Engine Management System Diagnosis II: EMSD2 Course Guide

Engine Management System Diagnosis II
EMSD2 Course Guide 1



Course Guide
COURSE OVERVIEW This instructor-led course (ILC) is designed to continue
enhancement of the Kia technician’s diagnostic abilities
regarding engine management and OBDII.
COURSE GOALS This course increases a technician’s efficiency and

productivity through logical evaluation of engine
management and emission system concerns. This
course does this by systematically using the Kia 5-Step
Process and On-Board Diagnostics (OBDII). It also does
this by understanding the Kia engine management
systems through theory and instructor supervised
hands-on guided practices, thus achieving efficient Fix-
Right, First-Time repairs.
COURSE OBJECTIVES Without the assistance of others and using the skills
learned in this course and required prerequisite
courses, as well as technical information on KGIS, the
GDS, standard engine management diagnostic
equipment, and vehicles with various selected concerns
or data depicting a selected concern, the technician,
with 80% or greater accuracy, will be able to:
 Develop a systematic diagnostic troubleshooting
approach for OBDII management malfunctions or
concerns using the Kia 5-Step procedure.
 Identify the root cause of the malfunctions or
concerns presented in this course.
 List and print out the various diagnostic data
supporting the technician’s diagnostic approach and
the root cause for the identified malfunctions or
concerns using KGIS.
 Demonstrate the diagnostic key points that are
required to repair the malfunctions or concerns.
 Successfully complete four diagnostic scenarios.
 Answer 25 performance assessment questions
based on the class lecture, instructor-led demos,
and shop guided practice.
EXPECTATION You will be expected to use diagnostic processes,

service information, and available resources to diagnose
engine management, fuel, electrical circuit, and
customer drivability issues to fix the vehicle right the
first time.

TARGET AUDIENCES The target audience for this course consists of Kia
dealership technicians who have an intermediate level
of understanding of engine management systems and
have successfully completed the prerequisites.
PREREQUISITES The following web and ILCs must be completed prior to

the start of this course:
 Kia Engine Management System I (EMS1) instructor-
led course
 Introduction to OBDII (IOBD) web course
TECHNICAL TRAINING Kia University has adopted a training delivery system

SYSTEM where you will need to successfully pass several
prerequisite courses and a web course containing
knowledge that supports this course. The courses cover
system theory and operation, and then provide a
chance for you to practice what you have learned.
Finally, we will test what you have learned.
REVIEW The Review Module will review critical objectives from

the introduction to OBDII web course.
THEORY A Theory Module presents information to increase

your working knowledge of the subject, which helps
guide you to successful diagnosis and repair.
GUIDED PRACTICE The Guided Practice Module allows you the

opportunity to practice diagnostic skills through hands-
on experience. The tasks are to be instructor
supervised and verified.
PERFORMANCE The Performance Assessment Module provides you the

ASSESSMENT opportunity to demonstrate and prove that you can
diagnose engine management concerns.
COURSE ACHIEVEMENT A final score of 80% or higher is needed for successful

completion of this course.

PERFORMANCE SCORECARD The Performance Scorecard is used to track your

performance on guided practices, diagnosis and
troubleshooting, and written knowledge assessments.
SCORECARD ROUTING One copy of the scorecard is yours, and one copy is
used to update your Kia technical training records.
Should you not complete the course, the third copy is
forwarded to your Kia District Parts and Service
Manager.
ANSWER SHEET Record your Performance Assessment answers on this

sheet and turn it in to your instructor for grading. Your
score will be transferred to the scorecard.
COURSE MATERIAL
Performance
Module Title
Assessment
Course Day
Diagnosis
Timeline
Practice
Number
Module
Guided
Theory
Course
01 Day 1: Course Guide ** X 1 8:00 – 8:30 am
02 Review Module X 1 8:30 – 9:30 am
03 DTC Diagnosis (PC Lab) X 1 9:30 – 11:30 am*
Lunch 11:30 – 12:30 pm
04 Analyzing DTC Faults X 1 12:30 – 1:00 pm
05 Analyzing DTC Faults X 1 1:00 – 4:30 pm*
Review and Cleanup 1 4:30 – 5:00 pm
Day 2: Misfire, Monitoring and
06 X 2 8:00 – 8:45 am
Catalytic Converter
Analyzing Catalyst Damaging
07 X 2 8:45 – 11:30 am*
Faults
Lunch 11:30 – 12:30 pm
Performance Assessment
 Questions 12:30 – 4:30 pm*
08 X 2
 Concerns – Computer
 Concerns – On-vehicle
Review and Cleanup 2 4:30 – 5:00 pm
** Kia update information *Includes Break
Begin each day with a review of modules completed the previous day.

COURSE MATERIAL The course and its materials are here for you to learn
EXPECTATIONS and keep. Use them and your time in a way that will
benefit you when you return to your dealership.
TAKE NOTES Make drawings, jot down notes, and highlight these
materials to help you remember important details. Each
module is designed with ample margins for your
important notes.
ASK QUESTIONS If you do not understand something in this course, ask

your instructor for clarification. Asking questions is
strongly encouraged to help you get the most out of
this course.
TEAMWORK During the hands-on activities, you will often be

working as a team. By actively engaging in each
activity, you will maximize your learning experience.
While in the lab, feel free to ask the instructor
questions at any time.
LEARN AT EVERY This course is an opportunity for you to learn in a

OPPORTUNITY controlled environment under the guidance of a trained
Kia instructor. Through active participation you can
build confidence in your abilities to diagnose customer
concerns right the first time, every time!
ICONS
The Reference Icon indicates you must refer to
additional publications in order to complete the
questions or activity.
The Activities Icon indicates an activity that

supports a critical learning objective. These activities
are offered to help you master the material.
The Feedback Icon indicates a progress check meant

to provide you with feedback on your understanding of
the course material.

On-Board Diagnostic Review
MODULE GOAL Upon completion of this module, you will demonstrate,

through discussion, an understanding of OBDII
functions, which are required to successfully diagnose
engine management system faults.
MODULE OBJECTIVES Given this module, and information learned from

successfully completing the prerequisite courses, you
will be able to participate in class discussions and
answer questions on the following:
 On-Board Diagnostic II
 Monitoring Strategies
 Trip and drive cycle logic
 Continuous and noncontinuous monitors
 Diagnostic Trouble Code (DTC) definition
MODULE INSTRUCTIONS During this review, participate in the discussion to get

the most out of this review module while answering the
questions and recording your answers.
Questions are based upon the web and instructor-led

courses that are required prerequisites.
EXPECTATIONS It is expected that you passed the prerequisite web

course that supports this course, and will be able to
complete this review module, and participate in class
discussion on the information presented.
TIME TO COMPLETE Approximately: 60 minutes

ON-BOARD DIAGNOSTIC
WRITE IN YOUR ANSWER 1. Where is the OBDII software located and what is its
BASED UPON THE function?
PREREQUISITE WEB __________________________________________
COURSE DISCUSSION
__________________________________________
__________________________________________
__________________________________________
2. The first generation OBD primarily monitored:
__________________________________________
3. The second generation OBD monitors:
__________________ and ____________________
4. List three Diagnostic Link Connector (DLC)
specifications that were standardized with OBDII:
__________________________________________
__________________________________________
__________________________________________
5. Generic powertrain diagnostic trouble codes start
with a P followed by: _________________________
6. The engine operating condition data that OBDII

retains during a monitored malfunction is called:
__________________________________________
7. What OBD II mode monitors system and component
tests?
__________________________________________
8. A blinking malfunction indicator lamp (MIL)
indicates:
__________________________________________
9. OBDII illuminates the MIL when a malfunction is
detected that may exceed:
__________________________________________

10. List three electrical malfunctions that OBDII

monitors can detect:
__________________________________________
__________________________________________
__________________________________________
11. The OBDII 5-digit DTC can define conditions,

systems and:
__________________________________________
12. List three continuous monitors that OBDII checks:
__________________________________________
__________________________________________
__________________________________________
13. List three noncontinuous monitors that OBDII
checks:
__________________________________________
__________________________________________
__________________________________________
14. List two types of OBDII continuously monitored
faults that are always present/detected:
__________________________________________
__________________________________________
15. List three examples of OBDII intermittent faults that
are random and not always present:
__________________________________________
__________________________________________
__________________________________________

