Ec Kia Soul 2014

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Kia Soul: Emission Control System
 Specifications
 Components Location
 Description
 Schematic Diagram
 Troubleshooting
 Crankcase Emission Control System
 Evaporative Emission Control System
 Exhaust Emission Control System
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Kia Soul: Specifications

Purge Control Solenoid Valve (PCSV)
▷ Specification
Item Specification
Coil Resistance (Ω) 22.0 ~ 26.0 [20°C(68°F)]
Fuel Tank Pressure Sensor (FTPS)

▷ Type: Piezo-Resistive Pressure Sensor
▷ Specification
Pressure [kPa (kgf/cm², in H2O)] Output Voltage (V)
-6.67 (-0.068, -26.8) 0.5
0 2.5
+6.67 (0.068, 26.8) 4.5
Canister Close Valve (CCV)

▷ Specification
Item Specification
Tightening Torques
Item kgf.m N.m lb-ft
Positive crankcase ventilation valve 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Fuel tank air filter mounting bolt 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
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Kia Soul: Components Location
1. PCV valve 5. Canister close valve (CCV)

2. Canister 6. Fuel level sender (FLS)
3. Purge control solenoid valve (PCSV) 7. Fuel tank air filter
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4. Fuel tank pressure sensor (FTPS) 8. Catalytic converter (WCC + UCC)
1. PCV valve 2. Canister
3. Purge control solenoid valve (PCSV) 4. Fuel tank pressure sensor (FTPS)
5. Canister Close Valve (CCV)

7. Fuel tank air filter 6. Fuel level sender (FLS)
8. Catalytic converter (WCC) 8. Catalytic converter (UCC)
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Kia Soul: Description

Emissions Control System consists of three major systems.
The Crankcase Emission Control System prevents blow-by gas from releasing into the atmosphere. This system recycles gas back into
• the intake manifold (Closed Crankcase Ventilation Type).
The Evaporative Emission Control System prevents evaporative gas from releasing into the atmosphere. This system burns gas at
• appropriate engine operating condition after gathering it in the canister.
The Exhaust Emission Control System converts the three pollutants [hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen
• (NOx)] into harmless substances by using the 3-way catalytic converter.
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Kia Soul: Schematic Diagram
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Kia Soul: Troubleshooting
Symptom Suspect area
Engine will not start or struggle to start Vapor hose damaged or disconnected
Engine struggles to start Malfunction of the Purge Control Solenoid Valve
Vapor hose damaged or disconnected
Rough idle or engine stalls Malfunction of the PCV valve
Rough idle Malfunction of the Evaporative Emission Control System
Excessive oil consumption Positive crankcase ventilation line clogged
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Kia Soul: Crankcase Emission Control System

 Inspection
 Positive Crankcase Ventilation (PCV) Valve Operation Principle
 Positive Crankcase Ventilation (PCV) Valve Removal
 Positive Crankcase Ventilation (PCV) Valve Inspection
 Positive Crankcase Ventilation (PCV) Valve Installation
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Kia Soul: Inspection

1. After disconnecting the vapor hose from the PCV valve, remove the PCV valve.
2. Reconnect the PCV valve to the vapor hose.
Run the engine at idle, then put a finger over the open end of the PCV valve and make sure that intake manifold
vacuum can be felt.
The plunger inside the PCV valve will move back and forth at vacuum.
3.
4. If the vacuum is not felt inspect PCV operation, if operating correctly clean or replace the vapor hose.
Kia Soul: Positive Crankcase Ventilation (PCV) Valve Operation Principle
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Kia Soul: Positive Crankcase Ventilation (PCV) Valve Removal

1. Disconnect the vapor hose (A).
Remove the PCV valve (B).
2.
Kia Soul: Positive Crankcase Ventilation (PCV) Valve Inspection

Insert a thin stick (A) into the PCV valve (B) from the threaded side to check that the plunger movement.
1. If the plunger does not move (PCV valve is clogged), clean or replace the valve.
Kia Soul: Positive Crankcase Ventilation (PCV) Valve Installation

Install in the reverse order of removal.
PCV Valve:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
1.
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Kia Soul: Evaporative Emission Control System

 Description
 Operation
 Components Location
 Inspection
 Canister Removal
 Canister Inspection
 Canister Installation
 On-board Refueling Vapor Recovery (ORVR) valve Removal
 On-board Refueling Vapor Recovery (ORVR) valve Installation
 Fuel Filler Cap Description
 Fuel Tank Air Filter Removal
 Fuel Tank Air Filter Installation
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The Evaporative Emission Control System prevents fuel vapor stored in fuel tank from vaporizing into the atmosphere. When the fuel
evaporates in the fuel tank, the vapor passes through vent hoses or tubes to a canister filled with charcoal.
The canister temporarily holds the vapor in the charcoal. The ECM will control the system in order to draw the gathered vapor into the
combustion chambers during certain operating conditions. Engine manifold vacuum is used to draw the vapor into intake manifold.
Kia Soul: Operation

Evaporative System Monitoring
Evaporative And ORVR Emission Control System

This system consists of a fill vent valve, fuel shut-off valve, fuel cut valve (for roll over), two way valve (pressure/vacuum relief), fuel
liquid/vapor separator which is installed beside the filler pipe, charcoal canister which is mounted under the rear floor LH side member and
protector, tubes and miscellaneous connections.
While refueling, ambient air is drawn into the filler pipe so as not to emit fuel vapors in the air. The fuel vapor in the tank is then forced to flow
into the canister via the fill vent valve. The fuel liquid/vapor separator isolates liquid fuel and passes the pure vapor to the charcoal canister.
While the engine is operating, the trapped vapor in the canister is drawn into the intake manifold and then into the engine combustion
chamber. Using this purge process, the charcoal canister is purged and recovers its absorbing capability.
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1. Fuel Filler Cap

