment

Binding or sticking of components

Establish location of binding and adjust or replace necessary components

Failure of Power Sliding Door or Body Control Module

Check for diagnostic trouble codes

Sliding Door seal force too high

Inspect seals for damage, mis-assembly, foreign matter or other possible obstruction

Failure of motor assembly

Test motor assembly

Latch will not release from primary position

Not in Park or false indication

Check switch status with SCAN tool

Battery voltage at PSDM is too low < 9.5V to start operation and < 8.0V to continue operation

Check for proper voltage at the PSDM Charge battery

Blown fuse Check fuse and replace if required

Failure of latch assembly

Check switch status with scan tool Check for foreign matter or damaged components

preventing the operation of latch assembly Troubleshoot using BCM (BODY CONTROL

MODULE) . Replace latch assembly, if necessary

Failure of outside or inside handle connection

Check handle connections on drain plate.

Failure of Power Sliding Door or Body Control Module

Check for diagnostic trouble codes.

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Binding or sticking of components

Establish location of binding and adjust or replace necessary components

Key fob or overhead console switch does not power operate sliding door

Blown Fuse Check fuse and replace Battery voltage at

PSDM is too low

Check for proper voltage at the PSDM. Charge battery

Wiring problems (system or vehicle)

Refer to appropriate SYSTEM WIRING DIAGRAMS. Check for diagnostic trouble codes.

Does Not Power Unlatch

Failure of latch assembly

Check for foreign matter preventing the operation of latch assembly

Check for diagnostic trouble codes. Check Detent switch. Troubleshoot using BCM (BODY CONTROL

MODULE) .

Failure of Latch Release Actuator

Check actuator and replace if necessary

Wiring problems (system or vehicle)

Refer to appropriate SYSTEM WIRING DIAGRAMS article. Check for diagnostic trouble codes.

Failure of Body Control Module (BCM)

Troubleshoot using BCM (BODY CONTROL MODULE) .

Replace BCM if necessary

Failure of key fob

Reprogram key fob Replace key fob if necessary

Failure of Power Sliding Door Module

Check for diagnostic trouble codes. See DTC CODES for detailed procedures

Failure of sliding door motor assembly

Check for foreign matter preventing the operation of motor assembly

Check wire connections Drive Unit clutch does not engage. Replace Drive Unit. Troubleshoot using BCM (BODY CONTROL

MODULE) . Replace motor if necessary

Sliding Door does not stay open

Hold Open Latch not working

Check if sliding door powers open to hold open latch Check if H-O-L is working

High inside/outside opening effort

Bound cables

Check for smooth manual operation Check for broken attachments

Drive unit jammed or did not disengage

Troubleshoot using BCM (BODY CONTROL MODULE) . Replace components, if necessary

Binding or sticking of components

Establish location of binding and replace necessary components

Failure of latch

Check wire connections and Detent switch Check for foreign matter

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DTC LIST DTC LIST

Sliding Door continues to power close

assembly Troubleshoot using BCM (BODY CONTROL

MODULE) .

Control Module Check for diagnostic trouble codes Wiring problems

(system or vehicle)

Troubleshoot using electrical schematics Refer to appropriate SYSTEM WIRING DIAGRAMS article.

Sliding Door continues to power open

Failure of PSDM

Check for diagnostic trouble codes. See DTC CODES for detailed procedures

Wiring problems (system or vehicle)

Troubleshoot using electrical schematics Refer to appropriate SYSTEM WIRING DIAGRAMS article.

Sliding Door opens very slowly

Battery voltage at PSDM is too low

Check for proper voltage at the PSDM Charge battery

Bound cables Replace drive unit if necessary Binding or sticking of

components

Establish location of binding and replace necessary components

Grade of vehicle too steep for power operation

Operate sliding door manually

Failure of sliding door motor assembly

Replace motor assembly, if necessary

Squeaks, Noises and rattles

Foreign material in Sliding Door

Remove foreign material

Worn or Loose components

Check and tighten loose components

DTC CODE DISPLAY

B1101 Battery Voltage High B1102 Battery Voltage Low B1105 Reference Voltage Fault B1223 VSS Fault B1270 Optical Sensor-1 Output Stuck High B1271 Optical Sensor-1 Output Stuck Low B1272 Optical Sensor-2 Output Stuck High B1273 Optical Sensor-2 Output Stuck Low B1274 Broken Cable (PSD Only) B1580 Ignition Start Switch Short High B1586 Chime Open Or Short High B1621 ECU Fault B1645 Drive Unit Fault

