Kia 2004.5 Spectra Service Technical Training

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Course Guide

2004.5

Spectra

Technology

Service Technical Training

Student Guide

NMLD.01

Table of Contents

Summary of Contents for Kia 2004.5 Spectra

Page 1 Course Guide 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.01...
Page 2: Safety First
SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 3 TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidate, Senior level, and Senior level candidate service technicians. Courseguide...
Page 4 2004.5 Spectra Technology ABOUT TRAINING Today's complex automotive technology demands that you, the professional Kia service technician, stay up- MODULES to-date with the latest service information, special tools, and complex repair procedures. We have adopted a modular training delivery system that breaks down the critical information into logical groupings.
Page 5: Table Of Contents
Performance Assessment Module. In the Performance Assessment module, you must pass a written and hands-on evaluation. COURSE MATERIAL This 2004.5 Spectra New Model course is comprised of the following modules: Guided Performance Job Number Module Title Theory Practice Assessment NMLD.01...
Page 6 Learning in the controlled environment of an OPPORTUNITY authorized Kia Training Center/Facility with the guidance of a trained Kia instructor will maximize your course experience. If you make a mistake, turn it into a learning experience as it will strengthen your ability when you are back at your dealership.
Page 7 30 points 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 (DPSM).
Page 8 2004.5 Spectra Technology TIMELINE All times are approximate. 8:00-8:15 Introduction & Course Outline 8:15-8:35 Walkaround Theory 8:35-9:05 Walkaround Tasks 9:05-9:25 Powertrain Theory 9:25-9:55 Powertrain Tasks 9:55-10:10 Morning Break (15 minutes) 10:10-10:30 Driveability Theory 10:30-11:00 Driveability Task 11:00-11:15 Brakes Theory 11:15-11:45...
Page 9 2004.5 Spectra Technology NOTES Courseguide...
Page 10 2004.5 Spectra Technology NOTES Courseguide...
Page 11 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 12 TT-NMLD204-IL-CG01 Kia Motors America, Inc.
Page 13: Nmld.02
Walkaround 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.02 Theory...
Page 14 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 15 MODULE GOAL The goal of this module is to help you become familiar with key features, attributes, and functions on the 2004.5 Spectra that you can apply to Fix It Right First Time (FIRFT). MODULE OBJECTIVES After completing this module and using this module...
Page 16 Spectra (LD) 2004.5 - 2005 The 2004 Spectra has been carried over from the 2003 model year. The 2004.5 Spectra LD 4- door will be introduced as mid-year model change. The Spectra 5-door is scheduled to be released in May.
Page 17 Federal States include: All states except CA States. TBA = To Be Announced From this point forward, your instructor will walk you around the 2004.5 Spectra and point out different systems, components, and features found in the vehicle. During this time, fill in the boxes that...
Page 18 2004.5 Spectra Technology ENTRY AT DRIVER DOOR A. Key operation Turn 1x: unlock driver door/lock all doors Turn 2x: global unlock and lock B. RKE operation for 4-door Spectra 1. Lock button: press 1x 2. Unlock button: press 1x for driver door and 2x for all doors 3.
Page 19 2004.5 Spectra Technology DRIVER DOOR PANEL SWITCHES A. Power windows switches (auto down only for driver power window) B. Outside mirror remote control for: • Right mirror • Left mirror C. Speakers with door-mounted tweeter D. Door open/lock E. Window lock button...
Page 20 2004.5 Spectra Technology DRIVER SIDE SEAT A. Fuel filler lid release B. Driver adjustable seat C. Seat track position sensor (under driver seat) D. Vehicle ID plate • Date manufactured • Trim code E. Driver Seat Back Adjustment Walkaround...
Page 21 2004.5 Spectra Technology DRIVER SIDE DASH A. Hood release B. Dash fuse/relay box & ETACS C. Power Saver Bar D. PCM (Siemens) or ECM for M/T (under dash) E. 16-pin DLC connector F. Mechanical shift interlock with cable (brake pedal) G.
Page 22 2004.5 Spectra Technology STEERING & HEADLAMP SWITCH Walkaround...
Page 23 2004.5 Spectra Technology A. Steering wheel B. Tilt steering column C. Combination switch 1. Fog light ON/OFF switch 2. Headlight ON/OFF switch 3. Park light ON/OFF switch 4. High Beams D. Front Windshield Wipers controls 1. Mist, hold up until wipers move 2.
Page 24 2004.5 Spectra Technology CENTER CONSOLE, SHIFTER & A/C SYSTEM Walkaround...
Page 25 2004.5 Spectra Technology A. SRS Occupant Classification System (OCS) Tell Tale Lamp B. Hazard Warning Flasher C. Rear Window DEF and Side Mirror DEF D. Manual Climate Control System (Actuators are electronic - no cables) 1. Fan Speed Control Knob 2.
Page 26: Instrument Panel
2004.5 Spectra Technology INSTRUMENT PANEL A. Warning lamps 1. ABS/EBD lamp (if equipped) 2. SRS lamp 3. Brake warning lamp 4. Parking brake and brake fluid warning lamp 5. Battery lamp 6. Engine oil pressure warning lamp B. Indicators 1. Trunk open 2.
Page 27 2004.5 Spectra Technology AIRBAGS A. Driver - dual squib airbag B. Passenger - dual squib airbag C. Driver and front passenger seats side airbags D. Curtain airbags on each side E. Airbag system computer (SRSCM) located in center console with: •...
Page 28: Vehicle Exterior
2004.5 Spectra Technology VEHICLE EXTERIOR A. Tires 4-door: LS P195/60-R15 5-door: RS-A P205/50-R16 B. Cable operated Fuel Filler Lid, no trunk release C. Rod radio antenna D. Rear windows (opens half way) Walkaround...
Page 29 2004.5 Spectra Technology TRUNK A. Interior trunk release (on interior of trunk lid) B. Spare tire is temporary use tire C. Seat back release pull cable releases right and left rear seat to fold down flat into passenger compartment Walkaround...
Page 30 2004.5 Spectra Technology BACK SEAT A. Center seat belt is 3-point shoulder and lap belt B. 60/40 fold down seat C. Fuel tank access (under seat) D. Child Car Seat Anchor Points (arrows point to them but not shown) Walkaround...
Page 31 2004.5 Spectra Technology FRONT PASSENGER SEAT A. Occupant Classification System (OCS) Label B. Passenger seat adjustments (has only back tilt) C. Side air bag D. Seat position sensor (under seat) Walkaround...
Page 32 A. Oil pressure valve and oil temperature sensor B. Front O2 sensor is 5-wire (new for Kia) C. A/T similar to Optima or M/T new to Kia line-up D. Location of front impact sensor on SRS E. Fuse relay box F.
Page 33 2004.5 Spectra Technology UNDER HOOD GROUNDS A. Engine ground B. Harness-Chassis ground C. Harness-Chassis ground D. Harness-Chassis ground E. Battery ground Walkaround...
Page 34 2004.5 Spectra Technology UNDER VEHICLE - FRONT A. Lower arm assembly B. Sub-frame C. Stabilizer bar D. Front strut E. Drive shaft F. ABS sensor, if equipped G. Toe adjustment, tie rods Walkaround...
Page 35 2004.5 Spectra Technology UNDER VEHICLE - REAR SUSPENSION A. Rear disc brakes (standard on all vehicles) B. Trailing arm C. Rear suspension rear arm D. Rear suspension front arm E. Rear cross member F. Rear stabilizer bar G. Rear stabilizer link H.
Page 36 2004.5 Spectra Technology SUMMARY Now, you have been thoroughly introduced to the 2004.5 Spectra and its technical systems and components. Additionally, you have learned about features and attributes of the new Spectra. This will prepare you for the remainder of this course as we look into these systems and components in depth.
Page 37 2004.5 Spectra Technology PROGRESS CHECK 1. What features are new on the 2004.5 MY Spectra 4-door? A. 2.0 liter CVVT DOHC engine B. HVAC optional air filter C. Electronic Time Alarm Control System D. All of the above 2. Which of the following are key systems to be discussed later? A.
Page 38 2004.5 Spectra Technology N O T E S : Walkaround...
Page 39 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 40 TT-NMLD204-IL-TH02 Kia Motors America, Inc.
Page 41: Nmld.03
Walkaround 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.03 Guided Practice...
Page 42 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 43 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL In this module, the target audience will be given the opportunity to inspect and discover the new Spectra so that you will become more familiar with key features, attributes, and functions on the 2004.5 Spectra.
Page 44 This guided practice will give you the opportunity to put into practice the specific information you have learned in the Walkaround theory module. Under the supervision of a trained Kia service-training instructor you will perform a series of tasks to fulfill the objectives of this guided practice.
Page 45 2004.5 Spectra Technology EXTERIOR Log on to KSIS and look up the following: Total Possible Points: 2 Wheel nuts • Tightening torque (KSIS): _________ lb ft Wheel run out spec (KSIS) • Steel Wheel • Radial: ____________ • Axial: _____________ •...
Page 46 2004.5 Spectra Technology INTERIOR Inspect and provide answers for the following on the 2004.5 Spectra. Total Possible Points: 3 Connect the Hi-Scan Pro, turn on the tool, select LD and select to reprogram an RKE. Write down Hi-Scan Pro menu screens that follow and explain the process.
Page 47 2004.5 Spectra Technology UNDER HOOD Identify and locate items listed below and write the letter corresponding to each item in the box provided. Total Possible Points: 3 A. Mass Air Flow (MAF) Sensor B. Intake Air Temperature (IAT) Sensor C. Engine Coolant Temperature (ECT) Sensor D.
Page 48 2004.5 Spectra Technology TEST DRIVE This exercise gives you a chance to test drive or ride in the Spectra. Be sure to follow your instructor's assigned Total Possible Points: 2 road test route and obey traffic laws. Check with your instructor prior to leaving and upon returning.
Page 49 2004.5 Spectra Technology CVVT operations • Engine noise: _______________________________ • Using the HSP, note the advance and retard during: • Idle: ____________________________________ • Acceleration:______________________________ • Deceleration:_____________________________ • Cruise: __________________________________ Walkaround...
Page 50 2004.5 Spectra Technology REVIEW Use the following to make notes and locations. List key items for discussion in class: Item: Discussion: Walkaround...
Page 51 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 52 TT-NMLD204-IL-GP03 Kia Motors America, Inc.
Page 53: Nmld.04
Powertrain 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.04 Theory...