2. Fuel Filler Pipe 8. Evaporative Hose
3. Fuel Shut-OFF Valve 9. Canister
4. Fuel Tank 10. Canister Close Valve (CCV)
5. ORVR Valve 11. Fuel Feed Line
6. 2-Way & Cut Valve 12. Fuel Tank Pressure Sensor (FTPS)
7. Evaporative Hose 13. Purge Control Solenoid Valve (PCSV)
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Canister
The Canister is filled with charcoal and absorbs evaporated fuel vapor from the fuel tank. The gathered fuel vapor in canister is drawn into
the intake manifold by the ECM/PCM when appropriate conditions are set.
The Purge Control Solenoid Valve (PCSV) is installed in the passage connecting the canister to the intake manifold. It is a duty type solenoid
valve and is operated by ECM/PCM signal.
To draw the absorbed vapor into the intake manifold, the ECM/PCM will open the PCSV, otherwise the passage remains closed.
Fuel Filler Cap
A ratchet tightening device in the threaded fuel filler cap reduces the chances of incorrect installation, when sealing the fuel filler. After the
gasket on the fuel filler cap and the fill neck flange make contact, the ratchet produces a loud clicking noise indicating the seal has been set.
The Fuel Tank Pressure Sensor (FTPS) is an integral part of the monitoring system. The FTPS checks Purge Control Solenoid Valve (PCSV)
operation and leaks in the Evaporative Emission Control System by monitoring pressure and vacuum level in the fuel tank during PCSV
operating cycles.
The Canister Close Valve (CCV) is located between the canister and the fuel tank air filter. It closes off the air inlet to the canister for the
Evaporative Emissions System and also prevents fuel vapors from escaping from the Canister when the vehicle is not operating.
Evaporative System Monitoring
The Evaporative Emission Control Monitoring System monitors fuel vapor generation, evacuation, and a leakage check step. At first, the
OBD-II system checks if vapor generation due to fuel temperature is small enough to start monitoring. Then it evacuates the evaporative
system by means of PCSV with ramp in order to maintain a certain vacuum level. The final step is to check if there is vacuum loss by any
leakage of the system.
Vapor Generation Checking
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During the stabilization period, the PCSV and the CCV are closed. The system pressure is measured as starting pressure (DP_A). After a
certain defined period (T1), the system pressure (DP_B) is measured again and the difference from the starting pressure is calculated. If this
difference (DP_B - DP_A) is bigger than the threshold, there should be excessive vapor pressure and the monitor is aborted for next check.
On the contrary, if the difference is lower than the negative threshold, the PCSV is regarded as having a malfunction such as clogged at
open position.
Large EVAP Leak Detection
The PCSV is opened with a certain ramp for the pressure to reach down to a certain level. If the pressure can’t be lowered below a threshold,
the system is regarded as having a fuel cap-open or having a large leak.
Leaking Checking
The PCSV is closed and the system waits for a period to get stabilized pressure. During checking period (T2), the system measures the
beginning and the end of the system pressure (DP_C, DP_D). The diagnosis value is the pressure difference corrected by the natural vapor
generation (DP_B - DP_A) rate from the vapor generation check step.
Kia Soul: Components Location
1. Purge Control Solenoid Valve (PCSV)

2. Vapor line 5. Canister Close Valve (CCV)
3. ORVR valve 6. Canister
4. Fuel tank air filter 7. Fuel Tank Pressure Sensor (FTPS)
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Kia Soul: Inspection
[EVAP. Leakage Test]
Select "Evap. Leakage Test".
1
.
2
. Proceed with the test according to the screen introductions.
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Kia Soul: Canister Removal

1. Lift the vehicle.
2. Disconnect the vapor hose quick-connector (A), vapor hose (B) and ventilation hose (C).
3. Remove the protector mounting nuts (D) and lock pin (E).
Remove the canister assembly.
4.
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Remove the canister bracket after loosening the mounting bolts (A).
5.
Kia Soul: Canister Inspection

Check for the following items visually.
- Cracks or leakage of the canister
- Loose connection, distortion, or damage of the vapor hose/tube
A: Canister ↔ Atmosphere
B: Canister ↔ Intake Manifold
1. C: Canister ↔ Fuel Tank
Kia Soul: Canister Installation

Canister mounting bolt:

3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
1.
Kia Soul: On-board Refueling Vapor Recovery (ORVR) valve Removal

1. Turn the ignition switch OFF, and then remove battery (-) cable.
Remove the fuel pump.

2. (Refer to Fuel System - "Fuel Pump")
3. Remove the ORVR (A) after releasing hooks (B).
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Kia Soul: On-board Refueling Vapor Recovery (ORVR) valve Installation

1. Install in the reverse order of removal.
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Kia Soul: Fuel Filler Cap Description
A ratchet tightening device on the threaded fuel filler cap reduces the chances of incorrect installation, which seals the fuel filler. After the
gasket on the fuel filler cap and the filler neck flange contact each other, the ratchet produces a loud clicking noise indicating the seal has
been set.
1. Cover 5. Spring
2. Torsion spring 6. Plate seal
3. Retainer 7. Vacuum valve
4. Gasket seal 8. Spring
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Kia Soul: Fuel Tank Air Filter Removal

1. Turn the ignition switch OFF and disconnect the battery negative (-) cable.
3. Disconnect the canister close valve connector (A).
4. Disconnect the ventilation hose (B).
Remove the fuel tank air filter after removing the mounting bolts (C).
5.
Release the lever (A), and then separate the canister close valve (B) from the fuel tank air filter (C) after rotating
it in the direction of the arrow in the figure.
Separate the canister close valve (A) from the fuel tank air filter (B) after rotating it in the direction of the arrow in
the figure.
6.
Kia Soul: Fuel Tank Air Filter Installation
• Install the component with the specified torques.

• Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
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Kia Soul: Exhaust Emission Control System

 Description
 Catalytic Converter Description
 CVVT (Continuously Variable Valve Timing) System
 CVVT Operation Principle
 [CVVT System Mode]
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Exhaust emissions (CO, HC, NOx) are controlled by a combination of engine modifications and the addition of special control components.
Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control system.
These items have been integrated into a highly effective system which controls exhaust emissions while maintaining good drivability and fuel
economy.
Kia Soul: Catalytic Converter Description

The catalytic converter of the gasoline engine is a three way catalyst. It oxidizes carbon monoxide and hydrocarbons (HC), and separates
oxygen from the oxides of nitrogen (NOx).
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Kia Soul: CVVT (Continuously Variable Valve Timing) System

Continuous Variable Valve Timing (CVVT) system advances or retards the valve timing of the intake and exhaust valve in accordance with
the ECM control signal which is calculated by the engine speed and load.
By controlling CVVT, the valve over-lap or under-lap occurs, which makes better fuel economy and reduces exhaust gases (NOx, HC) and
improves engine performance through reduction of pumping loss, internal EGR effect, improvement of combustion stability, improvement of
volumetric efficiency, and increase of expansion work.
This system consist of
the CVVT Oil Control Valve (OCV) which rgulates engine oil to and from the cam phaser in accordance with the ECM PWM (Pulse With
- Modulation) control signal,
- and the Cam Phaser which varies the cam phase by using the hydraulic force of the engine oil.
The engine oil getting out of the CVVT oil control valve varies the cam phase in the direction (Intake Advance/Exhaust Retard) or opposite
direction (Intake Retard/Exhaust Advance) of the engine rotation by rotating the rotor connected with the camshaft inside the cam phaser.
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Kia Soul: CVVT Operation Principle