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INPUT/OUTPUT MONITORING INPUT/OUTPUT MONITORING

B2420 Drive Motor Open B2421 Drive Motor Short High B2422 Drive Motor Short Low B2423 Clutch Open Or Short High B2424 Clutch Short Low B2425 Pinch strip (PSD) open or Stuck High B2426 Pinch strip (PSD) Stuck Low B2450 Unlatch Motor (PSD) Short High B2451 Unlatch or Cinch Motor (PTG)/Unlatch Motor (PSD) Short Low

BCM DISPLAY UNIT

1 Battery Logic Voltage Voltages 2 Battery Power Voltage Voltages 3 Optical Sensor Power Voltages 4 Door/Gate Optical Sensor 2-

Logical State

LOW/HIGH

5 Door/Gate Optical Sensor 1-

Logical State

LOW/HIGH

6 Detent Switch LOW/HIGH 7 Power Battery Voltage OUT OF RANGE/ IN RANGE 8 Pinch strip-pinch condition (PSD

Only)

Not Pinched/Pinched

9 Park Switch Out Of Park/Park 10 Ignition Switch LOW/HIGH 11 Child Lock Status (PSD Only) Lock/Unlock 12 Lock Status (PSD Only) Lock/Unlock 13 Handle Switch (PSD Only) Not Pressed/Pressed 14 Local Open/Close Switch Not Pressed/Pressed 15 Master Open/Close Switch Not Pressed/Pressed 16 Learn Process Complete Status Not Complete/Complete 17 Vehicle Speed Slow Status > or = 5 kph/< 5 kph 18 On/Off Switch ON/OFF 19 Start Switch LOW/HIGH 20 PSD Right Select Status Left/Right 21 Fuel Filler Door switch LOW/HIGH 22 Door/Gate Open Feedback Voltages 23 Door/Gate Close Feedback Voltages 24 Unlatch Feedback Voltages

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POWER SLIDING DOOR DRIVE UNIT

INSPECTION

SLIDING DOOR MOTOR INSPECTION

1. It will be able to diagnose defects of PSD motor with scan tool quickly.

2. Select model and menu (BCM).

Fig. 13: Diagnosis Tool Display

- BODY CONTROL MODULE

Courtesy of KIA MOTORS AMERICA, INC.

3. Select "rear area module (RAM)".

25 Clutch Feedback Voltages 26 Door/Gate Position Count 27 Most Recent Cinch Time ms 28 2nd Most Recent Cinch Time ms 29 3rd Most Recent Cinch Time ms 30 4th Most Recent Cinch Time ms 31 Left Pinch Strip Voltage Voltages 32 Right Pinch Strip Voltage Voltages

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Fig. 14: Diagnosis Tool Display - REAR AREA MODULE Courtesy of KIA MOTORS AMERICA, INC.

4. Select the "Actuation test" and "PSD open/close" to operate tailgate motor.

Fig. 15: Identifying Scan Tool Display

- ACTUATION TEST

Courtesy of KIA MOTORS AMERICA, INC.

5. Replace the drive unit, if actuator operates abnormal.

DRIVE UNIT CLUTCH INSPECTION

1. Check the power sliding door control module input/output value by using the diagnostic tool. If the operation of power sliding control module is abnormal, replace power sliding door drive unit.

2. When checking the clutch operation, select a vehicle type and "POWER SLIDING/TAILGATE" menu.

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Fig. 16: Identifying Scan Tool Display - POWER SLIDING/TAILGATE Courtesy of KIA MOTORS AMERICA, INC.

3. Select the "POWER SLIDING DOOR" to check.

Fig. 17: Identifying Scan Tool Display

- POWER SLIDING LH

Courtesy of KIA MOTORS AMERICA, INC.

4. Select the sensor output. And then check the clutch feedback sensor output while operating power sliding door in power mode.

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Fig. 18: Identifying Scan Tool Display - CLUTCH F/BACK Courtesy of KIA MOTORS AMERICA, INC.

* Above voltage and numerical value may be different from the real value.

5. Change the drive unit, if there is no change during operation.

OPTICAL SENSOR INSPECTION

1. Check the power sliding door control module input/output value by using the diagnostic tool.

2. When checking the optical sensor, select a vehicle type and "Power sliding/tailgate" menu.

Fig. 19: Identifying Scan Tool Display - POWER SLIDING/TAILGATE Courtesy of KIA MOTORS AMERICA, INC.

3. Select the "POWER SLIDING DOOR" to check.

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Fig. 20: Identifying Scan Tool Display - POWER SLIDING LH Courtesy of KIA MOTORS AMERICA, INC.