Page 54 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 55 The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL The goal of this module is to identify the 2004.5 Spectra Powertrain operation and interworking relationships of its new systems and components MODULE OBJECTIVES...
Page 56 CVVT: Continuously Variable Valve Timing EGR: Exhaust Gas Recirculation HC: Hydrocarbons HLA: Hydraulic Lash Adjustors HSP: Hi-Scan Pro KSIS: Kia Service Information System MLA: Manual Lash Adjustors mV: Milli-Volts NOx: Oxides of Nitrogen OCV: Oil Control Valve OTS: Oil Temperature Sensor...
Page 57 2004.5 Spectra Technology INTRODUCTION The new Kia Spectra is equipped with a Beta 2.0 liter 4 cylinder gasoline powered engine. Beta is a Kia engine family name. The horsepower, compression ratio, bore and stroke were increased from the previous Spectra 1.8L engine. The new cylinder head features a continuously variable valve timing (CVVT) system that improves performance and emissions.
Page 58 2004.5 Spectra Technology APPLICATION The following chart compares 2004 1.8L and 2004.5 2.0L Spectra engines and transaxles. SPECIAL SERVICE The following new SST’s have been released for TOOLS (SST) this module: • Valve adjustment tools • Clutch alignment tool (M/T) •...
Page 59: System Operation
2004.5 Spectra Technology SYSTEM OPERATION The 2004.5 Spectra has a Beta 2.0-liter Continuously Variable Valve Timing (CVVT) gasoline engine. The new engine has larger displacement, more horsepower, solid lifers, and constant variable valve timing compared to the previous Spectra. The Beta engine is considerably larger than the 1.8L engine...
Page 60 2004.5 Spectra Technology The information in this chart shows different 2004 Kia vehicles that use 4 cylinder engines. The PCM advances and retards the intake camshaft CVVT SYSTEM timing through the CVVT system depending on engine RPM and load. Advantages to the CVVT system include: •...
Page 61 2004.5 Spectra Technology • Reduced emission • Reduce NOx through an EGR effect due to optimization of valve overlap • Small overlap (Retard) causes increased burning time resulting in reduced HC emission • Large overlap (Advance) causes an EGR effect by lowering NOx •...
Page 62 2004.5 Spectra Technology Manual Transaxle (M/T) is standard equipment on the MANUAL TRANSAXLE 2004.5 Spectra. This is a new 5 speed with OD to the Kia M/T family. The manual transaxle identification (ID) plate location is shown above. To interpret the manual transaxle ID...
Page 63 2004.5 Spectra Technology The 2004.5 Spectra offers an optional F4A42 AUTOMATIC TRANSAXLE automatic transaxle, which is currently used on the CVVT ENGINE Optima 4 and 6 cylinder vehicles. The new Spectra transaxle differs from the Optima by: • Not having Sport shift •...
Page 64 2004.5 Spectra Technology The automatic transaxle (A/T) identification number location is shown above. To interpret the A/T ID characters, use the following: 1: M = F4A42-1 model 2: 4 or 5 = 2004 or 2005 production year 3: M = 3.770 gear ratio...
Page 65 2004.5 Spectra Technology POWERTRAIN COMPONENT OPERATION This section will cover Powertrain components and their operations, which are not commonly found on Kia vehicles with 4 cylinder engines. CONTINUOUSLY VARIABLE VALVE TIMING (CVVT) SYSTEM The CVVT system adds several components to the cylinder head assembly including the: •...
Page 66 2004.5 Spectra Technology • CVVT assembly on exhaust camshaft N N o o t t e e : : T T h h e e e e x x h h a a u u s s t t c c a a m m s s h h a a f f t t i i s s t t i i m m i i n n g g b b e e l l t t d d r r i i v v e e n n b b y y t t h h e e c c r r a a n n k k s s h h a a f f t t t t h h r r o o u u g g h h t t h h e e c c a a m m s s h h a a f f t t p p u u l l l l e e y y l l o o c c a a t t e e d d i i n n t t h h e e f f r r o o n n t t .
Page 67 SYSTEM COMPARISON This chart compares camshaft timing of the 2.0L Beta engine without CVVT (not available on Kia vehicles sold in the U.S.) and with CVVT. At 12 o’clock on the diagram is TDC, while 6 o’clock is BDC of the piston.
Page 68 2004.5 Spectra Technology Looking at the intake valve timing on the non-CVVT engine (top), at 12 o’clock (top), it starts to open 9 degrees before the piston reaches TDC and is closed 43 degrees after TDC. The CVVT engine varies intake valve timing with the...
Page 69 2004.5 Spectra Technology When the engine is off, the oil is drained from the advance chamber returning the housing to the retarded position and will become fixed in full retard position by the locking pin. N N o o t t e e : : F F a a i i l l s s a a f f e e i i s s a a t t f f u u l l l l r r e e t t a a r r d d w w i i t t h h t t h h e e l l o o c c k k p p i i n n e e n n g g a a g g e e d d .
Page 70 2004.5 Spectra Technology The CVVT assembly can be tested with 14 PSI of air. The CVVT should be in the retarded position with the lock pin in place. Plug the OCV passage line holes on the camshaft, except the hole closest to the CVVT assembly.
Page 71 2004.5 Spectra Technology each camshaft. Next a chain auto-tensioner is installed between the 2 camshafts to keep chain tension. The auto tension must be compressed with locking pin prior to installation on cylinder head. OIL CONTROL VALVE (OCV) The Oil-flow Control Valve (OCV) is a 12V electromagnetic coil operated spool valve mounted on the cylinder head.
Page 72 2004.5 Spectra Technology The waveforms show an engine at two speeds with the following OCV readings: N N o o t t e e : : T T h h e e p p a a t t t t e e r r n n o o n n t t h h e e r r i i g g h h t t s s h h o o w w s s t t h h e e 0 0 V V t t r r i i g g g g e e r r p p o o i i n n t t l l o o w w e e r r e e d d b b y y 1 1 g g r r a a d d .
Page 73 2004.5 Spectra Technology Oil enters the OCV filter from the cylinder block into the cylinder head passage. The oil then enters the OCV in the middle spool. Depending upon where the PCM has commanded the OCV spool valve position, by duty cycle, motor oil will flow to the exhaust camshaft and into the CVVT assembly.
Page 74 2004.5 Spectra Technology The OCV is a non-service item and is replaced when defective. When the CVVT sticks, the camshafts real position and target position as determined by the PCM is not matched. If it’s stuck in the advanced position, engine vibration and stoppage can occur at idle.
Page 75 2004.5 Spectra Technology Density of the engine oil changes according to its temperature. Only certain weights of engine oil can be used in a CVVT engine. By using high viscosity oil, the CVVT may not operate in cold conditions. It’s important that only the recommended oil weight (SAE) be used in the CVVT engine.
Page 76 2004.5 Spectra Technology OIL CONTROL VALVE FILTER OCV Filter is a screen style located on the side of the cylinder block. It’s the primary oil filter for the OCV. If the filter plugs up, the CVVT system will not operate.
Page 77 2004.5 Spectra Technology OCV WAVEFORM Looking at the waveform on the left, the CKP and CMP waveforms on the HSP can inspect the CVVT operation. Let's review basic engine operation. The waveform of 2-on/off square waves represents the CMP while the waveform of multiple and close together on/off signals represent the CKP.
Page 78 2004.5 Spectra Technology The waveform on the right shows the CKP waveform even narrower, which indicates higher RPM. The engine is running at +2000 RPM, full load condition and the CVVT system is maximum advanced. There are approximately 6.5 CKP waveforms from the CAM waveform on the left.
Page 79 2004.5 Spectra Technology CVVT TROUBLE SHOOTING PROCEDURE Start the engine and let idle. Test the items shown in the table at idle condition. This Checks: CONDITION TEST REMARKS 1. This checks CVVT position at maximum retard. 2. Check engine vibration and engine stall at idle.
Page 80: Valve Lash
2004.5 Spectra Technology VALVE LASH The 2.0L Beta CVVT engine uses a manual lash adjusting (MLA) valve train. The valves are adjusted by changing the size of the shim at the recommend service interval. Vehicle fuel consumption is reduced by using MLA due to reduction of friction: a.
Page 81 2004.5 Spectra Technology Inspect the valve clearance with the crankshaft at TDC VALVE INSPECTION and camshaft-timing pulley is aligned with the timing mark on the bearing cap, similar to timing when replacing the timing belt. In this position inspect the following valves #1 cylinder intake and exhaust, #2 intake and # 3 exhaust.
Page 82 2004.5 Spectra Technology Using the SST, press down on the valve lifter with the plier and place the stopper between the camshaft and valve lifter. Then remove the SST. Remove the adjusting shim with small screwdriver and magnet. Plier Stopper Measure the thickness of the removed shim using a micrometer.
Page 83: Intake Manifold
2004.5 Spectra Technology INTAKE MANIFOLD Intake manifold on the 2.0L Beta engine has a resonator for improved torque at middle and high speeds. Oil from the PCV can collect in the resonator. Oil collected in the resonator drains to the crankcase through the oil drain hose.
Page 84 2004.5 Spectra Technology The timing belt is serviceable: TIMING BELT The Beta 2.0L engine is interference type. Properly installed and timed timing belts are critical to long engine life. Timing belt tension is manually adjusted. There is no automatic tensioning to take up slack as the belt wears.
Page 85 2004.5 Spectra Technology TIMING BELT TIMING Crankshaft and Camshaft timing 1. Align the timing marks of the camshaft sprocket A and crankshaft sprocket B with the #1 piston placed at TDC compression stroke. N N o o t t e e : : S S e e t t c c r r a a n n k k s s h h a a f f t t a a f f e e w w t t e e e e t t h h o o f f f f T T D D C C p p r r i i o o r r t t o o r r o o t t a a t t i i n n g g c c a a m m s s h h a a f f t t s s o o p p i i s s t t o o n n s s d d o o n n o o t t h h i i t t t t h h e e v v a a l l v v e e s s .
Page 86 2004.5 Spectra Technology 3. Rotate crankshaft in regular clockwise rotation until the camshaft sprockets has moved 2 teeth or 18°. Rotate tensioner using 8mm allen wrench to give tension to the timing belt until tension side can be pushed by hand with approximately 5 lb pressure and belt flexes 1/8 to 1/4 inches (4 to 7mm).