16. List three causes of (sensitive) component

intermittent faults:
__________________________________________
__________________________________________
__________________________________________
17. List an example of a direct detected fault (actual
measurement):
__________________________________________
18. List an example of an indirectly detected fault
(inferred):
__________________________________________
__________________________________________
19. List three conditions that define a Trip:
__________________________________________
__________________________________________
__________________________________________
20. List two conditions that define a warm-up cycle:
__________________________________________
__________________________________________
21. Define a drive cycle:
__________________________________________
__________________________________________
__________________________________________
22. Define each trip of a two trip logic:
__________________________________________
__________________________________________
__________________________________________
__________________________________________

23. Define Circuit Integrity:

__________________________________________
24. Define Input Rationality:

__________________________________________
25. Define Output Functionality:

__________________________________________
26. An aftermarket service part may not fully meet OEM

calibrations causing a:
__________________________________________
27. When and how should a DTC be cleared?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
28. With a DTC set, MIL illuminated and fault not

present, when will the OBDII system turn the MIL
off?
__________________________________________
29. How many warm-up cycles are required to clear a
non-catalyst damaging emissions-related DTC that
does not reoccur?
__________________________________________

30. Using the Current Data above, if you have a

confirmed drivability concern that will not set a DTC,
what five items would you check?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________

FEDERAL TEST PROCEDURE
FEDERAL TEST PROCEDURE OBDII requires that the on-board computer monitors
and actively performs diagnostic tests on vehicle
emission systems. The Federal Test Procedure (FTP)
sets maximum allowable emissions levels. The FTP is
an emission-testing program required of vehicle
manufacturers by the government to become certified
for sale in the United States.
The Federal Test Procedure (FTP) was designed as a

model of a typical commute in an urban area, and later,
part of it became an emissions dynamometer test called
I/M240.
The vehicle being tested is run through four stages:

 Started cold (Cold start phase)
 Driven for a specific amount of time at different
speeds (Cold stabilized phase)
 Allowed to sit with the engine off (10 minute soak)
 Restarted and driven a second time (Hot start phase)
A Malfunction Indicator Lamp (MIL) must illuminate if a

system or component either fails or deteriorates to the
point where the vehicle emissions could exceed 1-1/2
times the FTP standard. Emission related faults include:
 Random misfires
 Reduced catalytic converter efficiency
 Detected air leak in the sealed fuel system
 A key sensor or actuator fails


Diagnostic Executive
Engine OBDII
Management Diagnostic
System System
ECM/PCM
INTRODUCTION The OBDII system stores a DTC when the emission

control system or component exceeds the emission
threshold or operates outside tolerances.
DIAGNOSTIC EXECUTIVE The diagnostic executive is a computer program in the

(TASK MANAGER) ECM that coordinates the OBDII monitoring system.
This program controls the:
 Monitors and interactions
 DTC and MIL operations
 Freeze frame data and GDS interface
It also keeps track of:

 Warm-up cycles and trip counters for clearing DTCs
 DTC info, status, and MIL request
FREEZE FRAME DATA Freeze Frame data is stored engine and vehicle
information that existed when a fault was first
detected. It is a snapshot of what the vehicle was doing
when the fault occurred. The freeze frame data clears
when the DTC is cleared. Freeze Frame is overwritten if
a malfunction capable of damaging the catalytic
convertor (CAT damaging malfunction) is detected.
Freeze frame data is available using the GDS DTC
status function.
Freeze frame data includes:

 Calculated load value
 Engine RPM
 Fuel trim
 Vehicle speed
 Coolant temperature
 Intake manifold pressure/air density

MONITORING RELATED OBDII can also monitor and set DTCs for non-emission
SYSTEMS related faults. These faults may or may not illuminate
the MIL or set Freeze Frame Data.
TYPES OF TESTING
Inputs: Diagnostic Executive Outputs:

 Actuators
 Sensors Engine OBDII  MIL ON/OFF
Management Diagnostic
 GDS request System System GDS:
 DTC
Information
 Current Data
 Readiness
Flags
ECM/PCM
DIAGNOSTIC TESTING One of the primary functions of OBDII is testing the

performance of engine management and emissions
systems. Inputs and outputs are connected to the ECM.
The diagnostic tests run on systems or component to
determine if they are operating properly. Commands,
information requests, data, and test results using the
GDS, are sent and received through the Diagnostic Link
Connector (DLC).
The following are the three types of diagnostic tests:
PASSIVE Passive testing monitors the system and components

during normal operation.
ACTIVE During Active testing, the PCM controls the system or

component in a specific action while monitoring takes
place. The PCM may perform active tests as the result
of failed passive tests.
INTRUSIVE The Intrusive test is a special type of active test that

involves an action by the PCM that may affect vehicle
performance or emissions

DIAGNOSTIC TROUBLE CODE – DTC – SAE J2012
DTC CLASSIFICATIONS DTC’s use a unique numbering system to breakdown

each type of fault. It begins with a letter followed by
four numbers.
The letter identifies what system monitored the device

that failed. A “P” indicates a powertrain device. The first
number indicates if the code is generic or manufacturer’s
specific. The second number indicates the system
effected and the last two numbers identifies the fault or
type of failure.
DTC SETTING A DTC sets based upon specific detecting conditions.

DTC detecting conditions can also assist in diagnosing
the cause of the DTC.
DTC faults include:

 System failure
 A mechanical component failure
 An electrical/electronic failure
 A rationality failure
Note: Some DTCs may have an alpha character

(example: P2A00, P161B.) These codes provide an
increased level of diagnostic information.

EXAMPLES OF DTC DETECTING CONDITIONS
First trip example
Second consecutive
trip example
No MIL, first trip

TYPES OF DTCS Each Diagnostic Trouble Code (DTC) is directly related

to a diagnostic test. The Diagnostic Management
Instructor Note: System sets DTCs based on the failure of the tests
The Drive Cycle shown in during a trip or trips. Certain tests must fail two
Detecting Conditions is consecutive trips before the DTC is set such as the
considered a trip. second trip example shown. Kia shop manuals and DTC
detecting conditions will refer to a trip as a driving
cycle.
MIL ON CONDITION The following are the types of DTCs and the
characteristics of those codes:
FLASHING MIL, ONE TRIP Emissions related:

 Flashes MIL when emission levels are high enough
to cause catalyst damage.
MIL ON, ONE TRIP  Requests illumination of the MIL on the first trip
when emission levels exceed 1.5 times the FTP
standard.
 Stores a Present DTC on the first trip with a fail.
 Stores a Freeze Frame on the first trip with a fail.*
MIL ON, TWO TRIP Emissions related:

 "Pending" after one trip with a fail.
 "Not Present" after one trip with a pass.
 Requests illumination of the MIL on the second
consecutive trip with a fail.
 Stores a Present DTC on the second consecutive
trip with a fail (the DTC is armed after the first fail).
 Stores a Freeze Frame on the second consecutive
trip with a fail.*
NO MIL, ONE TRIP Non-emissions related

 Stores a Present DTC on the first trip with a fail.
 Does NOT store a Freeze Frame.
 The DTC MIL ON Condition indicates No MIL when
DTC is set.
Note: Example, a P0112 (Intake Air Temperature

Sensor Circuit Low) is a two trip code, but a P1112
(Intake Air Temperature Sensor Circuit Intermittent
Low) is a no MIL code.
* If a Freeze Frame has not already been stored.

DTC STRATEGY The DTC Strategy is generally based upon one of three
fault types shown below, and the test results are
compared to the Threshold Value.
INTEGRITY TYPE  The input signal circuit is either open (high voltage)
or shorted (low voltage).
RATIONALITY TYPE  The input signal value is not correct based on the
operating conditions of the vehicle.
FUNCTIONALITY TYPE  The input sensor circuit value did not change
according to the operating conditions of the output
device.

DTC DETECTING CONDITION
ENABLE CONDITIONS The Enable Conditions are the exact conditions required
in order for a diagnostic test to run. The Enable
Conditions are available on KGIS in the DTC service
information section. The Enable Condition shown above
indicates the test will run when the listed conditions are
met.
THRESHOLD VALUE Threshold Value is the parameter(s) stored in the ECM

that the measured or calculated value of the data is
being compared too.
CASE THRESHOLD Some DTCs have different threshold values referred to

as a case. These relate to different operating conditions
of the vehicle and the severity of the fault.
The PCM also has the ability to "learn" from the results
of its diagnostic testing. The PCM internally charts the
results of diagnostic testing over time and creates a
baseline, of the "normal" test results. By using this
learning capability, the PCM is able to filter out
information that could cause a false DTC.
DIAGNOSTIC TIME Diagnostic Time is the amount of time the condition

must be present before the DTC will set.