The CVVT has the mechanism rotating the rotor vane with hydraulic force generated by the engine oil supplied to the advance or retard
chamber in accordance with the CVVT oil control valve control.
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Kia Soul: [CVVT System Mode]
(1) Low Speed / Low Load (2) Part Load
(3) Low Speed / High Load (4) High Speed / High Load
Exhaust Valve Intake Valve
Driving Valve Valve

Condition Timing Effect Timing Effect
(1) Low * Valve Under-lap * Valve Under-lap

Speed Completely * Improvement of combustion Completely * Improvement of combustion
/Low Load Advance stability Retard stability
* Increase of expansion work

* Reduction of pumping loss
(2) Part Load Retard * Reduction of HC Retard * Reduction of pumping loss
(3) Low * Prevention of intake back flow

Speed (Improvement of volumetric
/High Load Retard * Increase of expansion work Advance efficiency)
(4) High
Speed * Improvement of volumetric
/High Load Advance * Reduction of pumping loss Retard efficiency
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Kia Soul: Engine Control / Fuel System
 Specifications
 Special Service Tools
 Troubleshooting
 Engine Control System
 Fuel Delivery System
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Fuel Delivery System
Items Specification
Fuel Tank Capacity 54 lit. (14.3 U.S.gal., 57.1 U.S.qt., 47.5 Imp.qt.)
Fuel Filter Type Paper type
Low Pressure Fuel Line 480 ~ 520 kPa (4.89 ~ 5.30 kgf/cm², 69.6 ~ 75.4 psi)
2.0 ~ 15.0 MPa (20.4 ~ 153.0 kgf/cm², 290.1 ~ 2175.6

Fuel Pressure High Pressure Fuel Line psi)
Type Electrical, in-tank type
Fuel Pump Driven by Electric motor
Type Mechanical type
High Pressure Fuel Pump Driven by Camshaft
Sensors
Manifold Absolute Pressure Sensor (MAPS)
▷ Type: Piezo-resistive pressure sensor type
▷ Specification
Pressure
[kPa (kgf/cm², psi)] Output Voltage (V)
20.0 (0.20, 2.9) 0.79
46.7 (0.47, 6.77) 1.84
101.3 (1.03, 14.7) 4.0
Intake Air Temperature Sensor (IATS)

▷ Type: Thermistor type
▷ Specification
Temperature
°C °F Resistance (kΩ)
-40 -40 40.93 ~ 48.35
-20 -4 13.89 ~ 16.03
0 32 5.38 ~ 6.09
10 50 3.48 ~ 3.90
20 68 2.31 ~ 2.57
40 104 1.08 ~ 1.21
50 122 0.76 ~ 0.85
60 140 0.54 ~ 0.66
80 176 0.29 ~ 0.34
Engine Coolant Temperature Sensor (ECTS)

▷ Type: Thermistor type
▷ Specification
Temperature Resistance (kΩ)
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°C °F
-40 -40 48.14
-20 -4 14.13 ~ 16.83
0 32 5.79
20 68 2.31 ~ 2.59
40 104 1.15
60 140 0.59
80 176 0.32
Throttle Position Sensor (TPS) [integrated into ETC module]

▷Type: Hall IC Non-contact sensor type
▷Specification
[TPS1]
Item Opening Percentage (%) Output Voltage (V) [Vref = 5V]
C.T 7 ~ 13 0.35 ~ 0.65
W.O.T 88.6 ~ 94 4.43 ~ 4.70
[TPS2]
C.T 87 ~ 93 4.35 ~ 4.65
W.O.T 6 ~ 11.4 0.3 ~ 0.57
Crankshaft Position Sensor (CKPS)

▷ Type: Magnetic field sensitive Type
▷ Specification
Item Specification
Coil Resistance (Ω) 774 ~ 946 [20°C (68°F)]
Camshaft Position Sensor (CMPS)

▷ Type: Hall effect type
Knock Sensor (KS)
▷ Type: Piezo-electricity type
▷ Specification
Item Specification
30
Capacitance (pF) 950 ~ 1,350
Resistance(MΩ) 4.87
Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]

▷ Type: Zirconia (ZrO2) [Linear] Type
▷ Specification
Item Specification
Heater Resistance (Ω) 2.4 ~ 4.0 [20°C(69.8°F)]

▷ Type: Zirconia (ZrO2) [Binary] Type
▷ Specification
A/F Ratio (λ) Output Voltage(V)
RICH 0.6 ~ 1.0
LEAN 0 ~ 0.4
Item Specification
Heater Resistance (Ω) Approx. 9.0 [21°C(69.8°F)]
Rail Pressure Sensor (RPS)

▷ Type: Piezo-electricity type
▷ Specification
Accelerator Position Sensor (APS)

▷ Type: Variable resistor type
▷ Specification
Output Voltage (V) [Vref = 5V]
Accelerator
Position APS1 APS2
C.T 0.7 ~ 0.8 0.28 ~ 0.48
W.O.T 3.85 ~ 4.35 1.8 ~ 2.3

▷ Type: Piezo - Resistivity type
▷ Specification
Pressure
[kPa (kgf/cm², in H2O) Output Voltage (V)
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-6.67 (-0.068, -26.8) 0.5
0 2.5
+6.67 (0.068, 26.8) 4.5
Actuators
Injector
▷ Specification
Item Specification
Coil Resistance (Ω) 1.5 ± 0.075 [20°C(68°F)]
ETC Motor [integrated into ETC Module]

▷ Specification
Item Specification
Coil Resistance (Ω) 0.3 ~ 100 [20°C(68°F)]

▷ Specification
Item Specification
CVVT Oil Control Valve (OCV)

▷ Specification
Item Specification
Variable Intake Solenoid (VIS) Valve

▷ Specification
Item Specification
Fuel Pressure control Valve (FPCV)

▷ Specification
Item Specification
Ignition Coil
▷ Type: Stick type
▷ Specification
Item Specification
Primary Coil Resistance (Ω) 0.75 ± 15％[20°C(68°F)]
Secendary Coil Resistance (kΩ) 5.9 ± 15％[20°C(68°F)]