Page 87: Automatic Transaxle
2004.5 Spectra Technology AUTOMATIC TRANSAXLE The automatic transaxle has: (1) the vehicle speed sensor or VSS, (2) output shaft speed sensor, (3) input shaft speed sensor, (4) solenoid valve connector and (5) transaxle range switch. The A/T uses 3 clutch sets (underdrive, reverse and overdrive clutch), and 2 sets of brakes (low/reverse and second brake).
Page 88 2004.5 Spectra Technology The inputs to the A/T side of the PCM include the driver shifter/range switch, input and output speed sensor, A/T oil temperature, and A/T control relay for shift solenoids A to D. Output controls include the ground side of shift solenoid A, B, C, and D and the TCC solenoid.
Page 89 2004.5 Spectra Technology The inhibitor switch provides the driver selection to the PCM and IP, including back up lamps. It is powered from the IG1 circuit. Powertrain...
Page 90 2004.5 Spectra Technology The PCM turns ON the ATM relay when engine is running to provide B+ power to the 5 solenoids. These solenoids are controlled by the PCM on their groundside. The solenoids can be activated by the HSP and resistance checks can be performed on the coils.
Page 91 2004.5 Spectra Technology when the ignition key is turned OFF. A total of 8 diagnosis codes and 3 fail-safe codes can be memorized in RAM. Powertrain...
Page 92 2004.5 Spectra Technology Hydraulic pressure test can be performed at each of the ports. Connect the AT pressure gauges to the ports shown in the photos. ATF must be at operating temperature. Hydraulic Pressure Test with ATF at >176° F and engine RPM at 2,500.
Page 93 2004.5 Spectra Technology SUMMARY The 2004.5 Spectra is equipped with a 2.0-liter Beta engine, which has a Continuous Variable Valve Timing (CVVT) system to improve engine performance and emissions. The CVVT retards or advances intake camshaft timing based on engine RPM and load.
Page 94 2004.5 Spectra Technology PROGRESS CHECK 1. Technician A states that the Spectra 2.0L CVVT engine uses an oil temperature sensor to measure oil density for proper valve timing during cold weather operation. Technician B states that heavier weight oil is used in the CVVT engine to assure variable valve timing is accomplished.
Page 95 2004.5 Spectra Technology 4. Technician A states the CVVT engine has Hydraulic lash adjusters that require adjustment. Technician B states that the CVVT engine uses Mechanical lash adjustors that do not require adjustment other than during reassembly. Who is correct? A.
Page 96 2004.5 Spectra Technology N O T E S : Powertrain...
Page 97 2004.5 Spectra Technology N O T E S : Powertrain...
Page 98 2004.5 Spectra Technology N O T E S : Powertrain...
Page 99 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 100 TT-NMLD204-IL-TH04 Kia Motors America, Inc.
Page 101: Nmld.05
Powertrain 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.05 Guided Practice...
Page 102 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 103 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL In this module, you will be given the opportunity to perform engine-related service and diagnostic procedures.
Page 104 This guided practice will give you the opportunity to put into practice the information you have learned in the Powertrain theory module. Under the supervision of a trained Kia service training instructor you will perform a series of tasks to fulfill the objectives of this guided practice.
Page 105 2004.5 Spectra Technology TIMING BELT SERVICE Enter KSIS using your sign on, and use KSIS or your AND CAMSHAFT TIMING student guide as resource material to: Total Possible Points: 3 CAM SHAFT TIMING • List Key steps to install and time CVVT intake and...
Page 106 2004.5 Spectra Technology TIMING BELT SERVICE • When installing a timing belt, list position of: • Camshaft Pulley: _____________________________ • Crankshaft pulley: ___________________________ • List order (pulley sequence) in which the belt is installed. __________________________________________ __________________________________________ __________________________________________ __________________________________________ __________________________________________ • List the procedures to adjust the timing belt and...
Page 107 2004.5 Spectra Technology TESTING OCV AND Check the Resistance of the Oil Control Valve (OCV) CVVT SYSTEM 1. Disconnect OCV connector Total Possible Points: 4 2. Measure resistance of OCV a. Results: ____________________________ b. Specification: 6.9-7.9 Ohms @ 68° F...
Page 108 2004.5 Spectra Technology CVVT TROUBLESHOOTING 1. Start the engine, idle speed PROCEDURE Record the operating condition of the engine at idle: ___________________________________________ 2. Perform the tests procedures shown in the chart below at idle speed Record the operating condition of the engine with the...
Page 109 2004.5 Spectra Technology ADJUSTING AND Below are the valve lash specifications. Measure Valve Clearance on CVVT engine: MEASURING VALVE CLEARANCE PROCEDURES ECT: 68° F Total Possible Points: 5 Specification: Intake: 0.0079” Exhaust: 0.0110” Limit: Intake: 0.0067-0.0091” Exhaust: 0.0098-0.0122” 1. Using the adjusting shim selection chart (Exhaust),...
Page 110 2004.5 Spectra Technology Powertrain...
Page 111 2004.5 Spectra Technology ENGINE GROUND TESTING Locate the primary engine ground cable and record its position: Total Possible Points: 3 _____________________________________________ Using a DVOM measure the voltage drop across it with the engine OFF and Key ON. Record the results:...
Page 112 2004.5 Spectra Technology N O T E S : Powertrain...
Page 113 2004.5 Spectra Technology N O T E S : Powertrain...
Page 114 2004.5 Spectra Technology N O T E S : Powertrain...
Page 115 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 116 TT-NMLD204-IL-GP05 Kia Motors America, Inc.
Page 117: Nmld.06
Driveability 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.06 Theory...
Page 118 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 119 The target audience for this module will be Kia Master level, Master level candidate, Senior level, and Senior level candidate service technicians. The goal of this module is to explain 2004.5 Spectra MODULE GOAL engine management system certified to US and...
Page 120 2004.5 Spectra Technology This module will take approximately 20 minutes. TIME TO COMPLETE AFR: Air-Fuel Ratio ACRONYMS BOB: Break-Out-Box CPSI: Cells Per Square Inch ECM: Engine Control Module HO2S: Heated Oxygen Sensor PCM: Powertrain Control Module SST: Special Service Tools...
Page 121 The 2004.5 Spectra is equipped with a modern Siemens Powertrain Control Module (PCM) for driveability management and emission control when equipped with A/T.
Page 122 2004.5 Spectra Technology The Spectra fuel system is designed for the driver to use only unleaded fuel with a minimum Octane Rating of 87 Anti-Knock Index (AKI). The Spectra engine and emission system can accept fuel with maximum of 10% ethanol (grain alcohol) and no methanol (wood alcohol).
Page 123 2004.5 Spectra Technology APPLICATION The Kia Spectra uses a Siemens engine and automatic transmission management system. The following chart compares several driveability items between the 2003- 2004 Spectra and 2004.5 Spectra. SPECIAL SERVICE TOOLS The following new SSTs have been released for this vehicle: (SST) •...
Page 124 2004.5 Spectra Technology SYSTEM OPERATION Inputs (Sensor): PCM: Output: Oxygen Sensors B1S1 Ignition B1S2 Fuel Injectors MAF/IAT Idle Speed Actuator Main relay control Engine Fuel Pump Control Control Cooling fan Control Knock Canister Purge Control Tank Pressure Sensor Canister Close Valve...
Page 125 The OBD II software controls all the monitors and interactions, DTC and MIL operation, freeze frame data, and Hi-Scan Tool (HSP) interface. California emission certified 2004.5 Spectra vehicles meet the SULEV emission standard due to significant changes made to exhaust emission and adoption of CVVT and a zero evaporative emission system instead of a conventional evaporative system.
Page 126 2004.5 Spectra Technology COMPONENT OPERATION Component: Function: Fuel Injector Changed to 12 multi-hole injector (SULEV) Secondary Auxiliary Added a secondary Canister charcoal canister to decrease bleed emissions Liquid-Vapor Fuel Changed the location to be built-in the fuel tank with vent valve to...
Page 127: Fuel Injector
2004.5 Spectra Technology FUEL INJECTOR The Federal emission certified engine uses the Bosch EV6 6-hole fuel injector. The CA SULEV emission certified engine uses a new Denso 12-hole fuel injector. The Denso 12-hole injector allows for a more controlled and finer spray pattern. The injectors are high resistance type measuring 14 ohms at 70°F degrees.
Page 128: Fuel Pump
FUEL PUMP Instead of the typical 8 or 9 screw fasteners to secure the fuel pump assembly into the tank, the 2004.5 Kia Spectra uses a lock ring. The following procedures are used to remove the fuel pump module, which includes the fuel filter: 1.
Page 129 2004.5 Spectra Technology 3. Turn pump module “C” counter-clockwise until it stops (5o) and take out of the tank. 4. Remove O-ring “D” and inspect. Installation is the reverse of removal: 1. Insert new O-ring into groove in fuel tank.
Page 130 These have all been moved to inside the tank to decrease hydrocarbon vapor leak. A new style fuel cap for Kia will be used. This is the return fuel cap, designed to prevent cross threading when installing the cap after refueling. Insert fuel cap into the fuel filler neck and turn 1/4 turn clockwise, then turn until clicks are heard.
Page 131 2004.5 Spectra Technology EVAPORATIVE TESTING The 2004.5 Spectra fuel and evaporative system is designed with the following components: 1. Non-threaded fuel cap 7., 8., 9. & 11. 3 ply evap-hose 2. Fuel filler pipe 10. Canister 3. Check valve (CCV) 12.
Page 132 2004.5 Spectra Technology MASS AIR FLOW (MAF) AND INTAKE AIR TEMPERATURE (IAT) SENSORS The Mass Air Flow (MAF) sensor is a hot film style sensor. MAF sensors provide more accurate mass airflow information to the ECM for precise engine control. It is located between the air filter box and throttle valve.
Page 133 2004.5 Spectra Technology The MAP or air fuel sensor (AFS) feedback signal is based upon the air flowing across the hot wire. The MAF recieves system voltage supplied by the main relay through the 10A “SNSR” fuse to MAF pin 2. Pin 4 is ground for MAF and IAT.
Page 134 2004.5 Spectra Technology SPARK PLUGS The SULEV engines use Iridium tip spark plugs. These plugs have more stable ignition during cold starts with a leaner air/fuel mixture, and longer durability. Federal emission vehicles (ULEV) use Platinum Plugs. The very thin 1.1mm diameter center electrode tip on the iridium plug is a hard and strong alloy of Iridium and rhodium for increased oxidation wear resistance.