DTC DETECTING CONDITION
2010 Soul P0121 Throttle Pedal Position Sensor Circuit Range Performance
The delta symbol (∆) is mathematic shorthand for “a change in”
TRIP Diagnostic testing occurs during a trip. A trip is a key-

on cycle in which all the enable conditions for a given
diagnostic test are met, followed by a key-off/power-
down. In the example above, the engine speed needs
to be greater than 480 rpm. Since the enable conditions
for each DTC are different, a trip for each DTC is
different. Trips are referred to as a driving cycle in
KGIS.
WARM-UP CYCLE During trips, the PCM counts warm-up cycles instead of
key cycles to clear DTCs. A warm-up cycle is achieved
when the engine coolant temperature rises at least
22° C (40° F) from start-up and achieves a minimum
temperature of 71° C (160° F).

Readiness Tests (Image 1) Readiness Flag (Image 2)
READINESS TESTS The GDS Readiness Tests list the monitors supported
by the vehicle and the status of each monitor as
COMPLETED, NOT COMPLETED, or NOT APPLICABLE. A
value of >0 in “Number of DTC”, and the “Malfunction
Indicator Lamp (MIL)” indicating ON, determines a
system faults exists.
READINESS FLAG A readiness flag can be found by clicking on the DTC

Status button. A readiness flag sets when a particular
component or system has finished testing and the results
are stored.
In image 1, the Readiness Tests indicate if the specific

DTC enable condition(s) is:
 NOT COMPLETED
 COMPLETED
 NOT APPLICABLE
In image 2, the DTC Status is the result of the specific

DTC detecting condition testing and is listed as:
 PRESENT
 NO DTC
 PENDING
 HISTORY
Depending upon the results of the specific DTC detecting
condition testing and the type of DTC, the MIL Status will
be ON or OFF.
In order to verify a vehicle repair, you will need to use

the GDS to retrieve and evaluate vehicle fault related
DTCs and DTC status. Also, verify that the fault has
been corrected, and confirm that the DTC Readiness
Flag indicates Complete.

Example of a drive cycle. Drive cycle varies by year, model, and manufacturer of the ECM/PCM.
DRIVE CYCLE The purpose of the OBDII Drive Cycle is to run all of
the emission-related on-board diagnostics. When all
diagnostics have been run, the readiness tests are set
to "Complete." They are set to "Not Complete" if the
battery or PCM is disconnected, DTCs have been
cleared, or the PCM has been reprogrammed.
The GDS is used to determine if the readiness tests are

complete or not. The readiness tests only reports
whether or not a diagnostic test has been run and not
the outcome. In addition, for multiple sensor
diagnostics, such as oxygen sensors, tests must be
completed for all sensors.
Next is a list of the tests based on the drive cycle:
COLD START Cold start is determined by measuring Engine Coolant

Temperature and comparing it to the Intake Air
Temperature during start-up. The PCM considers the
engine to be cold if the following conditions are met:
 ECT less than 40° C (104° F)
 ECT and IAT are within 6° C (11° F) of each other
at start-up

IDLE (5 MIN.) During this period, the O2 heater, Purge, Misfire, and
Fuel Trim diagnostics will run. The A/C and electrical
loads will help the Misfire diagnostic by stabilizing
normal combustion variation.
ACCELERATE Prior to accelerating, turn off the A/C. Then apply half
throttle until 55 mph is achieved. During acceleration,
the Misfire, Fuel Trim, and Purge Flow diagnostics will
run.
STEADY STATE CRUISE During this portion of the cycle, the O2 Response,
Purge, Misfire, and Fuel Trim diagnostics will run.
DECELERATE During the deceleration portion of the Drive Cycle, the

Purge and Fuel Trim diagnostics will run. It is important
to have a gradual coast down with NO brake
application.
ACCELERATE Apply 3/4 throttle until 55-60 mph is reached. The

same diagnostics will run as during the last acceleration
portion of the Drive Cycle.
STEADY STATE CRUISE During this portion of the Drive Cycle, the Catalyst
Monitor diagnostic will run. Note that if the catalyst is
marginal and if a battery disconnect has occurred prior
to the Drive Cycle, it may take six separate Drive Cycles
to determine the state of the catalyst. The same
diagnostics that were performed during the last steady
state cruise are repeated during this portion of the
Drive Cycle.
DECELERATE The same diagnostics that were performed during the

last deceleration portion of the Drive Cycle are
repeated.

CONDITIONS TO SET DTC A DTC sets when the enable condition is met, the
diagnostic test is run and the results of the test are
outside of the PCM parameters. Most DTCs require two
consecutive trips with a fault to set as a present DTC
and turn on the MIL. Some DTCs have certain
conditions in which they are stored in history and
illuminate the MIL without two consecutive trips with a
test fail.
TURNING THE MIL OFF The ECM will turn the MIL off after three consecutive
trips without a fail, but the DTC and freeze frame will
remain.
CONDITIONS TO CLEAR DTCs can be cleared in two ways.
1. GDS GDS can be used to clear the DTC information. This

also clears all Freeze Frame and statistical PCM filters.
“Verification of Repair” might tell you to not clear the
code, but see if the code goes to “History.” All monitor
status flags are cleared with the GDS. When code
clearing is required, this method is the preferred
procedure.
2. WARM-UP CYCLES If the fault that caused the DTC to be stored into
memory is no longer present, the Diagnostic Executive
begins to count the warm-up cycles. Once it has
counted forty consecutive warm-up cycles with no
further faults detected, the DTC is automatically cleared
from the PCM memory. Eighty warm-up cycles must
pass for misfire and CAT damaging DTCs to clear.

MONITORS
MONITOR Two types of monitors are used in OBDII:

CLASSIFICATIONS  Continuous monitors are always running when the
vehicle is being driven and their enabling conditions
are met. This is because it is important for OBDII to
continuously monitor Misfire, Fuel System, and
Comprehensive Component in order to protect the
catalytic converter from damage.
 Noncontinuous monitors generally run only once per
trip, when enabling conditions are met and the ECM
does not detect any conditions or malfunctions that
would cause the test results to be inaccurate.
CONTINUOUS MONITOR  Misfire

o Catalyst Damaging (MIL flashing)
o Emissions Related (MIL ON)
 Fuel System
 Comprehensive Component
o CMP
o CKP
o RPM
o ECT
o MAF/MAP/BARO
o IAT
o EVAP
o Knock
o VSS
o Brake switch
NONCONTINUOUS  HO2S Heater Circuit

MONITOR  O2S
 Catalyst Efficiency
 EVAP


DTC Diagnostic Information Guided Practice
MODULE GOAL Upon completion of this module, Kia Service

Technicians will have an opportunity to practice and
demonstrate their ability to retrieve, evaluate and use
the DTC diagnostic information contained in KGIS.
MODULE OBJECTIVES Upon completion of this module and access to KGIS,

you will retrieve, print, and answer specific DTC
information questions with 80% or greater accuracy.
These questions are related to pre-selected DTCs from
the shop manual and DTC sections in the Kia Service
Information (KGIS). This includes:
 Sedona P1112
 Soul P1119
 Forte P0420
 Optima P0300
 Sportage P0133
MODULE INSTRUCTIONS Carefully read and follow the instructions for each task.
Fill in the blanks with the requested information using
the DTC information listed on KGIS as you perform the
task. When you have finished, discuss your work and
results with your instructor, who will evaluate your
work, provide positive feedback, and sign off on your
scorecard.
Take this module with you to the computer lab.
Clean up your area as instructed.
Note: Sometimes, you will look up the DTC information

using the “Shop” section and sometimes the “DTC”
section.
REQUIRED MATERIALS In order to complete this module, you will need:

 GDS or computer with internet access
 Printer

task stations
STATION ONE Task One: Use GDS/KGIS to retrieve and evaluate DTC
P1112 diagnostic information
Task Two: Use GDS/KGIS to retrieve and evaluate