▷ Specification
Item Specification
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Coil Resistance (Ω) 19.5 ~ 22.5 (20°C)
Service Standard
Item Specification
Ignition Timing (°) BTDC 5 ± 10
Neutral, N, P-range 630 ± 100
A/C OFF D-range 630 ± 100
Neutral, N, P-range 670 ± 100
Idle Speed (rpm) A/C ON D-range 670 ± 100
Tightening Torques
Engine Control System
ECM mounting nut 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Manifold absolute pressure sensor mounting bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Intake air temperature sensor mounting bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Engine Coolant Temperature Sensor mounting 3.0 ~ 4.0 29.4 ~ 39.2 21.7 ~ 28.9
Crankshaft position sensor mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Camshaft position sensor (Bank 1 / Intake) mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Camshaft position sensor (Bank 1 / Exhaust) mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Knock sensor mounting bolt 1.9 ~ 2.5 18.6 ~ 24.5 13.7 ~ 18.1
Heated oxygen sensor (Bank 1 / sensor 1) 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Heated oxygen sensor (Bank 1 / sensor 2) 4.0 ~ 5.0 39.2 ~ 49.1 28.9 ~ 36.2
Rail pressure sensor 3.0 ~ 3.5 29.4 ~ 34.3 21.7 ~ 25.3
Electronic throttle body mounting bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
CVVT oil control valve (Bank 1 / Intake) mounting bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
CVVT oil control valve (Bank 1 / Exhaust) mounting bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Ignition coil mounting bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
Fuel Delivery System

Fuel tank mounting bolt 4.0 ~ 5.5 39.2 ~ 54.0 28.9 ~ 39.8
Fuel pump plate cover mounting bolt 0.2 ~ 0.3 2.0 ~ 2.9 1.4 ~ 2.2
Accelerator pedal module mounting nut 1.3 ~ 1.6 12.8 ~ 15.7 9.4 ~ 11.6
Accelerator pedal module mounting bolt 0.8 ~ 1.2 7.8 ~ 11.8 5.8 ~ 8.7
Fuel tube clamp mounting nut 0.4 ~ 0.6 3.9 ~ 5.9 2.9 ~ 4.3
Delivery pipe mounting bolt 1.9 ~ 2.4 18.6 ~ 23.5 13.7 ~ 17.4
High pressure fuel pump mounting bolt 1.3 ~ 1.5 12.8 ~ 14.7 9.4 ~ 10.9
High pressure fuel pipe flang nut 2.7 ~ 3.3 26.5 ~ 32.4 19.5 ~ 23.9
High pressure fuel pipe function block mounting bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7
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Kia Soul: Special Service Tools

Special Service Tools
Tool Name / Number Illustration Description
Fuel Pressure Gauge Used for measuring the pressure in fuel

09353-24100 line
Fuel Pressure Gauge Used for connecting between high

Adapter pressure fuel pump and low pressure fuel
09353-02100 feed tube to measure the pressure in fuel
line
Used for removing / installing heated

Heated Oxygen Sensor oxygen sensor
Socket Wrench
09392-1Y100 ※SST 09392-2H100 also can be used
Torque Wrench Socket

09314-3Q100 or Used for removing / installing high
09314-27130 (19mm) pressure fuel pipe
Injector Combustion
Seal Guide & Sizing
tool Used for installing injector combustion
09353-2B000 seal on injector
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Kia Soul: Troubleshooting

Basic Troubleshooting
Basic Troubleshooting Guide
35
Customer Problem Analysis Sheet
36
Basic Inspection Procedure
37
Measuring Condition of Electronic Parts' Resistance

The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient
temperature (20°C, 68°F), unless stated otherwise.
The measured resistance in except for ambient temperature (20°C, 68°F) is reference value.
Intermittent Problem Inspection Procedure
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing. An example
would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician should thoroughly
make out a "Customer Problem Analysis Sheet" and recreate (simulate) the environment and condition which occurred when the vehicle was
having the issue.
1. Clear Diagnostic Trouble Code (DTC).
Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded
pins, and then verify that the connectors are always securely fastened.
2.
3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
5. Verify that the problem has disappeared with the road test.
● Simulating Vibration
Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.
1) Strong vibration may break sensors, actuators or relays
Connectors and Harness

2) : Lightly shake the connector and wiring harness vertically and then horizontally.
● Simulating Heat
Heat components suspected of causing the malfunction with a hair dryer or other heat source.
• DO NOT heat components to the point where they may be damaged.

1)
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• DO NOT heat the ECM directly.
● Simulating Water Sprinkling

Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
1) DO NOT sprinkle water directly into the engine compartment or electronic components.
● Simulating Electrical Load

1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window defogger, etc.).
Connector Inspection Procedure
Handling of Connector
Never pull on the wiring harness when disconnecting connectors.
A.
When removing the connector with a lock, press or pull locking lever.
B.
Listen for a click when locking connectors. This sound indicates that they are securely locked.
1. C.
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When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness
side.
D.
Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from
harness side.
• Use a fine wire to prevent damage to the terminal.

• Do not damage the terminal when inserting the tester lead.
E.
Checking Point for Connector

While the connector is connected:
A. Hold the connector, check connecting condition and locking efficiency.
When the connector is disconnected:
Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
B. Visually check for rust, contamination, deformation and bend.
Check terminal tightening condition:
C. Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
2. D. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
40
Repair Method of Connector Terminal

Clean the contact points using air gun and/or shop rag.
A. Never use sand paper when polishing the contact points, otherwise the contact point may be damaged.
3. B. In case of abnormal contact pressure, replace the female terminal.
Wire Harness Inspection Procedure

1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.
Electrical Circuit Inspection Procedure
● Check Open Circuit
Procedures for Open Circuit
A. Continuity Check
B. Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or
Step 3 (Voltage Check Method) as shown below.
1.
Continuity Check Method
2. When measuring for resistance, lightly shake the wire harness above and below or from side to side.
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Specification (Resistance)
1Ω or less → Normal Circuit
1MΩ or Higher → Open Circuit
Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [FIG. 2].
In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1MΩ and below 1 Ω respectively. Specifically the
open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as described in next step.
A.
Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and (A) as
shown in [FIG. 3].
In this case the measured resistance between connector (C) and (B1) is higher than 1MΩ and the open circuit is
between terminal 1 of connector (C) and terminal 1 of connector (B1).
B.
Voltage Check Method

With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each
connectors (A), (B) and (C) as shown in [FIG. 4].
The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between connector (C)
and (B).
3. A.
● Check Short Circuit