Page 135 2004.5 Spectra Technology VOLTAGE REQUIREMENT This chart represents the voltage required by both normal and Iridium power spark plugs to perform 4 engine-operating conditions. In all four cases the Iridium required less voltage. Using Iridium on the surface area of the center electrode causes it to be reduced.
Page 136 ECM for air-fuel ratio control. Bank 2 or rear sensor is used to check catalytic converter efficiency. Kia vehicles in current production use conventional narrow range Zirconium (Zirconia) Dioxide HO2S that generate a 0 to 1V signal in response to the oxygen level measured in the exhaust stream.
Page 137 2004.5 Spectra Technology NARROW RANGE HO2S The 2004.5 Spectra only uses this type (Zirconia) of HO2S for its sensor 2, or rear sensor. It’s mounted after the catalytic converter in the rear exhaust pipe. Sensor 2 provides feedback to the PCM estimating the converter’s oxygen storage capability and monitoring...
Page 138 • The voltage signal can be measured and graphed on Hi-Scan Pro. WIDE RANGE HO2S The Sensor 1, front HO2S, used on the 2004.5 Spectra 2.0L engine is a linear oxygen sensor mounted on the front side (upstream) of the catalytic converter in the exhaust manifold.
Page 139 2004.5 Spectra Technology Typical H02S Let's compare the operation of the two HO2S. The key element of the down stream Zirconia oxygen sensor is a ceramic body that is coated on both sides, creating a Nernst Cell. This coating takes over the...
Page 140 2004.5 Spectra Technology This process is carried out by a miniature pump (pump cell), which supplies the electrodes on the exhaust side with enough oxygen to ensure that the voltage between the electrodes remains a constant 450mV. The PCM interprets the current consumption of the pump cell to determine the air-fuel ratio value.
Page 141 The electronics in the unit converts the “Ip” into a “Vout” which is the output of the unit to the PCM. The heater unit is similar to other HO2S used in Kia HO2S HEATER vehicle with the exception of a faster light off for quicker response time.
Page 142 2004.5 Spectra Technology To review Linear HO2S: • Indicate HOW rich or lean the AFM is • This how rich or lean ability is important to more closely control the AFR in order to reduce exhaust emissions or when the engine is operated in a lean condition •...
Page 143 2004.5 Spectra Technology HO2S STEADY STATE CRUISING SIGNAL This is a typical Linear O2 signal recording during a Steady Cruising State using Hi-Scan Pro flight recording. HO2S FUEL-CUT DURING DECELERATION This is a typical linear O2 signal recording of Fuel-Cut...
Page 144 2004.5 Spectra Technology HO2S STRONG ACCELERATION This is a typical linear O2 signal recording during a Strong Acceleration, using Hi-Scan Pro flight recording HO2S GENTLE ACCELERATION This is a typical linear O2 signal recording during Gentle Acceleration from stop to 16 MPH, using Hi- Scan Pro flight recording.
Page 145: Catalytic Converter
Its design is flat in appearance. The SULEV emission vehicle for CA specification states uses a 900 CPSI catalytic converter that is new to Kia vehicles. It’s located in the same place, but its appearance is different being round instead of flat.
Page 146 2004.5 Spectra Technology SULEV CATALYTIC CONVERTER This type of CAT has complex internal structures with 800 to 1000 cpsi substrates and wall thickness down to 0.025 mm. This progress in ceramic and metal substrate technology has major benefits. A larger...
Page 147 2004.5 Spectra Technology OBDII SYSTEM The OBDII system readiness tests are used by many READINESS TEST states in their smog check or inspection/maintenance (I/M) program. If the drive cycle has not been previously completed, showing that the OBDII system is ready to monitor for faults, the vehicle cannot be I/M tested.
Page 148 2004.5 Spectra Technology SUMMARY The 2004.5 Spectra is equipped with an Engine Management System (EMS) to monitor and manage the engine and transaxle and the On-Board Diagnostic II System (OBDII) and a variety of emission control systems and components. California emission certified Spectra vehicles meet the SULEV emission standard.
Page 149 C. Two Charcoal Canisters are used D. New Double Palladium spark plugs are used 2. Technician A states that the 2004.5 Spectra uses a new wide range oxygen sensor that shows high voltage lean and low voltage rich just opposite typical Zr02 sensors.
Page 150 2004.5 Spectra Technology 5. Select the correct type of spark plugs used on the 2004.5 Spectra. A. Double palladium B. Iridium with grooved side electrode C. NGK Copper with platinum center core D. Champion extended heat range 6. Select the best reason Spectra with SULEV certification uses a new style three-way catalytic converter.
Page 151 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 152 TT-NMLD204-IL-TH06 Kia Motors America, Inc.
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Driveability 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.07 Guided Practice...
Page 154 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 155 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL In this module, you will be given the opportunity to perform specific diagnostic procedures on the Spectra engine management system.
Page 156 This guided practice will give you the opportunity to put into practice the information you have learned in the Driveability theory module. Under the supervision of a trained Kia service-training instructor you will perform a series of tasks to fulfill the objectives of this guided practice.
Page 157 2004.5 Spectra Technology KSIS SPECIFICATIONS You will need KSIS to complete this task. If computers AND DTC INFORMATION are in use, proceed to the next task and complete this one later. Total Possible Points: 4 Using KSIS, sign/log on and look up the following...
Page 158 2004.5 Spectra Technology LINEAR HO2S INSPECTION Total Possible Points: 3 1. Disconnect the Bank 1 Sensor 1 HO2S 2. Measure the voltage to the heater, list results below a. Don’t probe with test lead, use narrow test pin b. Key ON c.
Page 159 2004.5 Spectra Technology Driveability...
Page 160 2004.5 Spectra Technology OBDII SYSTEM Using a Hi-Scan Pro, clear the OBDII Readiness flags. READINESS TESTS Then perform the following four-drive cycle test using a lift: (1) Idle Test mode (comprehensive component), Total Possible Points: 8 (2) Short Driving Test mode, (3) Long Driving Test mode, and (4) Evap.
Page 161 2004.5 Spectra Technology IDLE TEST 1. Safely rack the Spectra, have instructor inspect. 2. Connect a HSP to the 16-pin DLC 3. List the ECT reading: _________________________ a. Is the engine coolant cold? __________________ 4. Idle Test mode for Comprehensive component: Hi- Scan Pro select the DTC function.
Page 162 2004.5 Spectra Technology SHORT DRIVING TEST Driveability...
Page 163 2004.5 Spectra Technology 1. With a Spectra safely on the lift, shift gears to drive with the engine running. Be sure you have the instructor’s approval. Remember to advise others that you are about to run the vehicle. 2. List what a warm up cycle is: __________________ 3.
Page 164 2004.5 Spectra Technology LONG DRIVING TEST 1. Long Driving Test mode. Refer to drive cycle map for alpha letters (A-C) labels. 2. Connect Hi-Scan Pro to 16-pin DLC and select DTC functions. 3. Start engine and let idle for 35 seconds (A) 4.
Page 165 2004.5 Spectra Technology HSP EVAP LEAKAGE TEST 1. Hi-Scan Pro Evaporative Leakage Test. Connect Hi- Scan Pro to 16-pin DLC and select Evap Leakage Test. 2. Start and warm up engine. 3. Idle in P/N with no loads. 4. Conduct Leakage test using the Hi-Scan Pro.
Page 166 2004.5 Spectra Technology N O T E S : Driveability...
Page 167 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 168 TT-NMLD204-IL-GP07 Kia Motors America, Inc.
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Brakes 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.08 Theory...
Page 170 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 171 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL The goal of this module is to identify and explain the operation and diagnosis of the 2004.5 Spectra...
Page 172 2004.5 Spectra Technology TIME TO COMPLETE This module will take approximately 15 minutes. ACRONYMS ABS: Antilock Brake System ABSCM: Antilock Brake System Control Module CAN: Controller Area Network CBS: Conventional Brake System EBD: Electronic Brake-Force Distribution HECU: Hydraulic and Electronic control Unit...
Page 173 2004.5 Spectra Technology INTRODUCTION The 2004.5 Spectra comes standard with a 4-wheel disc Conventional Brake System (CBS) with optional Antilock Brake System (ABS) and Electronic Brake-Force Distribution (EBD). Brakes are designed to reduce the motion of the vehicle when the driver applies the brake pedal. This...
Page 174 Following is a list of brake related instrument panel lights that the driver should be observing for the ABS/EBD system installed in the 2004.5 Spectra. 1. The brake and ABS indicators are all brake related warning lights on fully equipped Spectra. The...
Page 175 2004.5 Spectra Technology 3. The Anti-Lock Brake light will illuminate for 3 seconds when the ignition key is turned ON. The light should turn off after 3 seconds as part of the system self-diagnosis procedure to indicate that the ABS is operating normally. The ABS will not operate if the ABS light stays ON.
Page 176 Amanti MK25 Chart indicates options available on 2004 Kia vehicles. ABS and EBD are options on most Kia vehicles, and standard on Amanti. TCS and ESP are available as an option only on the 2004 Amanti. The MGH20 ABS/EBD is an option on the 2004.5 Spectra.
Page 177 • Front and rear disc assemblies with pads (D/E) • Proportioning Valve (B) • Parking Brake lever (F) The 2004.5 Kia Spectra Conventional Brake System (CBS) is a hydraulic 4-wheel disc brake system with ventilated brake discs on the front axle and solid brake discs on the rear axle.
Page 178 2004.5 Spectra Technology The proportioning valves are a mechanical device mounted under the master cylinder in the diagonal brake system only on the CBS (non-ABS). During braking, these valves regulate pressure to the rear brakes to create balanced braking between the front and rear wheels.
Page 179 2004.5 Spectra Technology The ABS adds the following to the Conventional Brake System: • A Mando MGH-20 integrated hydraulic and electronic control unit (HECU) located in the right front engine compartment • A passive wheel speed sensor (WSS) at each wheel •...
Page 180 2004.5 Spectra Technology The diagram shows the hydraulic circuit of the HECU. Because Spectra's ABS is a 4-channel system, there is one inlet and dump valve for each wheel caliper. The inlet or isolation solenoid valve is a NO (normally...
Page 181 2004.5 Spectra Technology ELECTRONIC BRAKE-FORCE DISTRIBUTION (EBD) The Electronic Brake-Force Distribution (EBD) system is a sub-system of the ABS. EBD is designed to control rear wheel traction and is included when the ABS option is added to the Spectra. EBD software uses the ABS to control rear wheel slip in the partial braking range.