DTC P1119 diagnostic information
Task Three: Use GDS/KGIS to retrieve and evaluate

Task Four: Use GDS/KGIS to retrieve and evaluate

Task Five: Use GDS/KGIS to retrieve and evaluate

EXPECTATONS Technicians will use GDS to diagnose pre-determined

faults using service information. Then they will analyze
the results of tests performed to determine the correct
repair to fix the vehicle right the first time, while
demonstrating their diagnostic ability to the instructor.
Clean up your workstations as directed by the

instructor.
TIME TO COMPLETE Approximately: 2 hours

STATION 1 - task 1
IAT RELATED DTC In order to diagnose a concern, you will need to

retrieve and evaluate the DTC information from the
DTC section in Service Information (KGIS).
Year: 2012 Model: Sedona Engine: 3.5L
1. Analyze the pre-selected DTC and list the requested

diagnostic information using the DTC section in
KGIS Service Information for the above vehicle.
2. Select DTC P0112.
3. List the DTC component and description:

__________________________________________
__________________________________________
4. List the enable conditions of Case 1 and Case 2:
Case 1 Case 2
___________________ ____________________
___________________ ____________________
___________________ ____________________
___________________ ____________________
5. List the shown diagnosis time:
__________________________________________
6. List the amount of testing time required for the
circuit to fail:
__________________________________________
__________________________________________
7. List the 4 possible causes for the DTC:
___________________ ____________________
___________________ ____________________

STATION 1 - task 1 continued
8. Using the waveform/data provided in the DTC

answer the following:
a. With an engine at ambient temperature, the IATS

and ECTS data should be __________
b. During engine warm up, the ECTS output signal

should _____________________________, while
the IATS should show a _______________
9. Using the current data provided in the DTC, list the

requested readings:
a. Short to ground temperature reading: ___________
b. Open circuit temperature reading: ______________
10. With an ambient temperature of 20°C (68°F), list

the approximate IATS resistance:
__________________________________________
11. With the vehicle repaired, list the procedure to
verify the repair:
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
Feedback: When finished, discuss your results with
your instructor.

STATION 1 - TASK 2
ECT RELATED DTC In order to diagnosis a concern, you will need to

DTC section in Service Information (KGIS.)
Year: 2012 Model: Soul Engine: 2.0L

2. Select DTC P1119
3. List the DTC component and description:

__________________________________________
4. List the DTC enable conditions :
__________________________________________
__________________________________________
5. List the shown diagnosis time:
__________________________________________
6. List the MIL ON condition with a DTC:
__________________________________________
7. List the 3 possible causes for the DTC:
__________________________________________
__________________________________________
__________________________________________

station 1 - task 2 Continued
Use Scan tool Diagnostics to answer the following

question:
8. With the A/C OFF and the cold engine idling for five
minutes, the Engine Coolant Temperature Sensor
rises to above 50°C (122°F); what should be
checked next?
__________________________________________
9. List the four possible “DTC Status” parameters:
__________________________________________
__________________________________________
__________________________________________
__________________________________________
10. What are the first two items checked in the
System Inspection?
_________________________________________
11. In System Inspection, what is the procedure for
measuring the ECTS resistance?
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
12. At 60° C (140° F), what should the resistance of
the ECTS be?
_________________________________________
13. When verifying the repair, it’s important for the
GDS to indicate the following has been completed:
_________________________________________
14. List what “DTC Status” parameter should be
displayed after correcting the fault and number 13
above has been completed.
_________________________________________
your instructor.

STATION 1 - task 3
CATALYTIC CONVERTER In order to diagnosis a concern, you will need to

RELATED DTC retrieve and evaluate the DTC information from the
Year: 2012 Model: Forte Engine: 2.4L

2. Select DTC P0420
3. Based on the DTC and description, what does the

system monitor to measure catalyst efficiency?
__________________________________________
__________________________________________
4. List the DTC Enable conditions:
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
5. List shown threshold value and diagnosis time:
___________________ ____________________
6. List the number of driving cycles for a MIL ON

condition:
__________________________________________

STATION 1 - TASK 3 CONTINUED
7. List the 3 components shown as possible causes for

the fault:
__________________________________________
__________________________________________
__________________________________________
8. Using General Information, Signal
Waveform & Data, answer the following:
With the engine idling after warm up, the

Downstream Catalyst HO2S signal should be
__________________________________________,
while the Upstream Catalyst HO2S signal should be:
__________________________________________
9. If the scan tool shows a present fault, what three
components should be inspected?
__________________________________________
__________________________________________
__________________________________________
10. When verifying the repair, what DTC Status
indicates that the vehicle is repaired?
_________________________________________
your instructor.

STATION 1 - TASK 4
MISFIRE RELATED DTC In order to diagnose a concern, you will need to

shop manual and DTC sections in Service Information
(KGIS).
Year: 2012 Model: Optima Engine: 2.4 GDI

2. Select DTC P0300
3. List the possible causes for setting the DTC:

__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
4. List the following Detecting Conditions for P0300:
a. Threshold Value
__________________________________________
b. Diagnostic Time
__________________________________________
c. MIL On Condition
__________________________________________
__________________________________________

STATION 1 - TASK 4 CONTINUED
5. Using Scan Tool Diagnostics, DTCs related to which

components need to be repaired before diagnosing
a P0300 DTC?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
6. If the MIL is blinking, which DTC needs to be
monitored and cleared before continuing the
diagnosis?
__________________________________________
7. If the DTC is occurring at the present time, list the
five inspections you would need to perform:
a. ________________________________________
b. ________________________________________
c. ________________________________________
d. ________________________________________
e. ________________________________________
8. With the vehicle repaired, list the procedure to
verify the repair:
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
your instructor.

STATION 1 - task 5
OXYGEN SENSOR RELATED In order to diagnose a concern, you will need to

DTC retrieve and evaluate the DTC information from the
Year: 2012 Model: Sportge Engine: 2.4 DOHC

2. Select DTC P0133
3. Using the DTC General Information, the ECM

determines that the H02 is “slow” by measuring its
amplitude against:
__________________________________________
__________________________________________
4. Using the Enable Conditions, list conditions when the
ECM checked the signal:
__________________________________________
__________________________________________
__________________________________________
5. List the threshold value and diagnosis time:
__________________________________________
__________________________________________
6. List the number of driving cycles for a MIL ON
condition:
__________________________________________
7. List the three possible causes shown:
__________________________________________
__________________________________________
__________________________________________

STATION 1 - task 5 continued
8. Using System Inspection:

a. What should be inspected for Air Leakage?
___________________________________________
___________________________________________
___________________________________________
___________________________________________
b. What should be inspected as part of the
Visual/Physical Inspection?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
9. If there are no problems found in either of the

inspections, what is the next troubleshooting step?
__________________________________________
10. If contamination of the HO2S is indicated, what test
needs to be performed?
__________________________________________
__________________________________________
Feedback: When finished, discuss your results with your
instructor. Clean up your workstations as directed by the
instructor.

Analyzing DTC Faults
Theory Module

Technicians will demonstrate their knowledge of DTC
diagnostic strategies, needed to enhance the skills
required to diagnose a DTC.
MODULE OBJECTIVES Given this module on formulating a sound diagnostic

plan, each technician will be able to complete Progress
Check Questions based on the following content with
80% or greater accuracy:
 Formulating a sound diagnostic plan
 Modeled ECM data
 Diagnostic resources
 The Kia Diagnostic Plan
MODULE INSTRUCTIONS This theory module will conclude with Progress Check
questions that will assess what you have learned. Pay
attention, ask questions, and participate to get the
most out of this module.
TIME TO COMPLETE Approximately: 20 minutes.