Test Method for Short to Ground Circuit
A. Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2
1. (Continuity Check Method with Chassis Ground) as shown below.
42
Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness above and below, or from side to side when measuring the resistance.
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1MΩ or Higher → Normal Circuit
Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown in
[FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively. Specifically
the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of line 1 as
described in the following step.
A.
Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1)
and chassis ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground circuit is
between terminal 1 of connector (C) and terminal 1 of connector (B1).
2. B.
● Testing For Voltage Drop

This test checks for voltage drop along a wire, or through a connection orswitch.
1) Connect the positive lead of a voltmeter to the end of the wire (or to the side of the connector or switch) closest to the battery.
43
2) Connect the negative lead to the other end of the wire. (or the other side of the connector or switch)
3) Operate the circuit.
The voltmeter will show the difference in voltage between the two points. A difference, or drop of more than 0.1 volts (50mV in 5V
4) circuits), may indicate a problem. Check the circuit for loose or dirty connections.
Symptom Troubleshooting Guide Chart

Main symptom Diagnostic procedure Also check for
Test the battery. (Refer to Engine Electrical System -

1. "Battery")
Unable to start
2. Test the starter. (Refer to Engine Electrical System - "Starter")
(Engine does not
turn over) 3. Inhibitor switch (A/T) or clutch start switch (M/T)

1. "Battery")
Check the fuel pressure (Refer to Fuel Delivery System - • DTC
2. "Fuel Pressure Test")
• Low compression
Check the ignition circuit. (Refer to Engine Electrical System
• Intake air leaks
3. - "Ignition System")
Unable to start Slipped or broken
Troubleshooting the immobilizer system. (Refer to Body
• timing belt
(Incomplete Electrical System - "Immobilizer System")
combustion) 4. (In case of immobilizer lamp flashing) • Contaminated fuel

1. "Battery")
• DTC
Check the fuel pressure (Refer to Fuel Delivery System -
• Low compression
3. Check the ECT sensor and circuit (Check DTC)
• Contaminated fuel
Difficult to start 4. - "Ignition System") • Weak ignition spark
Check the fuel pressure. (Refer to Fuel Delivery System -

Check the Injector. (Refer to Engine Control System -
2. "Injector")
• DTC
Check the long term fuel trim and short term fuel trim
3. (Refer to CUSTOMER DATASTREAM) • Low compression
4. Check the idle speed control circuit (Check DTC) • Intake air leaks
Poor idling
5. Inspect and test the Throttle Body • Contaminated fuel
(Rough, unstable or
incorrect Idle) 6. Check the ECT sensor and circuit (Check DTC) • Weak ignition spark
Engine stall 1. Test the battery. (Refer to Engine Electrical System - • DTC
44
"Battery") • Intake air leaks

Check the fuel pressure. (Refer to Fuel Delivery System - • Contaminated fuel
• Weak ignition spark
3. Check the idle speed control circuit (Check DTC)
5. Check the CKPS Circuit (Check DTC)

2. Inspect and test Throttle Body
• DTC
4. Check the ECT Sensor and Circuit (Check DTC)
• Low compression
Test the exhaust system for a possible restriction. (Refer to
5. Engine Mechanical System - "Exhaust Manifold")
• Contaminated fuel
Poor driving Check the long term fuel trim and short term fuel trim (Refer
(Surge) 6. to CUSTOMER DATASTREAM) • Weak ignition spark

Inspect the engine coolant. (Refer to Engine Mechanical
2. System - "Radiator")
Inspect the radiator and the electric cooling fan. (Refer to
3. Engine Mechanical System - "Radiator")
• DTC
Check the spark plugs. (Refer to Engine Electrical System -
Knocking 4. "Ignition System") • Contaminated fuel
Check customer's driving habitsIs

· A/C on full time or the defroster mode on?
· Are tires at correct pressure?
· Is excessively heavy load being carried?
1. · Is acceleration too much, too often?
• DTC
• Low compression
Check the injector. (Refer to Engine Control System -
3. "Injector") • Intake air leaks
4. Test the exhaust system for a possible restriction • Contaminated fuel
Poor fuel economy 5. Check the ECT sensor and circuit • Weak ignition spark
Inspect the fuel filler hose/pipe

· Pinched, kinked or blocked?
1. · Filler hose is torn Malfunctioning gas
station filling nozzle (If
Hard to refuel Inspect the fuel tank vapor vent hose between the EVAP.
this problem occurs at a
2. canister and air filter
(Overflow during specific gas station
refueling) 3. Check the EVAP. canister • during refueling)
45
Kia Soul: Engine Control System
 Description and Operation

 Components and Components Location
 Engine Control Module (ECM). Schematic Diagrams
 Engine Control Module (ECM). Repair procedures
 ETC (Electronic Throttle Control) System. Description and Operation
 ETC (Electronic Throttle Control) System. Troubleshooting
 ETC (Electronic Throttle Control) System. Specifications
 ETC (Electronic Throttle Control) System. Schematic Diagrams
 ETC (Electronic Throttle Control) System. Repair procedures
 Manifold Absolute Pressure Sensor (MAPS). Description and Operation
 Manifold Absolute Pressure Sensor (MAPS). Specifications
 Manifold Absolute Pressure Sensor (MAPS). Troubleshooting
 Manifold Absolute Pressure Sensor (MAPS). Schematic Diagrams
 Manifold Absolute Pressure Sensor (MAPS). Repair procedures
 Intake Air Temperature Sensor (IATS). Description and Operation
 Intake Air Temperature Sensor (IATS). Specifications
 Intake Air Temperature Sensor (IATS). Schematic Diagrams
 Intake Air Temperature Sensor (IATS). Repair procedures
 Engine Coolant Temperature Sensor (ECTS). Description and Operation
 Engine Coolant Temperature Sensor (ECTS). Specifications
 Engine Coolant Temperature Sensor (ECTS). Schematic Diagrams
 Engine Coolant Temperature Sensor (ECTS). Repair procedures
 Crankshaft Position Sensor (CKPS). Description and Operation
 Crankshaft Position Sensor (CKPS). Specifications
 Crankshaft Position Sensor (CKPS). Troubleshooting
 Crankshaft Position Sensor (CKPS). Schematic Diagrams
 Crankshaft Position Sensor (CKPS). Repair procedures
 Camshaft Position Sensor (CMPS). Description and Operation
 Camshaft Position Sensor (CMPS). Troubleshooting
 Camshaft Position Sensor (CMPS). Schematic Diagrams
 Camshaft Position Sensor (CMPS). Repair procedures
 Knock Sensor (KS). Description and Operation
 Knock Sensor (KS). Specifications
 Knock Sensor (KS). Schematic Diagrams
 Knock Sensor (KS). Knock Sensor (KS).
 Heated Oxygen Sensor (HO2S). Description and Operation
 Heated Oxygen Sensor (HO2S). Specifications
 Heated Oxygen Sensor (HO2S). Troubleshooting
 Heated Oxygen Sensor (HO2S). Schematic Diagrams
 Heated Oxygen Sensor (HO2S). Repair procedures
 Rail Pressure Sensor (RPS). Description and Operation
 Rail Pressure Sensor (RPS). Specifications
46
 Rail Pressure Sensor (RPS). Troubleshooting