Page 182 2004.5 Spectra Technology The slip of each rear wheel is calculated to determine EBD OPERATION ABSCM control of the rear wheel brake pressure. During normal braking with no rear wheel slippage, pressure from the master cylinder is passed directly through the valves.
Page 183 2004.5 Spectra Technology COMPONENT OPERATION Brake calipers DISK BRAKES Brake disc Indicator Brake pads Pad retainers Brake pad shims The front disc brakes have floating type calipers with ventilated rotors. The brake pads have wear indicators and can be visually inspected with out removal of the caliper.
Page 184: Parking Brake
2004.5 Spectra Technology PARKING BRAKE The parking brake is V-type cable that mechanically actuates the rear wheel pads against the rotors. Typical parking brake set is 8 clicks of the parking brake pawl and is adjusted at A. The same brake pads are used as the rear brakes, not a shoe in the hat type of design.
Page 185: Master Cylinder
2004.5 Spectra Technology BRAKE WARNING LAMPS The brake fluid level sensor in the brake fluid reservoir is a normally open (NO) switch that is closed when emerged in fluid. Signal is sent to the ETACS, which illuminates the brake lamp when fluid exposes the switch (low fluid).
Page 186 HECU. The system houses an inlet valve and outlet valve for each wheel. The pump and valve assembly are similar to other Kia models' ABS/EBD systems. The HECU has a min/max operating range of 9.7 to 18 volts with a normal operating range of 12-14 volt range through the two 30A fuses.
Page 187 2004.5 Spectra Technology The HECU is energized when the ignition key is turned HYDRAULIC AND ON. After completing the initialization phase, the ELECTRONIC CONTROL HECU is ready for operation. In normal operating UNIT (HECU) condition, the HECU is ready (within specified limits, COMPONENT OPERATION i.e.
Page 188 2004.5 Spectra Technology ABS/EBD Diagnostic 1. If the CPU cannot be activated or the CPU fails, the Trouble Codes (DTCS) ABS indicator light comes on, but the DTC is not memorized. 2. When the same DTC is detected more than once, the later one is written over the old one.
Page 189 2004.5 Spectra Technology WSS FAILSAFE Sensor Failure Outside the 1. Only one wheel failure ABS Control Cycle • Only the ABS is inhibited • The ABS warning lamp is activated and the EBD warning lamp is not activated. 2. More than two wheels failure •...
Page 190 2004.5 Spectra Technology WSS DTC Detecting Conditions DTC failure conditions detected by the WSS include: • When the wheel velocity is less than 5 MPH due to an open or short in the wire • Faulty wheel speed sensor • Faulty HECU.
Page 191 2004.5 Spectra Technology 2. Check waveform signal on Hi-Scan Pro. 3. Check the exciter teeth for foreign objects or damaged teeth. Brakes...
Page 192 2004.5 Spectra Technology BRAKE LAMP SWITCH The brake lamp switch is an adjustable normally closed (NC) switch located on the brake pedal assembly. With the brake pedal at its normal resting position (brakes OFF) the switch is pushed to an open position.
Page 193: Troubleshooting
2004.5 Spectra Technology SYSTEM DIAGNOSTICS & The following are normal ABS operations and checks. TROUBLESHOOTING Phenomenon Explanation System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment. This is because the system operation check is being performed.
Page 194: Brake System Bleeding
2004.5 Spectra Technology BRAKE SYSTEM BLEEDING The KSIS procedure should be followed to ensure adequate bleeding of air and filling of the CBS and ABS. Brake fluid bleeding for the Spectra diagonally split system is conducted in the following order: •...
Page 195 SUMMARY In this module, you have learned about the Conventional Brake System (CBS) that comes standard with the 2004.5 Spectra, which has front and rear disc brakes. Antilock Brake System (ABS) with Electronic Brake-Force Distribution (EBD) are optional. The Spectra ABS with EBD (if equipped)
Page 196 A. A only B. B only C. Both a and B D. Neither A or B 2. The 2004.5 Spectra uses Active wheel speed sensors. A. True B. False? 3. Technician A states that four wheel disc brake systems come only with the ABS option. Technician B states that all 2004.5 Spectra comes with four...
Page 197 2004.5 Spectra Technology 4. Technician A states the proportioning valve in a Spectra has malfunctioned and he must replace the HECU. Technician B states the proportioning valve may be replaced as a separate part. Who is correct? A. A only B.
Page 198 2004.5 Spectra Technology N O T E S : Brakes...
Page 199 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 200 TT-NMLD204-IL-TH08 Kia Motors America, Inc.
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Brakes 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.09 Guided Practice...
Page 202 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 203 In order to complete this module, you will need the following items: • 2004.5 Spectra (LD) (Task 1) • 2004.5 Spectra (LD) with ABS (Task 1 and 2) • #2 pencil or preferred writing instrument • Hi-Scan Pro (HSP) • DVOM and T-Connector •...
Page 204 2004.5 Spectra Technology WHEEL SPEED SENSOR DIAGNOSTICS Total Possible Points: 3 1. Sign on to KSIS, search and list the resistance specification for the WSS. List in chart below. 2. Go to a Spectra to measure WSS output voltage and...
Page 205 2004.5 Spectra Technology BRAKE BLEEDING On Spectra with ABS, perform the following part of activating the ABSCM during a brake bleed. Total Possible Points: 2 1. Plug in Hi-Scan Pro to 16-pin DLC 2. Using a Hi-Scan Pro, select the brake bleeding procedure to ensure adequate bleeding of air.
Page 206 2004.5 Spectra Technology N O T E S : Brakes...
Page 207 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 208 TT-NMLD204-IL-GP09 Kia Motors America, Inc.
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Heating, Ventilation, and Air Conditioning (HVAC) 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.10 Theory...
Page 210 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 211 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL The goal of this module is to identify the heating, ventilation, and air conditioning (HVAC) systems and applications and for you to be able to diagnose electrical controls of these systems.
Page 212 2004.5 Spectra Technology INTRODUCTION The Spectra heating, ventilation, and air conditioning (HVAC) system provides interior temperature comfort to the driver and passengers. The new Spectra is equipped with a heating and ventilation system. A manual climate control air conditioning (A/C) system is an option on the Spectra 4-door LX trim level, and standard equipment on the EX trim level and the 5-door model.
Page 213 • Fan speeds (4) from LOW to HIGH • A/C system, if equipped. APPLICATION The Spectra is Kia’s second vehicle in the United States to use an air filter in the blower motor assembly to filter intake air for improved air quality in the passenger compartment.
Page 214 2004.5 Spectra Technology HEATING, VENTILATION, Spectra is equipped with a manually selected climate AIR CONDITIONING control system that includes the following: (HVAC) SYSTEM • Heating system SYSTEM OPERATION • Ventilation system • Air Conditioning system (if equipped) HEATING SYSTEM The heating system operates with engine coolant continuously flowing through the heater core tubes and transferring heat to the core fins.
Page 215 2004.5 Spectra Technology VENTILATION SYSTEM The ventilation system is the vehicle’s air mixture and distribution system. Starting at the air intake, fresh or recirculated air flows into the vent box when the vehicle is moving or is drawn in by the blower motor.
Page 216 2004.5 Spectra Technology AIR CONDITIONING SYSTEM The air conditioning (A/C) system uses the principles of thermodynamics to remove heat from the air entering the vehicle compartment. With the engine running: 1) The compressor compresses R-134a refrigerant into high-temperature/high-pressure gas. 2) Then, it pumps this gas into a condenser unit in front of the vehicle radiator.
Page 217 2004.5 Spectra Technology HVAC TEMPERATURE CONTROL The Spectra HVAC control panel consists of the following controls to allow vehicle occupants to adjust temperature and regulate airflow to suit their comfort: • Blower speed control switch with four speeds from 1 (LOW) to 4 (HIGH) •...
Page 218 2004.5 Spectra Technology The temperature switch controls the temperature door TEMPERATURE CONTROL position that will be used to regulate the ventilation SWITCH system’s discharge air temperature. The switch contains an electrical circuit to control an actuator that is connected to the temperature blend door.
Page 219 The purpose of the A/C system is to cool and dehumidify fresh or recirculated air before it enters the vehicle’s interior. The A/C components in the new Spectra are found in other Kia vehicles. A/C system components include: • Drive Belt •...
Page 220 2004.5 Spectra Technology N N o o t t e e : : A A l l w w a a y y s s r r e e f f e e r r t t o o u u n n d d e e r r h h o o o o d d A A / / C C l l a a b b e e l l f f o o r r s s y y s s t t e e m m t t y y p p e e a a n n d d s s p p e e c c i i f f i i c c a a t t i i o o n n s s .
Page 221 2004.5 Spectra Technology DRIVE BELT The A/C compressor is driven by the crankshaft pulley via a single drive belt that is adjusted to the deflection listed below. This deflection is measured at the midpoint (A) between the compressor and the crankshaft pulley.
Page 222 2004.5 Spectra Technology A/C COMPRESSOR The A/C compressor is a swash plate type unit mounted on the rear side of the engine. The magnetic clutch enables the compressor to start and stop while the engine is running. The compressor compresses the evaporated refrigerant into high pressure (high temperature) gas and pumps it out to the evaporator.
Page 223 2004.5 Spectra Technology CONDENSER AND RECEIVER/DRIER The condenser, which is mounted in front of the Spectra’s radiator, dissipates heat to the outside air. The heat is exchanged when air moves through the condenser fins/coils (by the cooling fan and vehicle speed).
Page 224 2004.5 Spectra Technology TRIPLE PRESSURE SWITCH AND CONDENSER FAN The 4-pin connector triple pressure switch is located on the high pressure line between the compressor and the condenser. It is a combination of a medium pressure switch as well as conventional low pressure and high pressure switches.
Page 225 2004.5 Spectra Technology This medium pressure switch signal is sent to the PCM/ECM, which uses it and the engine coolant temperature sensor to control the operation of the radiator and condenser fan motors through the NO radiator fan relay and 2 NO condenser fan relays (number 1 and number 2) to provide optional cooling fan operation.
Page 226 2004.5 Spectra Technology Heating, Ventilation, & Air Conditioning (HVAC)
Page 227 2004.5 Spectra Technology When the PCM/ECM sets a “low” speed for both radiator and condenser fans, the control coil of the radiator fan relay is grounded, closing the NO switch and providing B+ to both the radiator and condenser fan motors through both the radiator fan relay and the condenser fan relay #2, with a control coil that is not energized.