DIAGNOSTIC APPROACH
FORMULATING A SOUND A planned, deliberate approach to diagnosis is vital if

DIAGNOSTIC PLAN repairs are to be accurate and cost effective for both
the customer and the shop.
Vehicle systems are far too complex to permit random

guessing. While experience may point to a specific
component fault, a systematic verification of both the
fault's cause and correction are the only way to ensure
accurate and complete repairs.
Some malfunctions are not directly related to an OBDII

component (sensor or actuator). The DTC will be set by
a malfunction related to the DTC. For example:
 Low fuel pressure – Long Term Fuel Trim
 Plugged air filter – MAF
Do not forget to verify the mechanical operating

condition of the engine before troubleshooting an
apparent problem in the engine management system.
NO DTC DIAGNOSIS Always start by confirming the customer concern. If

you are not able to confirm it, have the customer drive
the vehicle to show you how it is acting.
Use service information to obtain the ECM/PCM

specifications. It will give you typical values that you
would expect when testing for proper operation.
Certain inputs provide the “core” information needed

for proper engine and emission functions and should be
checked as part of your diagnosis. When starting your
diagnosis, pay specific attention to the current data for
the following components:
 RPM, CKP, CMP (engine speed/timing)
 TPS and APS (throttle angle/engine load)
 ECT, IAT (engine/air temperature)
 MAF, MAP (airflow/engine load)
 HO2S, Fuel Trim (fuel mixture, rich/lean)

Note: Current data readings may be modeled (ECM

substituting calculated values) if a component is
malfunctioning. The ECM uses modeled values for fail-
safe operation. Example, if the ECT is open the ECM
thinks the engine temperature is -40° F. The ECM will
look at other engine operating conditions such as IAT,
engine run time, and closed loop fuel control. Based on
these operating conditions the ECM will substitute a
calculated value for continued engine operation.
If you suspect modeled values in your diagnosis,

individually test components and circuits instead of
relying on GDS current data.
PRACTICAL DIAGNOSTIC Although system operation is similar, components and

APPROACH circuit operation may vary by model and year.
A thorough understanding of the system operation and
its components is necessary for proper diagnosis.
Resources include :
 Service Information
o System Operation
o Component Operation
o Specifications
 TSBs and TechTimes
 ETMs – Circuit Schematics
 GDS Current Data – Inputs and Component Status
 Actuation Tests – Outputs
o S/W Management Checks – Circuit Operation
Develop a plan to reduce the amount of circuit testing

by using the available information and GDS monitoring
and testing capabilities.
 Monitor Current Data for circuit inputs
 Perform Actuation Tests, and Vehicle S/W
Management Checks, for circuit outputs and
component operation
This will eliminate unnecessary intrusive testing and

help identify specific circuits that may need further
testing.
Note: Most circuits and components are not easily

accessible. Excessive testing may cause damage to
connectors and/or terminals.

THE KIA DIAGNOSTIC PLAN Effective diagnosis requires knowledge of how a system
functions in order to accurately determine when it is
not operating correctly. It is equally true that your
"approach" to diagnosis and troubleshooting greatly
affects the accuracy and timeliness of troubleshooting.
You should be familiar with the following diagnostic

steps:
VERIFY  Verify the problem (customer’s driving conditions)

and using the DTC enable conditions:
o Determine what has gone wrong – the
symptoms.
o Determine when the problem occurs – under
what operating conditions.
o Understand how the affected system works and
related component interact. (DTC General
Description and DTC Description.)
o Determine that the problem is not an operator
issue.
ANALYZE  Analyze the problem

o Create a Diagnostic Plan
o Make preliminary checks of basic engine
conditions
o Research TSBs related to the concern/DTC
o Visually inspect the system and components
DIAGNOSE  Diagnose the cause

o Use the DTC detecting condition chart
 What strategy is being used for this DTC?
 What were the conditions that enabled the
test?
 What was the fault value?
 How many trips?
o Complete the inspection steps for the DTC
o Check easiest and most likely components first
REPAIR  Repair the cause of the problem
CHECK  Check the repair using DTC Status

o Inspect the readiness flag for completeness
o Inspect the DTC for status
o Drive the vehicle under the same conditions that
existed when the concern was verified or under
the enable conditions


PROGRESS CHECK 1. Which of the following is the best example of a

QUESTIONS problem setting a related DTC?
a. Catalyst Damaging misfire
b. Faulty MAP sensor
c. Open wire in ETC circuit
d. Bad HO2 sensor connector
2. Always start your diagnosis by:

a. Checking for DTCs
b. Clearing all existing DTCs
c. Confirming the customer concern
d. Performing a visual inspection of EMS
components
3. Technician A says modeled component data always

provides a valid test result.
Technician B says that modeled data is when the
ECM substitutes calculated data for actual data.
Who is correct?
a. Technician A only
b. Technician B only
c. Both Technician A and Technician B
d. Neither Technician A nor Technician B
4. Technician A says using GDS monitoring and testing

capabilities can reduce the need for individual circuit
and component.
Technician B says most vehicle systems operate the
same regardless of model, as long as they are the
same year.
Who is correct?

5. Which of the following best summarizes the Kia

Diagnostic Plan?
a. Verify, Analyze, Replace, Retest, Check the
Repair
b. Verify, Accurate, Diagnose, Repair, Check the
Repair
c. Verify, Analyze, Diagnose, Repair, Check the
Repair
d. Validate, Analyze, Repair, Diagnose, Check the
Repair

NOTES PAGE
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________


Analyzing DTC Faults Guided Practice

Technicians will practice and demonstrate their ability
to confirm, analyze, and diagnose preinstalled DTC
faults using diagnostic information from GDS.
MODULE OBJECTIVES Kia Technicians will complete this module using the
GDS, KGIS, diagnostic equipment, and vehicles with
preinstalled faults. Individual technicians or teams of
two technicians will complete the following guided
practice exercises with 80% or greater accuracy:
 Confirm, retrieve, and analyze the DTC.

 Analyze and record the diagnostic approach to
identify the root cause of the malfunction or
condition.
 Identify the root cause of the malfunction or
condition.
 Determine one trip and two trip DTCs.
 Compare Freeze Frame data to current data and
determine where fault occurred, if available.
 Describe to the instructor the results and operating
conditions of the vehicle at the time of failure.
 Determine why a pending DTC did not set Freeze
Frame Data.
 Review with the instructor printouts of current
Freeze Frame data (setting parameters) and
oscilloscope printouts.
 List and review with your instructor repair
recommendations to correct the malfunction or
condition with 100% accuracy to fix it right the first
time.
The following vehicles are used with preinstalled faults:

 Sorrento 3.5L
 Forte 2.0L
 Soul 2.0L
 Sportage 2.4L
 Sorrento 2.4L

Answer the questions and fill in the blanks with the
requested information as you perform the task. Check
off each item as it is completed. When you have
finished, discuss your work and results with your
instructor, who will evaluate your work, provide
constructive feedback, and sign off on your scorecard.
Clean up your area as instructed.

 GDS with printer, VCI, and VMI
 T-connectors
 DVOM
 Hand tools
STATION ONE Task: Evaluate Sorrento 3.5L
STATION TWO Task: Evaluate Forte 2.0L
STATION THREE Task: Evaluate Soul 2.0L
STATION FOUR Task: Evaluate Sportage 2.4L
STATION FIVE Task: Evaluate Sorrento 2.4L
EXPECTATIONS Technicians will use GDS to retrieve available DTCs

from vehicle and selected service information, VCI,
T-connectors, and DVOM to evaluate the fault, list the
results of tests performed, decide on a recommended
repair, and demonstrate their diagnostic ability to their
instructor.
Clean up your workstations as directed by the

instructor.
TIME TO COMPLETE Approximately: 3 hours

STATION 1
RELATED DTC Year: 2012 Model: Sorrento Engine: 3.5L
The customer states the light on the dash is ON. Check

and advise.
12. Connect the GDS to the vehicle.
13. Key ON, clear any codes, key OFF.
14. Start the engine and allow it to idle for 2 minutes,

while viewing current data and DTCs.
15. List any DTC(s) indicated and its description:

__________________________________________
__________________________________________
16. List the DTC status of each DTC retrieved:
DTC DTC Status Readiness MIL Status
17. Is Freeze Frame data available for any of the DTCs?
YES NO
18. If YES print the Freeze Frame data, if NO, why is

there no Freeze Frame data?
__________________________________________
__________________________________________
19. Turn the engine OFF until the “Vehicle

Communication Fail” message appears.
20. Start the engine and select OK on the “Vehicle

Communication Fail” message, and allow it to idle
for 2 minutes, while viewing current data and DTCs.