4. Select the sensor output. And then check the optical sensor volt while operating power sliding door in power mode.

Fig. 21: Identifying Scan Tool Display

- OPTICAL SNSR VOLT

Courtesy of KIA MOTORS AMERICA, INC.

* Above voltage and numerical value may be different from the real value.

5. Change the drive unit, if there is no change during operation.

REPLACEMENT

1. Disconnect the negative (-) battery terminal.

2. Remove the rear trim panel. Refer to INTERIOR TRIM

3. Disconnect the connectors (6EA) from the power sliding door drive unit.

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4. Remove the rear combination lamp. Refer to REAR BUMPER .

5. Remove the mounting bolts (4EA) and rail cover (A).

Fig. 22: Identifying Rail Cover Courtesy of KIA MOTORS AMERICA, INC.

6. Pull the rear cable (A) and draw the cable clip (B) to bottom of roller hinge post and then remove the rear cable (A).

Fig. 23: Identifying Rear Cable And Cable Clip Courtesy of KIA MOTORS AMERICA, INC.

7. Remove the roller hinge bracket assembly (A) as below.

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Fig. 24: Identifying Roller Hinge Bracket Assembly Courtesy of KIA MOTORS AMERICA, INC.

8. Remove the front cable (A) from center roller hinge (B).

Fig. 25: Identifying Front Cable And Center Roller Hinge Courtesy of KIA MOTORS AMERICA, INC.

9. Loosen the bolts (2EA) and remove the rear pulley bracket (A). And then remove the front pulley bracket (B) after loosening the mounting bolts (2EA) and nut (1EA).

TORQUE: 0.07-0.11 N.m (0.007-0.011 kg.m)

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Fig. 26: Identifying Rear And Front Pulley Brackets Courtesy of KIA MOTORS AMERICA, INC.

10. Loosen the mounting bolt (1EA) and nuts (2EA). And then remove the power sliding door drive unit assembly after removing the front cable.

TORQUE: 0.07-0.11 N.m (0.007-0.011 kg.m)

11. Installation is the reverse of removal.

12. When installation, check the grease on the center roller hinge barrel and club contact part (A).

Fig. 27: Identifying Center Roller Hinge Barrel And Club Contact Part Courtesy of KIA MOTORS AMERICA, INC.

WARNING:

 A learn cycle must be performed whenever the power is

removed.

 Check the normal operation whenever a power sliding door

component is removed or replaced. If the chime sound is heard, check the DTC, wiring harness and cable connections.

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POWER SLIDING DOOR CONTROL MODULE (PSDM)

REPLACEMENT

1. Disconnect the negative (-) battery terminal.

2. Remove the rear trim panel. Refer to INTERIOR TRIM

3. Remove the connectors and mounting bolts (2EA) from the power sliding door unit (A). And then remove the power sliding door control module (B).

TORQUE: 0.025-0.035 N.m (0.0025-0.0035 kg.m)

Fig. 28: Identifying Power Sliding Door Unit And Control Module Courtesy of KIA MOTORS AMERICA, INC.

4. Installation is the reverse of removal.

POWER SLIDING DOOR CHIME

REPLACEMENT

1. Remove the rear side trim. Refer to INTERIOR TRIM .

2. Disconnect the sliding door chime connector (A) from chime (B).

WARNING:

 A learn cycle must be performed whenever the power is

removed.

 Check the normal operation whenever a power sliding door

component is removed or replaced. If the chime sound is heard, check the DTC, wiring harness and cable connections.

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Fig. 29: Identifying Sliding Door Chime Connector And Chime Courtesy of KIA MOTORS AMERICA, INC.

3. Remove the chime from drive unit and replace it with a new one.

ADJUSTMENT

POWER SLIDING DOOR INITIALIZATION

A learn cycle must be performed whenever the power is removed, a Power Sliding Door component is removed or replaced, or a sliding door adjustment is performed. The learn cycle enables the Power Sliding Door control module (PSDM) to learn the range of full travel and effort required to power the Sliding Door which allows it to

erform properly and safely.

POWER SLIDING DOOR SYSTEM RESET

Certain conditions may require that the PSD system be reset

1. Remove the MEMORY fuse that provides power to the PSDM.

2. Wait 1 minute. Replace fuse. Initialize PSDM.

INITIALIZATION PROCEDURE

1. Manually close and latch the sliding door.

2. Power the sliding door open using the remote control, Open/Close switch, B-pillar switch, or handle.

3. Power the door close from full open to full closed position.

4. Power the door open again to full open position.

ALTERNATE METHOD

1. Remove the black connector (J2) from the PSDM.

2. Wait a short time. Replace connector. Initialize PSDM.

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DETENT SWITCH

INSPECTION

1. Detent switch detects the latch position within latch assembly.

Fig. 30: Identifying Detent Switch Connector Courtesy of KIA MOTORS AMERICA, INC.