 Rail Pressure Sensor (RPS). Schematic Diagrams
 Rail Pressure Sensor (RPS). Repair procedures
 Accelerator Position Sensor (APS). Description and Operation
 Accelerator Position Sensor (APS). Specifications
 Accelerator Position Sensor (APS). Schematic Diagrams
 Accelerator Position Sensor (APS). Repair procedures
 Fuel Tank Pressure Sensor (FTPS). Description and Operation
 Fuel Tank Pressure Sensor (FTPS). Specifications
 Fuel Tank Pressure Sensor (FTPS). Schematic Diagrams
 Fuel Tank Pressure Sensor (FTPS). Repair procedures
 Injector. Description and Operation
 Injector. Specifications
 Injector. Troubleshooting
 Injector. Schematic Diagrams
 Injector. Repair procedures
 Purge Control Solenoid Valve (PCSV). Description and Operation
 Purge Control Solenoid Valve (PCSV). Specifications
 Purge Control Solenoid Valve (PCSV). Schematic Diagrams
 Purge Control Solenoid Valve (PCSV). Repair procedures
 CVVT Oil Control Valve (OCV). Description and Operation
 CVVT Oil Control Valve (OCV). Specifications
 CVVT Oil Control Valve (OCV). Schematic Diagrams
 CVVT Oil Control Valve (OCV). Repair procedures
 Variable Intake Solenoid (VIS) Valve. Description and Operation
 Variable Intake Solenoid (VIS) Valve. Specifications
 Variable Intake Solenoid (VIS) Valve. Schematic Diagrams
 Variable Intake Solenoid (VIS) Valve. Repair procedures
 Fuel Pressure Control Valve. Description and Operation
 Fuel Pressure Control Valve. Specifications
 Fuel Pressure Control Valve. Troubleshooting
 Fuel Pressure Control Valve. Schematic Diagrams
 Fuel Pressure Control Valve. Repair procedures
 Canister Close Valve (CCV). Description and Operation
 Canister Close Valve (CCV). Specifications
 Canister Close Valve (CCV). Schematic Diagrams
 Canister Close Valve (CCV). Repair procedures
47
Kia Soul: Description and Operation

OBD-II review
1. Overview
The California Air Resources Board (CARB) began regulation of On Board Diagnostics (OBD) for vehicles sold in California beginning with the 1988 model
year. The first phase, OBD-I, required monitoring of the fuel metering system, Exhaust Gas Recirculation (EGR) system and additional emission related
components. The Malfunction Indicator Lamp (MIL) was required to light and alert the driver of the fault and the need for repair of the emission control
system. Associated with the MIL was a fault code or Diagnostic Trouble Code (DTC) idenfying the specific area of the fault.
The OBD system was proposed by CARB to improve air quality by identifying vehicle exceeding emission standards. Passage of the Federal Clean Air Act
Amendments in 1990 has also prompted the Environmental Protection Agency (EPA) to develop On Board Diagnostic requirements. CARB OBD-II
regulations were followed until 1999 when the federal regulations were used.
The OBD-II system meets government regulations by monitoring the emission control system. When a system or component exceeds emission threshold
or a component operates outside tolerance, a DTC will be stored and the MIL illuminated.
The diagnostic executive is a computer program in the Engine Control Module (ECM) or PowertrainControl Module (PCM) that coordinates the OBD-II
self-monitoring system. This program controls all the monitors and interactions, DTC and MIL operation, freeze frame data and scan tool interface.
Freeze frame data describes stored engine conditions, such as state of the engine, state of fuel control, spark, RPM, load and warm status at the point
the first fault is detected. Previously stored conditions will be replaced only if a fuel or misfire fault is detected. This data is accessible with the scan tool
to assist in repairing the vehicle.
The center of the OBD-II system is a microprocessor called the Engine Control Module (ECM) or Powertrain Control Module(PCM).
The ECM or PCM receives input from sensors and other electronic components (switches, relays, and others) based on information received and
programmed into its memory (keep alive random access memory, and others), the ECM or PCM generates output signals to control various relays,
solenoids and actuators.
2. Configuration of hardware and related terms
1) GST (Generic scan tool)
2) MIL (Malfunction indication lamp) - MIL activity by transistor
48
The Malfunction Indicator Lamp (MIL) is connected between ECM or PCM-terminal Malfunction Indicator Lamp and battery supply (open collector
amplifier).
In most cars, the MIL will be installed in the instrument panel. The lamp amplifier can not be damaged by a short circuit.
Lamps with a power dissipation much greater than total dissipation of the MIL and lamp in the tester may cause a fault indication.
▷ At ignition ON and engine revolution (RPM)< MIN. RPM, the MIL is switched ON for an optical check by the driver.
3) MIL illumination
When the ECM or PCM detects a malfunction related emission during the first driving cycle, the DTC and engine data are stored in the freeze frame
memory. The MIL is illuminated only when the ECM or PCM detects the same malfunction related to the DTC in two consecutive driving cycles.
4) MIL elimination
Misfire and Fuel System Malfunctions:
For misfire or fuel system malfunctions, the MIL may be eliminated if the same fault does not reoccur during monitoring in three subsequent
• sequential driving cycles in which conditions are similar to those under which the malfunction was first detected.
All Other Malfunctions:
For all other faults, the MIL may be extinguished after three subsequent sequential driving cycles during which the monitoring system responsible for
illuminating the MIL functions without detecting the malfunction and if no other malfunction has been identified that would independently illuminate
• the MIL according to the requirements outlined above.
5) Erasing a fault code
The diagnostic system may erase a fault code if the same fault is not re-registered in at least 40 engine warm-up cycles, and the MIL is not illuminated for
that fault code.
6) Communication Line (CAN)
• Bus Topology : Line (bus) structure
• Wiring : Twisted pair wire
• Off Board DLC Cable Length : Max. 5m
• Data Transfer Rate
- Diagnostic : 500 kbps
- Service Mode (Upgrade, Writing VIN) : 500 or 1Mbps)
7) Driving cycle
A driving cycle consists of engine start up, and engine shut off.
8) Warm-up cycle
A warm-up cycle means sufficient vehicle operation such that the engine coolant temperature has risen by at least 40 degrees Fahrenheit from engine
starting and reaches a minimum temperature of at least 160 degrees Fahrenheit.
9) DTC format
• Diagnostic Trouble Code (SAE J2012)
• DTCs used in OBD-II vehicles will begin with a letter and are followed by four numbers.
The letter of the beginning of the DTC identifies the function of the monitored device that has failed. A "P" indicates a powertrain device, "C" indicates a
chassis device. "B" is for body device and "U" indicates a network or data link code. The first number indicates if the code is generic (common to all
manufacturers) or if it is manufacturer specific. A "0" & "2" indicates generic, "1" indicates manufacturer-specific. The second number indicates the
system that is affected with a number between 1 and 7.
The following is a list showing what numbers are assigned to each system.
• 1 : Fuel and air metering
• 2 : Fuel and air metering(injector circuit malfunction only)
• 3 : Ignition system or misfire
• 4 : Auxiliary emission controls
49
• 5 : Vehicle speed controls and idle control system