STATION 1 - continued
22. Did it store Freeze Frame data? If YES, print the

Freeze Frame data.
YES NO
23. Did any Freeze Frame data appear to be abnormal?
YES NO
24. If YES, list the component and its value indicated in

the Freeze Frame data.
__________________________________________
25. Compare Current Data and Freeze Frame for the
complaint above. List the difference and why there
is a difference.
__________________________________________
__________________________________________
__________________________________________
26. Next, print and staple together the following
sections of the DTC:
 General information
 W/Harness inspection
 Component Inspection
27. Number the barometric pressure sensor pins using

the harness connector shown in the schematic of
the Diagnostic Circuit Diagram.

28. Perform each of the steps as outlined in the

following service information, record the results
below:
Service Information Value

Signal Circuit Inspection
a. Signal Terminal to Chassis __________

Ground
b. Between Signal Terminal and __________

Chassis Ground
c. Between signal and ground __________

terminals of IATS connector
d. Between signal terminal of IATS __________

connector and ground terminal
of BPS harness connector
Component Inspection __________
29. Is the measured resistance within specs?
YES NO
30. List the recommended next step.

__________________________________________
your instructor. Clean up your workstation as directed
by the instructor.

STATION 2
RELATED DTC Year: 2012 Model: Forte Engine: 2.0L
The customer states the radiator fan is on and the light

on the dash is ON. Check and advise.
2. Key ON, clear any codes, key OFF.

4. List any DTCs indicated and their description:

__________________________________________
__________________________________________

Communication Fail” message appears on the GDS.


STATION 2 - CONTINUED
9. Did it store Freeze Frame data? If YES, print the

Freeze Frame data.
YES NO
10. Did any Freeze Frame data appear to be abnormal?
YES NO
If YES, list the component and its value indicated in

Freeze Frame data.
__________________________________________
11. Compare Current Data and Freeze Frame for the

complaint above. List the difference and why there
is a difference.
__________________________________________
__________________________________________
__________________________________________
__________________________________________
12. Assume that the Ground Circuit, Signal Circuit, and
Terminal and Connector Inspections were
performed and all readings were within
specifications.

 General information
14. Number the ECT sensor pins using the harness

connector shown in the circuit signal schematic on
the left.

15. Perform the steps outlined in the component

inspection and record the results below:
Service Information Value

Component Inspection
__________
16. If the engine temperature is 176°, what should

the resistance of the ETC be? __________________
17. List the recommended next step.
_____________________________________________

by the instructor.

STATION 3
RELATED DTC Year: 2012 Model: Soul Engine: 2.0L
The customer states that the vehicle cranks awhile

before it starts.


__________________________________________
__________________________________________
__________________________________________
__________________________________________



STATION 3 task - continued

 General Information
 W/Harness Inspection
9. Perform the following tests as directed in the DTC

Inspection/Repair, W/Harness Inspection:
1. Power Circuit Inspection
2. Ground Circuit Inspection
3. Signal Circuit Inspection (3)
10. List each specification and values you measured.
Specification Actual
1. _________________ _________________
2. _________________ _________________
3a. _________________ _________________
3b. _________________ _________________
11. Use the GDS scope and T-Connector to measure the

CMPS signal waveform in the Component Inspection
and print the waveform.
12. Is the measured signal waveform normal?
YES NO
13. What repairs do you recommend?
_____________________________________________

by the instructor.

station 4
RELATED DTC Year: 2012 Model: Sportage Engine: 2.4L
The customer states the light on the dash is ON. Check

and advise.

while viewing Current Data and DTCs.

__________________________________________
__________________________________________
4. List the Current Data voltage for the Rear HO2S.
__________________________________________
5. Check the Signal Waveform while snapping the
throttle and print the waveform.
6. Did the waveform respond as expected?
YES NO
7. Print and staple together the W/Harness and

Component Inspection sections of the DTC.
8. Perform the Signal Circuit Inspection and list your

results below:
__________________________________________
9. Is this reading normal?
YES NO

10. Perform the Terminal and Connector Inspection and

list your results below:
__________________________________________
11. Perform the Component Inspection and list your
results below:
__________________________________________
12. Is the monitored voltage within specification?
YES NO
13. Based on the Waveform, Signal Circuit Inspection,

Terminal and Connector Inspection, and Component
Inspection, what is the likely cause of the DTC?
__________________________________________
__________________________________________
by the instructor.

STATION 5
The customer states the vehicle is hard to start, runs

poorly, and the light on the dash is ON. Check and
advise.

while viewing the current data and DTCs.
Note: After starting the vehicle you may need to

“feather” the throttle to keep the engine running.
3. List the DTCs indicated and their description:

__________________________________________
__________________________________________
__________________________________________
4. List the status of each DTC retrieved:



8. Next, print and staple together the General

Information, WH/Inspection and Component
Inspection sections of the DTC.
9. Using the scan tool, what is the status of the CVVT

Control State in Current Data?
__________________________________________
10. What does this tell you about the CVVT system?
__________________________________________
11. Using the Component Inspection section, check the
OCV and filter.
12. What were the results of the test?
OCV
Disconnected
Battery Voltage
Applied
13. The OCV and filter have been checked mechanically

and the OCV is stuck in the ON position.
14. Based on the test results, what would you do to

repair the vehicle?
__________________________________________
Feedback: When finished, discuss your results with your
instructor. Clean up your workstation as directed by the
instructor.

NOTES PAGE
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________


Misfire Monitoring and Catalytic Converter Theory Module

Technicians will demonstrate their knowledge of the
effects operations upstream have on the catalytic
converter’s process to reduce emissions. This
knowledge will enhance the technicians’ skills required
to diagnose diagnostic trouble codes (DTC).
MODULE OBJECTIVES The Kia technician will monitor misfiring and test
components that could cause a misfire. The technician
will understand the components that affect peak
catalytic efficiency. The technician will be able to
complete the following with 80% or greater accuracy:
 Select how misfire occurs and what it results in:
o Ignition related system
o Engine mechanical related
o Valve timing related
o Air/fuel ratio related
 Identify components/functions operating efficiently
for proper catalyst operation
o HO2S1 and HO2S2
o Closed loop, Air/Fuel system, and electrical
wiring
 Select Catalyst monitoring - for operation rationale
o Identify difference between good, deteriorating,
and no-good catalyst
o Select the root cause of CAT failure, fatigue,
contamination, and shock
o Identify OEM vs. aftermarket CAT results
MODULE INSTRUCTIONS This theory module will conclude with Progress Check
questions that will assess what you have learned. Pay
attention, ask questions, and participate to get the
most out of this module.
EXPECTATIONS You will gain a better understanding of the process the

ECM uses to monitor catalyst converter efficiency. This
module will prepare you for the guided practice
modules to follow.
TIME TO COMPLETE Approximately: 45 minutes

ENGINE MISFIRE
TYPES OF MISFIRE Four types of misfires can exist in an engine.
 Ignition
 Engine mechanical
 Air/Fuel
 Valve timing

ENGINE MISFIRE – CONTINUED
IGNITION Ignition misfires are related to primary or secondary

ignition systems. The primary ignition system consists
of the ECM, an internal or external ignition module, and
primary ignition coil. The secondary ignition system
consists of either a secondary coil winding, plug wire
and spark plug, or the current designed coil on plug
with the coil mounted directly on the spark plug.
An ignition misfire is when there is not enough voltage

to jump the gap of the plug and ignite the air/fuel
mixture. This may be caused by a fault in the primary
or secondary ignition coils, faulty ignition wires, the
spark plug, or a CKP sensor concern.
ENGINE MECHANICAL Engine mechanical problems typically effect engine

compression. These include burnt exhaust valve, blown
head gasket between cylinders, coolant/oil leaking, or
collapsed or overheated compression rings.
AIR/FUEL Air/fuel problems can be related to fuel pressure or

volume problems. Other fuel injected related problems
include restrictions or leaking.

ENGINE MISFIRE – CONTINUED
Timing Mark Timing Mark
Timing Mark
VALVE TIMING Valve timing issues can be related to previous work

done where the timing chain or timing belt required
removal, such as a water pump replacement or a
scheduled timing belt replacement.