2. Check the power sliding door control module input/output value by using the diagnostic tool.

3. When checking the detent switch, select a vehicle type and "POWER SLIDING/TAIL GATE" menu.

CAUTION:

 The PSD system initialization must start from the primary or

secondary latched position.

 Obstacle detection shall be active during Sliding Door

initialization.

 Work on level ground.

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Fig. 31: Identifying Scan Tool Display - POWER SLIDING/TAILGATE Courtesy of KIA MOTORS AMERICA, INC.

4. Select the "POWER SLIDING DOOR".

Fig. 32: Identifying Scan Tool Display - POWER SLIDING LH Courtesy of KIA MOTORS AMERICA, INC.

5. Select the detent sensor output. And then check the detent switch output with operating power sliding door.

Fig. 33: Identifying Scan Tool Display - DETENT SWITCH Courtesy of KIA MOTORS AMERICA, INC.

* Above voltage and numerical value may be different from the real value.

6. If there is no change in output, change the latch assembly.

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LATCH SWITCH

INSPECTION

1. Check the power sliding door control module input/output value by using the diagnostic tool.

2. When checking the latch, select a vehicle type and "POWER SLIDING/TAIL GATE" menu.

Fig. 34: Identifying Scan Tool Display

- POWER SLIDING/TAILGATE

Courtesy of KIA MOTORS AMERICA, INC.

3. Select the "POWER SLIDING DOOR".

Fig. 35: Identifying Scan Tool Display

- POWER SLIDING LH

Courtesy of KIA MOTORS AMERICA, INC.

4. Select the sensor output. And then check the unlatch feedback (Unlocked state) voltage while operating power slidin

door in power mode.

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Fig. 36: Identifying Scan Tool Display - UNLATCH F/BACK Courtesy of KIA MOTORS AMERICA, INC.

* Above voltage and numerical value may be different from the real value.

5. If there is no change in voltage, change the latch.

ANTI PINCH STRIP

1. Check the power sliding door control module input/output value by using the diagnostic tool. If the operation of door control module is abnormal, replace anti pinch strip control module.

2. When checking the anti pinch strip operation, select a vehicle type and "POWER SLIDING/TAIL GATE" menu.

Fig. 37: Identifying Scan Tool Display

- POWER SLIDING/TAILGATE

Courtesy of KIA MOTORS AMERICA, INC.

3. Select power sliding door.

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Fig. 38: Identifying Scan Tool Display - POWER SLIDING LH Courtesy of KIA MOTORS AMERICA, INC.

4. Select the sensor output. And then check the anti pinch strip sensor output while operating power sliding door in power mode.

Fig. 39: Identifying Scan Tool Display

- PINCH STRIP CONDITION

Courtesy of KIA MOTORS AMERICA, INC.

* Above voltage and numerical value may be different from the real value.

5. Change the anti pinch strip sensor, if there is no change from OFF to ON during operation.

POWER SLIDING DOOR SWITCH

INSPECTION

OVERHEAD CONSOLE DOOR SWITCH INSPECTION

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1. Check the overhead console door switch input/output value by using the diagnostic tool. If the operation of overhead console door switch is abnormal, check the IPM and replace.

2. When checking the overhead console switch operation, select a vehicle type and "IPM" menu.

Fig. 40: Identifying Scan Tool Display - IN PANEL MODULE Courtesy of KIA MOTORS AMERICA, INC.

3. Select a in panel module (IPM) and "CURRENT DATA".

Fig. 41: Identifying Scan Tool Display - CURRENT DATA Courtesy of KIA MOTORS AMERICA, INC.

4. Check the PSD PTG power control switch and PSD left/ri

ht switch.

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Fig. 42: Identifying Scan Tool Display - LH PSD OPEN/CLOSE Courtesy of KIA MOTORS AMERICA, INC.

5. Confirm that output is changed by the controlling ON/OFF of each switch on the overhead console.

DOOR HANDLE SWITCH INSPECTION

1. Check the power sliding door control module input/output value by using the diagnostic tool. If the operation of door control module is abnormal, replace power sliding door control module.

2. When checking handle switch operation, select a vehicle type and "POWER SLIDING/TAIL GATE" menu.

Fig. 43: Identifying Scan Tool Display - POWER SLIDING/TAILGATE Courtesy of KIA MOTORS AMERICA, INC.