Page 228: Blower Motor
2004.5 Spectra Technology BLOWER MOTOR ASSEMBLY AND AIR DISTRIBUTION The blower motor assembly, located on the right side BOX COMPONENTS of the dash and behind the glove box, houses the following: • Blower motor • Blower Relay • Air filter (if equipped) •...
Page 229 2004.5 Spectra Technology BLOWER MOTOR CONTROL OPERATION When the ignition switch is in the ON position and the mode switch is in any position except OFF, the blower switch in any speed position energizes the blower motor relay coil. The blower motor fan relay is located next to the blower motor.
Page 230 2004.5 Spectra Technology AIR FILTER (IF EQUIPPED) Spectra is Kia’s second vehicle in the United States to use an air filter in the blower motor assembly to filter intake air for improved air quality in the passenger compartment. The blower motor draws fresh or recirculation air through the air filter into the air distribution box.
Page 231 2004.5 Spectra Technology The air distribution box houses the following: AIR DISTRIBUTION BOX COMPONENTS • Heater Core with engine coolant flowing through it • Evaporator Core (if equipped) • Fin Sensor (Thermostatic Switch) • Mode Control Actuator • 3 doors for the following positions •...
Page 232 2004.5 Spectra Technology AIR DISTRIBUTION BOX ACTUATORS When the ignition switch is in the ON position and the mode switch is selected by the vehicle occupant to any position except OFF, the control module supplies voltage to the 3 actuators and potentiometers.
Page 233 2004.5 Spectra Technology The control module operates the temperature actuator in one direction and by reversing polarity, it will operate the motor in the opposite direction to control the amount of air moving through the heater core. The control module supplies a 5V reference to the potentiometer, which is grounded.
Page 234 2004.5 Spectra Technology The control module operates the mode control actuator similar to the temperature actuator. Instead of actuating one temperature door, the mode actuator operates a cam, which moves the 3 mode doors into 5 possible positions for distributing air into the cabin.
Page 235 2004.5 Spectra Technology The control module operates the intake (fresh and recirculation) actuator open or closed. With B+ applied to terminal 2, the motor rotates clockwise (CW) to close the fresh air inlet duct. With B+ applied to terminal #1, the motor rotates counter clockwise (CCW) to open the fresh air inlet duct.
Page 236 2004.5 Spectra Technology A/C CONTROL CIRCUIT (IF EQUIPPED) When the ignition switch is in the ON position, the mode control switch is in any position except OFF and the A/C request button is turned ON, an A/C ON signal is sent to the PCM. With the low and high switches of...
Page 237 2004.5 Spectra Technology When the engine management system parameters are in place for the PCM to activate the air conditioning system, the PCM energizes the A/C relay coil and the A/C relay contact closes. Battery voltage is applied to the A/C compressor magnetic clutch through the 15 amp relay fuse to the engine relay and fuse box, turning the A/C compressor ON.
Page 238 Unique to the new Spectra is an air filter in the blower assembly for filtering intake air. The 2004.5 Spectra is Kia's second vehicle in the U.S. to use an air filter, following the 2004 Amanti. This air filter is an optional accessory.
Page 239 2004.5 Spectra Technology PROGRESS CHECK 1. Technician A states that the triple switch controls blower speeds in the HVAC system. Technician B states that the triple switch controls the mode doors to determine at what level the conditioned air will be delivered.
Page 240 2004.5 Spectra Technology 4. Technician A states that the cooling fans when operating on low speed are in series and are switched to parallel for high speed operation. Technician B states that the cooling fan relays control fan speed. Who is correct? A.
Page 241 2004.5 Spectra Technology N O T E S : Heating, Ventilation, & Air Conditioning (HVAC)
Page 242 2004.5 Spectra Technology N O T E S : Heating, Ventilation, & Air Conditioning (HVAC)
Page 243 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 244 TT-NMLD204-IL-TH10 Kia Motors America, Inc.
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Heating, Ventilation, and Air Conditioning (HVAC) 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.11 Guided Practice...
Page 246 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 247 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL In this module, you will be given the opportunity to practice performing heating, ventilation, and air conditioning-related service and diagnostic procedures.
Page 248 Heating, Ventilation, and Air conditioning (HVAC) theory module. Under the supervision of a trained Kia service-training instructor you will perform a series of tasks to fulfill the objectives of this guided practice.
Page 249 2004.5 Spectra Technology FAN COMPONENT 1. Using the circuit below, trace and mark the power OPERATION and groundside for the cooling and condenser fans during low speed operation. Total Possible Points: 2 2. Now trace and mark the power and ground side for the cooling and condenser fans during high-speed operation.
Page 250 2004.5 Spectra Technology HVAC AIR FILTER Remove and replace the HVAC air filter. Total Possible Points: 1 Record procedure below. _____________________________________________ _____________________________________________ _____________________________________________ List the direction (A) the air filter goes in: ___________ N N o o t t e e : : C C o o m m p p l l e e t t e e g g u u i i d d e e d d p p r r a a c c t t i i c c e e i i f f a a i i r r f f i i l l t t e e r r i i s s n n o o t t i i n n s s t t a a l l l l e e d d i i n n y y o o u u r r t t r r a a i i n n i i n n g g v v e e h h i i c c l l e e .
Page 251 2004.5 Spectra Technology CONTROL ACTUATOR 1. Locate the Mode or Temperature actuator and potentiometer. Total Possible Points: 2 2. Disconnect the connector. 3. Verify that the actuator operates by connecting B+ to terminal 2 and grounding terminal 1. 4. Verify the actuator operates in the opposite direction when reversing B+ and ground connection.
Page 252 2004.5 Spectra Technology N O T E S : Heating, Ventilation and Air Conditioning (HVAC)
Page 253 2004.5 Spectra Technology N O T E S : Heating, Ventilation and Air Conditioning (HVAC)
Page 254 2004.5 Spectra Technology N O T E S : Heating, Ventilation and Air Conditioning (HVAC)
Page 255 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 256 TT-NMLD204-IL-GP11 Kia Motors America, Inc.
Page 257: Nmld.12
Supplemental Restraint System (SRS) 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.12 Theory...
Page 258 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 259 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL Upon successful completion of this New Spectra Supplemental Restraint System (SRS) theory module, you will be able to: •...
Page 260 2004.5 Spectra Technology TIME TO COMPLETE This module will take approximately 20 minutes. ACRONYMS ACU: Airbag Control Unit ALR: Automatic Locking Retractor BPT: Belt Pretensioner BS: Belt Buckle Switch CAB: Curtain Airbag DAB: Driver Airbag DBPT: Driver Belt Pretensioner ELR: Emergency Locking Retractor...
Page 261 2004.5 Spectra Technology INTRODUCTION The seat belt is the primary restraint system to help reduce the risk and severity of injury to the driver and passengers in a frontal or side collision. The 2004.5 Spectra uses a Supplemental Restraint System (SRS) designed to deploy selected airbags and complement the seatbelts and seat belt pretensioners.
Page 262 The SRSCM continues to monitor for a frontal or side collision while performing self-diagnosis. If the SRI lamp illuminates any other time, the SRS should be inspected immediately and serviced by a Kia dealership. When the vehicle is involved in a frontal or side impact...
Page 263 2004.5 Spectra Technology APPLICATION 1996-1999 2000-2003 2004.5-2005 2004 Models Sephia Spectra SD Spectra LD SRSCM (TRW) SRSCM (Breed) Sensing Diagnostic Module (SDM) Driver's Airbag (DAB) Single Squib Driver's Airbag (DAB) Dual Squib Passenger's Airbag (PAB) Single Squib Passenger's Airbag (PAB) Dual' Squib...
Page 264 2004.5 Spectra Technology WARNING F F a a i i l l u u r r e e t t o o c c a a r r r r y y o o u u t t s s e e r r v v i i c c e e o o p p e e r r a a t t i i o o n n s s i i n n t t h h e e c c o o r r r r e e c c t t s s e e q q u u e e n n c c e e c c o o u u l l d d c c a a u u s s e e t t h h e e S S R R S S t t o o u u n n e e x x p p e e c c t t e e d d l l y y d d e e p p l l o o y y t t h h e e a a i i r r b b a a g g s s d d u u r r i i n n g g s s e e r r v v i i c c i i n n g g , , p p o o s s s s i i b b l l y y l l e e a a d d i i n n g g t t o o s s e e r r i i o o u u s s i i n n j j u u r r y y .
Page 265 In addition, the 2004.5 Spectra has an Occupant Classification System (OCS) and Passenger Airbag OFF Indicator, which is not found in any other Kia in the United States. The following chart displays SRS system and component comparisons for Kia vehicles.
Page 266 2004.5 Spectra Technology AIRBAG SYSTEM OPERATING SEQUENCE This drawing illustrates the operational and airbag deployment sequence: • The SRS advises the driver of its operating condition through the Service Reminder Indicator (SRI) • When a frontal, near frontal or side impact event occurs, it is detected by internal and external sensors to deploy airbags.
Page 267 2004.5 Spectra Technology SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE (SRSCM) The ignition key ON powers up the SRSCM, charges up the reserve power, performs a diagnostic routine, and turns ON the SRI for a bulb check. If a fault is present, the SRI lamp illuminates. The SRSCM continuously performs diagnostics on input sensors and deployment devices.
Page 268 2004.5 Spectra Technology OCCUPANT CLASSIFICATION SYSTEM (OCS) The 2004.5 Spectra has an Occupant Classification System (OCS) that continually monitors and senses the presence of an occupant in the front passenger seat. The OCS is designed to detect the presence of a...
Page 269 2004.5 Spectra Technology COMPONENT OPERATION The diagram indicates the locations of various SRS components. • FIS: Frontal Impact Sensor • DAB: Driver Airbag • SRSCM: Supplemental Restraint System Control Module (also called ACU) • DBPT: Driver Belt Pretensioner • BS: Belt Switch •...
Page 270 2004.5 Spectra Technology This diagram shows the wiring location of the SRS components. The upper left hand corner shows power input through the fuses to the SRSCM and SRI. Various inputs are shown down the left side. Outputs to deploy the airbags including the shorting bars, clock springs, and deployment stages are to the right of the diagram.
Page 271 2004.5 Spectra Technology SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE (SRSCM) OPERATION The Supplemental Restraint System Control Module (also known as the ACU) is located on the floor tunnel along the centerline of the vehicle for maximum impact signal reception. The SRSCM uses both internal and external sensors to detect that a sufficient impact force has occurred.