INTAKE GASES To understand how a catalytic converter works, it helps

to understand air, fuel, and exhaust gases.
Air consists of:
 21% oxygen (O2)
 78% nitrogen (N2)
 1% other gases
Fuel consists of:
 100% hydrocarbons (HC)
EXHAUST GASES When the correct ratio of air and fuel (stoichiometric –
14.7:1) is compressed and ignited at the correct time in
the combustion chamber, the exhaust gases should be
close to ideal and the results would be CO2 and H2O.
However, due to engine design and operating
conditions, this does not take place. The example
above shows typical exhaust gases:
 HC < 50 ppm
 CO < 0.1%
 O2 < 0.5%
 CO2 > 14%
 NOx < 2000 ppm
 N2 > 71%
 H2O

THREE-WAY CATALYTIC CONVERTER
HC
NOx
CO
14.7:1
A/F ratio
CATALYTIC CONVERTER The three-way catalytic converter installed in the

exhaust converts and reduces exhaust gases into
harmless components through a chemical process.
The catalytic converter starts operating when it reaches

an operating temperature of ≈ 600° F (315° C) and
reaches maximum efficiency at ≈ 700° F (371° C) to
1500° F (815° C)
When the CAT is at operating temperature and the

air/fuel ratio is close to 14.7:1, the catalyst efficiency is
at 90% or greater to convert the HC and CO into CO2
and H2O, and the NOX is reduced to N2.
The graph above shows how the catalytic converter

works on the principle of the rich lean cycle. During the
lean cycle, the oxidizing (HC & CO) section of the CAT
is the most efficient and during the rich cycle the
reduction (NOx) section of the CAT is the most
efficient.

THREE-WAY CATALYTIC CONVERTER – CONTINUED
The two types of converters used are shown above.
The oxidation converter can be before or after the

reduction converter. It stores oxygen when the exhaust
is lean, and releases oxygen when the exhaust is rich.
It converts HC and CO into CO2 and H2O. The post
HO2S is located after the oxidation converter to monitor
the oxidizing converter efficiency.
The reduction converter absorbs NOX when the exhaust

is lean and reduces NOX to N2 when the exhaust is rich.
The oxidizing converter operates at peak efficiency

when the exhaust gas is at stoichiometric or leaner.
The reduction converter operates at peak efficiency

when the exhaust gas is at stoichiometric or richer.
The problem arises when the engine is operating

outside of the stoichiometric range, such as during
acceleration (rich), or deceleration (lean).

HEATED OXYGEN SENSORS Two types of B1S1 heated oxygen sensors (H02S) are
currently used by Kia:
 Narrow Band
 Wide Band
Normal B1S1 Narrow Band
NARROW BAND The Narrow Band produces a voltage between 0 and 1

volt dc. The voltage should be cycling above and below
0.45 volts when the system is idling in closed loop.
Normal B1S1 Wide Band
WIDE BAND The Wide Band controls a voltage of approximately 2

volts dc that is monitored by the ECM/PCM. The voltage
should be steady (very close to a straight line) when
the system is idling in closed loop.

CATALYST EFFICIENCY The ECM/PCM monitors the B1S1 and B1S2 heated
oxygen sensors (H02S) to determine catalyst efficiency.
The B1S1 H02S (prior to the catalytic converter)

monitors the exhaust stream during closed loop
operation to maintain the A/F ratio as close as possible
to 14.7:1 referred to as stoichiometric. The B1S1 can
be either a Wide Band or Narrow Band type.
The B1S2 (after the oxidizing converter) is a Narrow

Band type and monitors the catalysts efficiency. It
monitors the O2 level leaving the converter.
Normal B1S2 Narrow Band
In the example above, when the CAT is operating

properly, the B1S2 voltage should be steady typically
between .3 vdc and .8 vdc and not cycling, indicating
the CAT has adequate oxygen storage capacity.
B1S2 Narrow Band Reduced Catalyst Efficiency
If the B1S2 voltage is cycling, the converter’s efficiency

is reduced. Possibly from poisoning or a misfire.

POISONED CATALYTIC Catalytic converters don’t die, they are murdered.

CONVERTER A catalytic converter can fail due to contamination,
overheating, shock, and vibration.
Contamination can come from several sources. An

engine that is burning oil in the combustion chamber
coats the surface of the monolith and plugs the pores
with black carbon soot reducing its efficiency. Silicone
contamination can be caused by coolant entering the
combustion chamber or the use of non-oxygen sensor
safe silicone sealant on engine areas exposed to the
crankcase. It coats the surface with a white powder that
also blocks the surface pores.
Overheating of the catalyst can be caused by the

exhaust being too rich (excessive fuel entering the
converter), or too lean (high exhaust temperatures)
causing the catalyst to melt.
Shock and/or vibration can crack or shatter the

monolith. This can be caused by extremely rough road
conditions over an extended period of time. It can also
be caused by failure or modification of the exhaust
mounting brackets and components.
In addition, aftermarket catalytic converters may not

contain the same type and amount of catalyst material,
which may also cause false failures of the converter
and related components.

PROGRESS CHECK QUESTIONS
SELECT THE BEST ANSWER 5. When should B1S2 voltage be steady?

AND RECORD IT ON THE a. When the CAT is cold
ANSWER SHEET b. When the CAT is poisoned
c. When the CAT is efficient
d. None of the above
6. What can damage a CAT?

a. Engine burning oil
b. A misfire
c. Silicon contamination
d. All the above
7. Technician A says that valve timing problems can be

caused by previous engine work.
Technician B says that valve timing problems can be
caused by a failure of the CVVT OCV.
Who is correct?
e. Technician A only
f. Technician B only
g. Both Technician A and Technician B
h. Neither Technician A nor Technician B
8. Technician A says that the oxidizing portion of the

CAT reduces NOX to N2.
Technician B says that the oxidizing portion of the
CAT converts the HC and CO into CO2 and H2O.
Who is correct?
9. Technician A says that a faulty ignition coil can

cause an engine misfire.
Technician B says that a fouled spark plug can
cause an engine misfire.
Who is correct?

SELECT THE BEST ANSWER 10. Which compression component(s) can cause a
AND RECORD IT ON THE misfire?
ANSWER SHEET a. Burned exhaust valve
b. Blown head gasket
c. Collapsed compression rings
d. All the above
11. Technician A says that incorrect fuel pressure can

cause an engine to misfire.
Technician B says that a restricted fuel injector can
cause an engine to misfire.
Who is correct?
12. Technician A says that a CAT reaches maximum

efficiency at approximately 700° F (371° C) to
1500° F (815° C).
Technician B says that a CAT reaches maximum
efficiency when the air/fuel ratio is close to 14.7:1.
Who is correct?
13. Technician A says that a Narrow Band B1S1 oxygen

sensor should cycle above and below 0.45 volts
when the system is idling on closed loop.
Technician B says that a Wide Band B1S1 oxygen
sensor should be steady at approximately 2 volts dc
when the system is idling in closed loop.
Who is correct?


Analyzing Catalyst Damaging Faults Guided Practice

Technicians will have an opportunity to practice and
demonstrate their ability to analyze catalyst-damaging
faults using DTC information from GDS.
MODULE OBJECTIVES Kia Technicians will complete this module using the
GDS, KGIS, diagnostic equipment, and vehicles with
preinstalled faults. Individual technicians or teams of
two technicians will complete the following guided
practice exercises with 80% or greater accuracy:
 Confirm, analyze, and diagnose catalyst damaging
Integrity Faults.
 Confirm, analyze, and diagnose a rich/lean fault that
could damage the catalyst.
 List and review with your instructor repair
recommendation(s) to correct the malfunction or
condition with 100% accuracy for first visit fix.
The following vehicles will be used with preinstalled

faults:
 Sportage 2.4L
 Sorrento 3.5L
 Forte 2.0L
 Soul 2.0L
 Sorrento 2.4L
Although all the tasks may seem similar, there are
important differences. DO NOT assume an activity
requires printing the DTC information when it is not
called for in the instructions.
Answer the questions and fill in the blanks with the
requested information as you perform the task. Check
off each item as it is completed. When you have
finished, discuss your work and results with your
instructor, who will evaluate your work, provide
constructive feedback, and sign off on your scorecard.
Clean up your workstation as instructed.