• 6 : Computer output circuits
• 7 : Transmission
The last two numbers of the DTC indicates the component or section of the system where the fault is located.
10) Freeze frame data
When a freeze frame event is triggered by an emission related DTC, the ECM or PCM stores various vehicle information as it existed the moment the fault
ocurred. The DTC number along with the engine data can be useful in aiding a technician in locating the cause of the fault. Once the data from the 1st
driving cycle DTC ocurrence is stored in the freeze frame memory, it will remain there even when the fault ocurrs again (2nd driving cycle) and the MIL is
illuminated.
• Freeze Frame List
1) Calculated Load Value
2) Engine RPM
3) Fuel Trim
4) Fuel Pressure (if available)
5) Vehicle Speed (if available)
6) Coolant Temperature
7) Intake Manifold Pressure (if available)
8) Closed-or Open-loop operation
9) Fault code
3. OBD-II Readiness Test
[Kia Motors Drive Cycle]
Kia OBDII Drive Cycle is designed to execute and complete the OBDII monitors. To complete a specific monitor for repair verification, follow the Drive
Cycle chart below.
Kia OBDII Drive Cycle consists of two modes (Mode 1 and Mode 2) and the Mode 2 is to perform the catalyst diagnostics on Delphi EMS only.
- Continental, Bosch or Kefico EMS : Mode 1 drive cycle should be done one time for diagnostics on all systems.
- Delphi EMS : Mode 2 drive cycle should be done two times in a row after Mode 1 is carried out one time for diagnostics on all systems
Mode 1
•
• Mode 2
50
Speed Duration E/Time

Mode No Operation (mph) (s) (s) Remarks
1 Engine Start 0 0 0 ECT @ Start 32~104°F
2 Idling (N) 0 30 30 Neutral Range
3 Idling (D) 0 270 300 D Range
4 Acceleration 0 → 50 15 315
5 Steady Speed 50 230 545
6 Deceleration 50 → 45 5 550
12 Repeat 8 through 11 ten times. - 180 755
Mode 1 28 Acceleration 40 → 50 15 2035
51

30 Deceleration 50 → 40 15 2055
32 Repeat 28 through 31 five times. - 380 2495
33 Acceleration 40 → 50 15 2510
Mode 1 36 Idling (D) 0 25 2580 D Range
1 Engine Start 0 0 0
5 Deceleration 49 → 47 2 258 Lift Foot Up : APS = 0
7 Acceleration 47 → 55 4 272 Middle Tip In or Deep Accel
12 Repeat 6 through 11 twelve times. - 330 620
Mode 2
52
Kia Soul: Components and Components Location

Components Location
1. Engine Control Module (ECM) 16. A/C Pressure Transducer (APT)

2. Manifold Absolute Pressure Sensor (MAPS) 17. ETC Motor [integrated into ETC Module]
53
3. Intake Air Temperature Sensor (IATS) 18. Injector

4. Engine Coolant Temperature Sensor (ECTS) 19. Purge Control Solenoid Valve (PCSV)
5. Throttle Position Sensor (TPS) [integrated into ETC 20. CVVT Oil Control Valve (OCV) [Bank 1 / Intake]
Module] 21. CVVT Oil Control Valve (OCV) [Bank 1 /
6. Crankshaft Position Sensor (CKPS) Exhaust]
7. Camshaft Position Sensor (CMPS) [Bank 1 / Intake] 22. Variable Intake Solenoid (VIS) Valve
8. Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust] 23. Fuel Pressure Control Valve (FPCV)
9. Knock Sensor (KS) 24. Canister Close Valve (CCV)
10. Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 1] 25. Ignition Coil
11. Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 2] 26. Main Relay
12. Rail Pressure Sensor (RPS) 27. Fuel Pump Relay
13. Accelerator Position Sensor (APS) 28. Data Link Connector (DLC) [16-Pin]
14. Fuel Tank Pressure Sensor (FTPS) 29. Multi-Purpose Check Connector [20-Pin]
15. Fuel Level Sender (FLS)
2. Manifold Absolute Pressure Sensor (MAPS)

1. Engine Control Module (ECM) 3. Intake Air Temperature Sensor (IATS)
5. Throttle Position Sensor (TPS) [integrated into ETC

Module]
4. Engine Coolant Temperature Sensor (ECTS) 17. ETC Motor [integrated into ETC Module]
7. Camshaft Position Sensor (CMPS) [Bank 1 / Intake]

6. Crankshaft Position Sensor (CKPS) 8. Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust]
54
10. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]

9. Knock Sensor (KS) 11. Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2]
12. Rail Pressure Sensor (RPS)

18. Injector 13. Accelerator Position Sensor (APS)
14. Fuel Tank Pressure Sensor (FTPS) 15. Fuel Level Sender (FLS)
55
16. A/C Pressure Transducer (APT) 19. Purge Control Solenoid Valve (PCSV)
20. CVVT Oil Control Valve (OCV) [Bank 1 / Intake] 21. CVVT Oil Control Valve (OCV) [Bank 1 / Exhaust]
22. Variable Intake Solenoid (VIS) Valve 23. Fuel Pressure Control Valve (FPCV)
56
24. Canister Close Valve (CCV) 25. Ignition Coil
26. Main Relay