Page 272 2004.5 Spectra Technology SRSCM CONTROL PROCESSING UNIT (CPU) The SRSCM central processing unit (CPU) controls warning lamp functions (SRI), diagnostics, crash discrimination, deployment functions, power backup, and crash data, which is recorded within the SRSCM. If there is a failure in the SRSCM, the SRI lamp will either not blink or remain ON after the self-check.
Page 273 2004.5 Spectra Technology The Arming/Safing Sensor is a dual-contact ARMING/SAFING SENSOR electromechanical switch that closes if it senses a deceleration exceeding a specified threshold, such as an impact event. Exceeding a specific threshold activates the arming function and firing current must also flow across the safing sensor contact to deploy the air bags.
Page 274 2004.5 Spectra Technology CLOCK SPRING The Clock Spring is a component of the wiring harness and located between the steering wheel and steering column. The clock spring consists of two current carrying coils of wire that provide a continuous electrical circuit for the deployment loop of the dual squib inflator module at the Driver’s Air Bag (DAB).
Page 275 2004.5 Spectra Technology SUPPLEMENTAL RESTRAINT INDICATOR (SRI) The Supplemental Restraint Indicator (SRI) is located in the instrument cluster, with B+ power from the 10A cluster fuse and ground controlled by the SRSCM. When the ignition key is first turned ON, the SRI illuminates for a bulb check, flashes 6 times and goes OFF with no faults.
Page 276 2004.5 Spectra Technology SRS EXTERNAL SENSORS When an impact event occurs, the SRSCM calculates whether or not the front airbags should be deployed and determines what the deployment timing should be. This deployment decision occurs after the SRSCM compares the Crash Severity Level from the FIS and the signal from the internal Acceleration sensor.
Page 277 2004.5 Spectra Technology Notice on the chart above that the FIS has an acceleration range of +/- from zero g. N N o o t t e e : : A A f f t t e e r r f f r r o o n n t t a a l l i i m m p p a a c c t t , , t t h h e e F F I I S S m m o o u u n n t t i i n n g g p p o o s s i i t t i i o o n n s s m m u u s s t t b b e e i i n n s s p p e e c c t t e e d d t t o o d d e e t t e e r r m m i i n n e e w w h h e e t t h h e e r r t t h h e e y y a a r r e e w w i i t t h h i i n n s s p p e e c c i i f f i i c c a a t t i i o o n n .
Page 278 2004.5 Spectra Technology SIDE IMPACT SENSORS (SIS) The SISs are remote intelligent acceleration sensors that detect acceleration when a collision occurs near their mounted locations and send acceleration data information to the SRSCM. The primary purpose of remote Side Impact Sensors is to detect a collision impact earlier than possible from a centrally mounted sensor.
Page 279 2004.5 Spectra Technology The SRSCM sends command signals to the SIS and SRSCM/SIS COMMUNICATION receives response signals from the SIS. INTERFACE The command and response signals are separated in time; when the SRSCM sends the clock synchronized signal command out to the SIS, the SIS responds when the SRSCM sends out the next command.
Page 280 2004.5 Spectra Technology BUCKLE SWITCH (BS) OPERATION The BSs are located in the buckle portion of the driver and front passenger’s seat belts. The BSs are 5 volt reference hall effect type sensors that are able to determine if the seat belts are...
Page 281 2004.5 Spectra Technology N N o o t t e e : : D D i i a a g g n n o o s s i i s s o o f f t t h h e e B B u u c c k k l l e e S S w w i i t t c c h h i i s s a a c c c c o o m m p p l l i i s s h h e e d d w w i i t t h h t t h h e e H H i i - - S S c c a a n n P P r r o o t t o o o o l l a a n n d d K K S S I I S S f f o o r r p p r r o o c c e e d d u u r r e e s s .
Page 282 2004.5 Spectra Technology SEAT TRACK POSITION SENSOR (STPS) OPERATION The Seat Track Position Sensors (STPSs) are beneath the seat cushion on the inside seat rail of the front driver and passenger seat. There is one sensor for each seat. The STPS is a non-contacting magnetic proximity...
Page 283 2004.5 Spectra Technology The STPS resistance changes depending on its location relative to a vane mounted on the seat rail. When the STPS is positioned over the vane (9 latching positions or more rearward of the forward-most position), its resistance is approximately 900 ohms. When it is...
Page 284 2004.5 Spectra Technology DRIVER’S AIR BAG (DAB) OPERATION The DAB, located in the center of the steering wheel, contains a folded cushion and an inflator unit. The inflator assembly is equipped with two squibs designed to deploy in stages depending on the severity and velocity of the collision.
Page 285 2004.5 Spectra Technology PASSENGER AIR BAG (PAB) OPERATION The PAB, located on the right side dash pad assembly just above the glove box, contains a folded cushion and an inflator unit. The inflator assembly also has two squibs similar to the DAB. The inflator assembly is equipped with two squibs designed to deploy in stages depending on the severity and velocity of the collision.
Page 286 2004.5 Spectra Technology FRONT SIDE AIR BAGS Both right and left Front Side Airbags (FSAB) are located on the outboard side of the driver and (FSAB) OPERATION passenger seat backs. The FSAB contains a folded cushion and a single squib inflator unit. The two-pin connector is located under the seat back frame.
Page 287 2004.5 Spectra Technology CURTAIN AIR BAG (CAB) OPERATION The CAB contains a rolled cushion and an inflator unit. The CAB drops down from the headliner and can inflate on either side of the vehicle. The curtain airbags operate independently of each other and of the DAB and PAB.
Page 288 2004.5 Spectra Technology SEAT BELTS The Spectra front seat belts are Automatic Locking Retractor (ALR)/Emergency Locking Retractor (ELR) with a pretensioner and load limiter. The seatbelt anchor has a height adjustment. ALR are automatic locking retracting. When you pull the belt all the way out to maximum and let it back in, the belt will lock in place when you stop.
Page 289 2004.5 Spectra Technology BELT PRETENSIONERS (BPT) OPERATION The front seat Belt Pretensioners are located at the bottom of the “B” pillar behind the trim panel, incorporated within the seat belt retractor. When a vehicle has experienced an impact event that causes the SRSCM to determine the event has exceeded a threshold value, the BPTs will be deployed.
Page 290 2004.5 Spectra Technology SEAT BELT FORCE LIMITER The front seatbelt force limiter is designed to reduce the restraining force of the seatbelt webbing to the occupant’s chest during a collision. If the collision force reaches a certain value, the torsion bar in the...
Page 291 2004.5 Spectra Technology DIAGNOSTIC TROUBLESHOOTING FLOW The above chart from KSIS outlines the SRS diagnostic flow. Start your diagnosis by verifying the customer’s concern, such as viewing the action of the SRI. Does the concern come on during bulb and system check or...
Page 292 2004.5 Spectra Technology SUMMARY The 2004.5 Spectra uses a Supplemental Restraint System (SRS) designed to deploy selected airbags. Its SRS Control Module (SRSCM) has internal and external sensors to determine whether to deploy one or more airbags. Both driver and front passenger airbags are dual squib inflator design, which will deploy airbags in stages depending on the severity and velocity of the collision.
Page 293 2004.5 Spectra Technology REVIEW QUESTIONS 1. Technician A states that the 2004.5 Spectra has a dual squib air bag on the driver’s side and the passenger side is single squib but has a seat location sensor to detect seat position for deployment levels.
Page 294 4. All of these statements are true except: A. The 2004.5 SRS system is dual squib for both the driver and passenger’s airbags. B. The 2004.5 Spectra uses five impact sensors. C. The OCS may turn off the Passenger Airbag in a low speed impact event.
Page 295 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 296 TT-NMLD204-IL-TH12 Kia Motors America, Inc.
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Supplemental Restraint System (SRS) 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.13 Guided Practice...
Page 298 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 299 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOA In this module, you will be given the opportunity to practice performing Supplemental Restraint System (SRS) inspection and diagnostic procedures.
Page 300 2004.5 Spectra Technology SRS SENSOR INSPECTION 1. Locate both SIS on one side of the vehicle. Show instructor the location. Total Possible Points: 3 2. Record SRI lamp operating condition at key on. ___________________________________________ 3. Remove battery power and safely wait: __________ 4.
Page 301 2004.5 Spectra Technology SRS COMPONENT 1. Using KSIS, look up the diagnostic procedures for MALFUNCTION DIAGNOSIS the DTC recorded above and list the steps. Total Possible Points: 2 ____________________________________________ ____________________________________________ ____________________________________________ 2. List the specifications: ____________________________________________ ____________________________________________ ____________________________________________ 3. Perform the diagnostic procedures 4.
Page 302 2004.5 Spectra Technology N O T E S : Supplemental Restraint System (SRS)
Page 303 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 304 TT-NMLD204-IL-GP13 Kia Motors America, Inc.
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Body Electrical 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.14 Theory...
Page 306 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 307 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL The goal for this module is to identify and explain the operation of the 2004.5 Spectra Body Electrical System...
Page 308 2004.5 Spectra Technology TIME TO COMPLETE This module will take approximately 15 minutes. ACRONYMS BCM: Body Control Module ETACS: Electronic Time Alarm Control System ETACSCM: Electronic Time Alarm Control System Control Module IBEC: Integrated Bussed Electrical Center Body Electrical...
Page 309 2004.5 Spectra Technology INTRODUCTION The 2004.5 Spectra has many electrical accessories to provide comfort and convenience for the occupants. These accessories include: • Remote keyless entry (RKE) • Power windows • Power door locks • Lamps and windshield wiper/washer systems •...
Page 310 Spectra ETACS: Electronic Time Alarm Control System IBEC: Integrated Bussed Electric Center The 2004.5 Spectra is the first Kia vehicle sold in the U.S. to combine the ETACS/IBEC, includes the interior in-panel junction box, relay box, and fuse box, into one unit.
Page 311 Amanti Most of Kia’s vehicles use an ETACS unit to control time and alarm related electrical devices on the vehicle. Amanti is the only Kia to use a Body control Module (BCM) to control time and alarm systems and components.
Page 312 2004.5 Spectra Technology could be a wiper motor turning, a dome lamp illuminating, or a door lock solenoid energizing. The ETACS consists of wires and modules that control relays, buzzers, and chimes. Body electrical systems controlled by the ETACS include: •...
Page 313 2004.5 Spectra Technology COMPONENT OPERATION The ETACS/IBEC is located on the left side of the steering column, below the instrument panel (IP). Access to the entire ETACS unit requires removal of the lower left dash trim panel. With the trim panel removed, the ETACS plugs and harnesses are accessible.