 GDS with VCI and VMI
 T-connectors
 Hand tools

stations
STATION ONE Task: Evaluate Sportage 2.4L
STATION TWO Task: Evaluate Sorrento 3.5L
STATION THREE Task: Evaluate Forte 2.0L
STATION FOUR Task: Evaluate Soul 2.0L
STATION FIVE Task: Evaluate Sorrento 2.4L
Caution: When instructed to check terminals at the

ECM/PCM, touch only the outside of the terminal.
DO NOT probe inside the terminal, as this may cause
damage to the terminal.
EXPECTATIONS Technicians will use GDS to diagnose predetermined

faults using service information. Then, analyze the
results of tests performed to determine the correct
recommended repair for a first visit fix. At the same
time, the technician will demonstrate their diagnostic
ability to the instructor.
Clean up your workstation as directed by the instructor.
TIME TO COMPLETE Approximately: 2 hours and 30 minutes

STATION 1
RELATED DTC Year: 2012 Model: Sportage Engine: 2.4L
The customer states the vehicle runs poorly and the

light on the dash is ON. Check and advise.


__________________________________________
5. Is Freeze Frame data available for any of the DTCs?
YES NO


Communication Fail” message, then allow it to idle
for 2 minutes, while viewing Current Data and
DTCs.

__________________________________________

10. Review the Freeze Frame data for the DTC.

 Scan tool Diagnostics
 Inspection/Repair
12. Using Current Data, list the Misfire Counters and

cylinder that indicated a misfire?
__________________________________________
__________________________________________
13. The Visual and Timing Inspections have been

performed and all values are within specifications.
14. Perform the Ignition System Inspection and record

the results below.
__________________________________________
__________________________________________
__________________________________________
15. List the repairs you would recommend.

__________________________________________

by the instructor.

STATION 2
The customer states the vehicle runs poorly and the

light on the dash is ON. Check and advise.
1. Connect the GDS to the vehicle

while viewing the current data and DTCs.
3. List DTCs indicated and their description:

__________________________________________
__________________________________________
__________________________________________


8. Review the Freeze Frame data.
9. Perform the Power Circuit Inspection and list your

results below:
__________________________________________

10. Is the reading normal?
YES NO
11. Check the Signal Circuit for a short to ground and

list your results below.
__________________________________________
YES NO
13. Check the Signal Circuit harness for an open and

record your results below.
__________________________________________
YES NO
15. Perform the Ground Circuit Inspection and list your

results below.
__________________________________________
16. What does the results of this test determine?
__________________________________________
17. Perform the Component Inspection Procedure and
print the pattern.
18. What differences did you notice between the TPS

and MAP waveforms?
__________________________________________
19. Based upon all of your diagnostic test results, what
repair do you recommend?
__________________________________________
by the instructor

STATION 3
RELATED DTC Year: 2012 Model: Forte Engine: 2.0L
The vehicle failed an emissions test. Diagnose based

upon the vehicle having DTC P0420 which may or may
not be present.
1. Using GDS, retrieve DTC information.

 System Inspection
3. Using the DTC Detecting Conditions, what is the

DTC Strategy checking, and what evaluates the
condition?
__________________________________________
__________________________________________
__________________________________________
4. List the three inspections performed after reading
the (DTC Status) parameter:
__________________________________________
__________________________________________
__________________________________________
5. List the components in question 4 that can be
monitored in Current Data?
__________________________________________
6. What type of test/inspection is required for each
component?
__________________________________________

STATION 3 – continued

9. Graph, print, and analyze the Current Data for the

Front and Rear HO2S.
10. Review the Front and Rear HO2S graph. List what
you determined:
__________________________________________
__________________________________________
11. What component would you recommend for
replacement?
__________________________________________
12. List how to verify that the fault has been corrected:
__________________________________________
__________________________________________
__________________________________________
by the instructor.

STATION 4
RELATED CONCERN Year: 2012 Model: Soul Engine: 2.0L
Customer states vehicle is hard to start and MIL is ON.

Check and advise.

7. Is the vehicle hard to start and is the MIL ON?
YES NO

__________________________________________
__________________________________________
 Scan tool Diagnostics
 W/Harness Inspection
Use the information to complete this section.
10. What type of CKPS is on this vehicle?

__________________________________________

11. How many wires does the CKPS have?

__________________________________________
8. Check the voltages in the signal circuit and list your
results below.
__________________________________________
__________________________________________
YES NO
10. Check for an open in the signal circuit harness and

list your results below.
__________________________________________
__________________________________________
YES NO
12. Complete the component inspection and list your

results below.
Resistance:
__________________________________________
Signal Waveform:
__________________________________________
13. Based on your test results, what would you do to
repair the vehicle?
__________________________________________
by the instructor.

STATION 5
DIAGNOSE VEHICLE WITH Using the vehicle identified as Station 3, diagnose the
FLASHING MIL following customer concern:
Year: 2012 Model: Sorrento Engine: 2.4L
The customer states the vehicle runs badly and the

light on the dash is flashing. Check and advise.
2. Review the Current Data and list any

information/data that may indicate a fault.
__________________________________________
__________________________________________
3. Use the Monitor DTC Status section for DTC P0302
to answer the following questions.
4. Which DTC needs to be diagnosed first?

__________________________________________
5. Why didn’t DTC P0420 set?
__________________________________________
6. Complete the diagnosis as recommended. What is
your recommended repair?
__________________________________________

7. How did you identify the problem?

__________________________________________
__________________________________________
Evaluation: When you have finished, have your
instructor evaluate your work and sign off on your
scorecard.
 Reconnect any connector(s) that you disconnected.
 Clear any DTC and exit GDS.
 Clean up the workstation.

Engine Management System Diagnosis II: EMSD2 Course Guide

Uploaded by

Copyright:

Available Formats

You might also like

Engine Management System Diagnosis II: EMSD2 Course Guide

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine Management System Diagnosis II: EMSD2 Course Guide

Uploaded by

Copyright:

Available Formats

Engine Management System Diagnosis II

EMSD2 Course Guide 1

EMSD2 Course Guide 2

Engine Management System Diagnosis II

COURSE GOALS This course increases a technician’s efficiency and

EXPECTATION You will be expected to use diagnostic processes,

EMSD2 Course Guide 3

PREREQUISITES The following web and ILCs must be completed prior to

TECHNICAL TRAINING Kia University has adopted a training delivery system

REVIEW The Review Module will review critical objectives from

THEORY A Theory Module presents information to increase

GUIDED PRACTICE The Guided Practice Module allows you the

PERFORMANCE The Performance Assessment Module provides you the

COURSE ACHIEVEMENT A final score of 80% or higher is needed for successful

EMSD2 Course Guide 4

PERFORMANCE SCORECARD The Performance Scorecard is used to track your

ANSWER SHEET Record your Performance Assessment answers on this

EMSD2 Course Guide 5

ASK QUESTIONS If you do not understand something in this course, ask

TEAMWORK During the hands-on activities, you will often be

LEARN AT EVERY This course is an opportunity for you to learn in a

The Activities Icon indicates an activity that

The Feedback Icon indicates a progress check meant

EMSD2 Course Guide 6

On-Board Diagnostic Review

MODULE GOAL Upon completion of this module, you will demonstrate,

MODULE OBJECTIVES Given this module, and information learned from

MODULE INSTRUCTIONS During this review, participate in the discussion to get

Questions are based upon the web and instructor-led

EXPECTATIONS It is expected that you passed the prerequisite web

TIME TO COMPLETE Approximately: 60 minutes

EMSD2 Course Guide 7

6. The engine operating condition data that OBDII

EMSD2 Course Guide 8

10. List three electrical malfunctions that OBDII

11. The OBDII 5-digit DTC can define conditions,

EMSD2 Course Guide 9

16. List three causes of (sensitive) component

EMSD2 Course Guide 10

23. Define Circuit Integrity:

24. Define Input Rationality:

25. Define Output Functionality:

26. An aftermarket service part may not fully meet OEM

28. With a DTC set, MIL illuminated and fault not

EMSD2 Course Guide 11

30. Using the Current Data above, if you have a

EMSD2 Course Guide 12

FEDERAL TEST PROCEDURE

The Federal Test Procedure (FTP) was designed as a

The vehicle being tested is run through four stages:

A Malfunction Indicator Lamp (MIL) must illuminate if a

EMSD2 Course Guide 13

EMSD2 Course Guide 14

INTRODUCTION The OBDII system stores a DTC when the emission

DIAGNOSTIC EXECUTIVE The diagnostic executive is a computer program in the

It also keeps track of:

Freeze frame data includes:

EMSD2 Course Guide 15