3. Select the "POWER SLIDING DOOR" menu to check.

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Fig. 44: Identifying Scan Tool Display - POWER SLIDING LH Courtesy of KIA MOTORS AMERICA, INC.

4. Select the sensor output. And then check the handle switch output value changed by the controlling PSD or PTG.

Fig. 45: Identifying Scan Tool Display

- HANDLE SWITCH

Courtesy of KIA MOTORS AMERICA, INC.

5. Check that the handle switch output changed from OFF to ON during PSD or PTG operation.

TRIM SWITCH INSPECTION

1. Check the trim switch input/output value by using the diagnostic tool. If the operation of rear area module (RAM) is abnormal, replace RAM.

2. When checking the trim switch operation, select a vehicle type and "IPM" menu.

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Fig. 46: Identifying Scan Tool Display - IN PANEL MODULE Courtesy of KIA MOTORS AMERICA, INC.

3. Select a rear area module (RAM) and sensor output.

Fig. 47: Diagnosis Tool Display

- REAR AREA MODULE

Courtesy of KIA MOTORS AMERICA, INC.

4. Check the value of RSD/LSD, left/right door switch.

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Fig. 48: Identifying Scan Tool Display - RH S/DOOR SW Courtesy of KIA MOTORS AMERICA, INC.

5. Confirm that the door switch output is changed by the controlling ON/OFF switch on center pillar trim.

REPLACEMENT

OVERHEAD CONSOLE SWITCH

1. Disconnect the negative (-) battery terminal.

2. Open the sunglass case cover from the overhead console then remove the 2 screws holding the overhead console (A). And then disconnect the connector (B).

Fig. 49: Identifying Overhead Console And Connector Courtesy of KIA MOTORS AMERICA, INC.

3. Installation is the reverse of removal.

DOOR TRIM SWITCH

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1. Disconnect the negative (-) battery terminal.

2. Remove the connector (B) and door trim switch (A) from the center pillar (C) by using the scraper.

Fig. 50: Identifying Door Trim Switch, Connector And Center Pillar Courtesy of KIA MOTORS AMERICA, INC.

3. Installation is the reverse of removal.

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2008 STEERING

Mechanical Power Steering System - Sedona

COMPONENTS

Fig. 1: Identifying Mechanical Power Steering System Components And Torque Specifications Courtesy of KIA MOTORS AMERICA, INC.

POWER STEERING GEAR BOX

COMPONENT

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Fig. 2: Identifying Power Steering Gear Box Components Courtesy of KIA MOTORS AMERICA, INC.

REMOVAL

1. Remove the both front wheel & tire assemblies.

2. Drain the power steering fluid.

3. Remove the bolt (A) connecting steering column to universal joint.

Tightening torque N.m (kgf.m, lb-ft):

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13-18 (1.3-1.8, 9.4-13.0)

Fig. 3: Identifying Bolt Between Steering Universal Joint Assembly Courtesy of KIA MOTORS AMERICA, INC.

4. Disconnect the pressure tube (A) from the power steering oil pump by loosening eye bolt. Tightening torque N.m (kgf.m, lb-ft):

65-75 (6.5-7.5, 47-54)

Fig. 4: Identifying Pressure Tube Courtesy of KIA MOTORS AMERICA, INC.

5. Disconnect the return hose (A)

2008 Kia Sedona EX

2008 STEERING Mechanical Power Steering System - Sedona

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Fig. 5: Identifying Return Hose Courtesy of KIA MOTORS AMERICA, INC.

6. Loosen the split pin and castle nut, and then remove the tie rod end (A) from the knuckle by using a SST (09568-4A000).

Tightening torque N.m (kgf.m, lb-ft):

50-55 (5.0-5.5, 36-40)

Fig. 6: Identifying Tie Rod End Courtesy of KIA MOTORS AMERICA, INC.

2008 Kia Sedona EX

2008 STEERING Mechanical Power Steering System - Sedona

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Fig. 7: Disconnecting Tie Rod And Knuckle With Special Tool (09568-4A000) Courtesy of KIA MOTORS AMERICA, INC.

7. Remove the split pin and lower arm bolts and nut (A). Tightening torque N.m (kgf-m, lb-ft):

90-120 (9.0-12.0, 65-87)

Fig. 8: Identifying Split Pin, Nut And Lower Arm Nut Courtesy of KIA MOTORS AMERICA, INC.

8. Disconnect the stabilizer link (B) from the strut assembly (A) by loosening nut. Tightening torque N.m (kgf.m, lb-ft):

100-120 (10.0-12.0, 72-87)

2008 Kia Sedona EX

2008 STEERING Mechanical Power Steering System - Sedona