Page 314 2004.5 Spectra Technology Interior Electrical Box Junction Upper housing Lower housing The IBEC is made up of two parts: the upper and lower housing assemblies. The upper housing contains the terminals for fuses, relays and connectors. The lower housing is a structure or frame that holds the IBEC.
Page 315 2004.5 Spectra Technology VOLTAGE CHECK HOLES The indicated “check holes” provide ETACS voltage information needed to perform diagnostics and troubleshooting procedures. ETACS LOGIC As seen above, many electrical accessories inputs are sent to the ETACS. Then, the ETACS outputs the command or actuation based on it’s programmed logic.
Page 316 2004.5 Spectra Technology Logic charts represent ON and OFF events of switches, lamps, motors, and solenoids. Logic charts may also indicate time between events, in which case they may be labeled as “timing charts.” As an example, the ETACS function of “Tail Lamp Auto Cut”...
Page 317 2004.5 Spectra Technology Looking at the boxed area on the logic chart, the tail lamp circuit may be turned ON in various ways, all of which are shown in the first third of this logic chart. To read this chart, break it down into activity segments and read from left to right.
Page 318 2004.5 Spectra Technology In the next boxed segment of the logic chart, the driver’s door is still open, and now the ignition key is turned ON and the tail lamp relay is ON. When the ignition switch is turned OFF, the tail lamp relay goes OFF.
Page 319 2004.5 Spectra Technology If one of the functions of this ETACS circuit is not operating as the logic chart shows, the next step is to divide the system into components to determine the fault. Other ETACS circuits work in similar fashion. For each...
Page 320 Note that the outside mirrors, which are in the same circuit, are not affected. Such a symptom indicates power could be lost on either side of the defogger grid. Refer to Kia Service Information System (KSIS) for diagnostic procedures and specifications. Body Electrical...
Page 321 The ETACS circut plugs into the upper half of the IBEC lower housing assembly. The 2004.5 Spectra ETACS incorporates several other components. For example, the lamp flasher relay for turn signal and hazard lamps is controlled by the ETACS and is plugged into the ETACS for lamp operation.
Page 322 2004.5 Spectra Technology TURN SIGNAL LAMP The turn signal switch inputs a voltage signal to the ETACS indicating LH or RH turn signal lamp operation. Then, the ETACS controls the LH and RH turn relay ON/OFF, which flashes related front and rear turn lamps ON/OFF through ground side control.
Page 323 2004.5 Spectra Technology AUTO SWITCH, AUTO LIGHT UNIT, AND AUTO LIGHT SENSOR Light switch inputs to the ETACS are headlamp ON/OFF voltage signals. The ETACS controls the high and low beam headlight relays in the engine compartment relay box, which turns the headlights ON/OFF through ground side control.
Page 324 2004.5 Spectra Technology RKE SIGNAL The RKE transmitted signal is received by the Remote Keyless Entry (RKE) unit, which inputs a serial data signal to the ETACS. The ETACS then controls related actuators such as the Burglar Alarm Horn Relay.
Page 325 2004.5 Spectra Technology Additional ETACS features include: ADDITIONAL ETACS FEATURES • Rear window washer control on 5-door model • Washer and Wiper for Front Windshield • Variable Intermittent Front Windshield Wiper • Turn and hazard lamp control • SRS crash all doors unlock •...
Page 326 2004.5 Spectra Technology ANTI-THEFT (BURGLAR ALARM SYSTEM) Alarm horn The Anti-Theft system is armed automatically after the ETACS determines an “open” circuit/signal to the doors, hood and trunk. The system alarm is activated (sounds) when: • Any door, hood, or trunk is opened without key or •...
Page 327 2004.5 Spectra Technology REMOTE KEYLESS ENTRY (RKE) The RKE system provides the driver with a system to lock and unlock the vehicle with a remote transmitter. The 4-door uses a 4-button (with trunk) and the 5-door uses a 3-button (without trunk) RKE. Two RKEs can be programmed into the receiver using the Hi-Scan Pro.
Page 328 2004.5 Spectra Technology RKE COMPONENTS The RKE receiver is located above the passenger glove compartment with a communication line to the ETACS. It only has a power and ground feed, serial communication line with ETACS and a line to the under-hood, 20-pin connector for RKE programming.
Page 329 2004.5 Spectra Technology BURGLAR ALARM SYSTEM The burglar alarm system is integrated with the keyless entry system. The burglar alarm system is armed automatically after the ignition switch is turned to the OFF position and the key removed. Then, the ETACS module must receive signals that the doors, hood, and trunk lid are closed and locked.
Page 330 2004.5 Spectra Technology ANTI-THEFT FUNCTION When the remote key lock button (transmitter) is depressed ONCE, a 0.5 second pulse command is issued to lock all doors. ARMING As part of the arming sequence, the alarm first enters a pre-armed state before the armed state. In the pre- armed state the vehicle and audible warnings are disabled.
Page 331 2004.5 Spectra Technology ALARM FUNCTIONS Once armed, should any door, hood or the trunk be opened without using the RKE, then: • The starter relay is disabled, inhibiting starting. • An audible alarm horn is activated for three cycles; each cycle is ON 27 seconds and OFF for 10 seconds.
Page 332 The Spectra uses a maintenance free 60AH battery, which has a 550A cold cranking amperage (CCA). A Kia Micro 570 Analyzer has been sent to all dealers as a new essential Kia special Service Tool (SST). This tool will assist technicians in battery management through technology that detects accurate battery condition in less than five minutes.
Page 333 2004.5 Spectra Technology STARTING CHARGING The Kia Micro 570 Analyzer also has the ability to test the charging and starting systems (alternator and starter). After the battery test, press ENTER immediately for the starter test. After starting the engine, cranking voltage and starter test results will be displayed on the screen.
Page 334 A. Body Control Module B. ETACS C. IBEC D. ETACS/IBEC 2. 2004.5 Spectra electronic timing and alarm control system (ETACS) is all of the following, EXCEPT: A. Centralizes SRS front and side impact sensors B. Centralized control and timing functions C.
Page 335 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 336 TT-NMLD204-IL-TH14 Kia Motors America, Inc.
Page 337: Nmld.15
Body Electrical 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.15 Guided Practice...
Page 338 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 339 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL In this module, you will be given the opportunity to practice performing ETACS related service and diagnostic procedures.
Page 340 This guided practice will give you the opportunity to put into practice the information you have learned in the Body Electrical theory module. Under the supervision of a trained Kia service-training instructor you will perform a series of tasks to fulfill the objectives of this guided practice.
Page 341 2004.5 Spectra Technology PRORAMMING AN RKE Get from your instructor an RKE to program on a Spectra. Total Possible Points: 3 1. Connect the HSP to: __________________________ a. Using which cable: __________________________ 2. On the HSP, select the: _______________________ 3. Select menu: ________________________________ 4.
Page 342 2004.5 Spectra Technology VOLTAGE CHECKS OF Gain access to the ETACS. THE ETACS Total Possible Points: 6 Notice the pins above the relays that are also listed by number below. The numbers are for this guided practice, not identified to any manual Measure each of the pins and record your reading below.
Page 343 2004.5 Spectra Technology Body Electrical...
Page 344 2004.5 Spectra Technology BATTERY TESTER The Spectra’s battery needs to be tested with the Kia Micro 570 Battery tester when it may be a warrantable Total Possible Points: 6 replacement item. This tester indicates if the battery needs to be replaced or recharged.
Page 345 13. Press the menu button for 2 seconds to turn ON the battery tester 14. Scroll and select the option PRINT RESULTS 15. Aim the top of the Kia Battery Tester at the infra- red receiver on the lower left of the printer and press ENTER 16.
Page 346 2004.5 Spectra Technology N O T E S : Walkaround...
Page 347 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 348 TT-NMLD204-IL-GP15 Kia Motors America, Inc.
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Performance Assessment 2004.5 Spectra Technology Service Technical Training Student Guide NMLD.16...
Page 350 SAFETY FIRST Appropriate service methods and proper repair procedures are essential for safe, reliable operation of all motor vehicles as well as the personal safety of the individual performing the repair. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual performing the service.
Page 351 2004.5 Spectra Technology TARGET AUDIENCE The target audience for this module will be Kia Master level, Master level candidates, Senior level, and Senior level candidates service technicians. MODULE GOAL This module is designed to evaluate what you have learned throughout this course. You will be assigned tasks, which must be successfully completed to receive credit for this performance assessment module.
Page 352 This module will give you the opportunity to demonstrate some of the information you have learned regarding the Spectra. Under the supervision of a trained Kia service training instructor you will answer a series of questions and perform a series of tasks in the areas of: •...
Page 353 B. B only C. Both a and B D. Neither A or B 4. Technician A states that the 2004.5 Spectra uses a new Trident negative resistive front sensor and a Zirconia rear sensor. Technician B states that the 2004.5 Spectra uses a new wide range oxygen sensor...
Page 354 2004.5 Spectra Technology 5. The ETACS on the 2004.5 Spectra is all of the following, EXCEPT: A. Centralized control and timing functions B. Simplifies electrical accessories wiring C. Centralizes SRS front and side impact sensors D. An input to output controller 6.
Page 355 2004.5 Spectra Technology 9. The air filter located in the Blower motor housing is used to remove __________ from the air before it enters the passenger compartment. A. Moisture B. Contaminants C. Odor D. All of the above 10. Technician A states the CVVT engine has a better power curve, lower emissions and better fuel economy than a fixed cam timed engine.
Page 356 2004.5 Spectra Technology PERFORMANCE Customer’s concern is CEL is illuminated ASSESSMENT 1. Verify the customers concern, perform a visual inspection and record results: Total Possible Points: 20 ___________________________________________ 2. Pull the DTC and record it: ____________________ 3. Review the data list that pertains to the DTC: ___________________________________________ 4.
Page 357 2004.5 Spectra Technology N O T E S : Performance Assessment...
Page 358 2004.5 Spectra Technology N O T E S : Performance Assessment...
Page 359 No part of this publication may be reproduced, stored electronically, or transmitted in any form or by any means without prior written approval from Kia Motors America, Inc. KMA reserves the right to make changes in the descriptions, specifications, or procedures without prior notice or obligation.
Page 360 TT-NMLD204-IL-PA16 Kia Motors America, Inc.

Kia 2004.5 Spectra Service Technical Training

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