27. Fuel Pump Relay 28. Data Link Connector (DLC) [16-Pin]
29. Multi-Purpose Check Connector [20-Pin]
57
58
Kia Soul: Engine Control Module (ECM). Schematic Diagrams

ECM Terminal And Input/Output signal [M/T]
ECM Terminal Function (M/T)

Connector [C100-MA]
Pin
No. Description Connected to
1 Injector (Cylinder #3) [High] control output Injector (Cylinder #3)
3 Injector (Cylinder #2) [Low] control output Injector (Cylinder #2)
4 -

5 heater control output Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 1]
6 -
7 -
8 -
9 -
10 -
11 -
12 -
13 -
14 Cooling fan relay [High] control output Cooling fan relay [High]
CVVT Oil Control Valve (OCV) [Bank 1/Exhaust]

15 control output CVVT Oil Control Valve (OCV) [Bank 1/Exhaust]
19 -
Heated Oxygen Sensor (HO2S) [Bank 1/Sensor2]

20 heater control output Heated Oxygen Sensor (HO2S) [Bank 1/Sensor 2]
21 -
22 -
Engine Coolant Temperature Sensor (ECTS) signal

23 input Engine Coolant Temperature Sensor (ECTS)
24 Sensor ground Engine Coolant Temperature Sensor (ECTS)
59
25 -
26 Fuel Tank Pressure Sensor (FTPS) signal input Fuel Tank Pressure Sensor (FTPS)
Fuel pump relay control output (Without Immobilizer) Fuel pump relay
Canister Close Valve (CCV) control output (With

27 Immobilizer) Canister Close Valve (CCV)
28 -
29 A/C compressor relay control output A/C compressor relay
30 -
31 Ignition coil (Cylinder #3) control output Ignition coil (Cylinder #3)
Fuel Pressure Control Valve (FPCV) [High] control

34 output Fuel Pressure Control Valve (FPCV)
35 ETC motor [-] control output ETC motor
36 -
37 Knock Sensor (KS) signal input Knock Sensor (KS)
38 Sensor ground Knock Sensor (KS)
39 -
40 Brake Lamp switch signal input Brake switch
41 -
42 -
43 -
44 -
CVVT Oil Control Valve (OCV) [Bank 1/Intake] control

45 output CVVT Oil Control Valve (OCV) [Bank 1/Intake]
Fuel Pressure Control Valve (FPCV) [Low] control

49 output Fuel Pressure Control Valve (FPCV)
50 ETC motor [+] control output ETC motor
51 -
52 -
53 Brake switch signal input Brake switch
54 -
55 Clutch switch signal input Clutch switch
56 Electric load [Defrost] signal input A/C Control Module
57 Alternator target voltage data signal output (COM) Alternator
58 -
59 Cooling fan relay [Low] control output Cooling fan relay
60
60 Variable Intake Solenoid (VIS) valve control output Variable Intake Solenoid (VIS) valve
Connector [C100-MK]
Pin
No. Description Connected to
1 ECM ground Chassis ground
4 Battery power (B+) Main relay
5 Battery power (B+) Battery
6 Battery power (B+) Battery
7 Battery power (B+) Main relay
8 Sensor ground Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 2]
9 Accelerator Position Sensor (APS) 1 signal input Accelerator Position Sensor (APS) 1
10 Sensor ground Accelerator Position Sensor (APS) 2
11 -
12 Sensor ground Fuel Tank Pressure Sensor (FTPS)
13 -
14 Throttle Position Sensor (TPS) 1 signal input Throttle Position Sensor (TPS) 1
15 -
16 -
17 Fuel Level sender signal input Fuel Level Sender (FLS)
18 Sensor power (+5V) Accelerator Position Sensor (APS) 2
19 -
Rail Pressure Sensor (RPS)
20 Sensor power (+5V) A/C Pressure Transducer (APT)
21 -
22 Electrical load [Wiper] signal input Multifunction switch
23 -
24 Alternator electric load signal input (FR) Alternator
25 -
26 -
27 -
28 -
29 Ignition switch signal input Ignition switch
Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 2]

30 signal input Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor 2]
31 Accelerator Position Sensor (APS) 2 signal input Accelerator Position Sensor (APS) 2
32 Sensor ground Accelerator Position Sensor (APS) 1
33 -
61
34 -
35 Sensor ground Throttle Position Sensor (TPS)
36 Throttle Position Sensor (TPS) 2 signal input Throttle Position Sensor (TPS) 2
37 -
38 -
39 Sensor power (+5V) Throttle Position Sensor (TPS) 1,2
40 Sensor power (+5V) Accelerator Position Sensor (APS) 1
Manifold Absolute Pressure Sensor (MAPS)
41 Sensor power (+5V) Fuel Tank Pressure Sensor (FTPS)
Camshaft Position Sensor (CMPS) [Bank 1 / Intake]
42 Sensor power (+5V) Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust]
43 -
44 -
45 A/C Pressure Transducer (APT) signal input A/C Pressure Transducer (APT)
46 Vehicle speed signal input Vehicle Speed Sensor
47 -
48 -
49 -
50 -
51 -
52 VS-/IP- (Common Ground for VS, IP) Heated Oxygen Sensor [Bank 1/Sensor 1]
53 Rc/Rp (Pump Cell Voltage) Heated Oxygen Sensor [Bank 1/Sensor 1]
54 -
55 -
56 -
57 -
58 Rail Pressure Sensor (RPS) signal input Rail Pressure Sensor (RPS)
59 -
60 Start signal input PDM module
61 LIN communication signal input Battery sensor
62 -
Other control module, Data Link Connector (DLC),

63 CAN [Low] Multi-Purpose Check Connector
64 Sensor ground Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust]
Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust]

65 signal input Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust]
66 -
62
Kia Soul: Engine Control Module (ECM). Repair procedures

Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the battery. (Refer to Engine Electrical System -"Battery")
3. Disconnect the ECM Connector (A).
Remove the mounting bolts (B) and nut ( C), and then remove the ECM bracket assembly.
4.
Remove the ECM after removing the nuts (A) from the bracket.
5.
Installation
ECM mounting nut:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
1.
ECM Problem Inspection Procedure
TEST ECM GROUND CIRCUIT: Measure resistance between ECM and chassis ground using the backside of
ECM harness connector as ECM side check point. If the problem is found, repair it.
Specification: Below 1Ω
1.
TEST ECM CONNECTOR: Disconnect the ECM connector and visually check the ground terminals on ECM side
2. and harness side for bent pins or poor contact pressure. If the problem is found, repair it.
If problem is not found in Step 1 and 2, the ECM could be faulty. If so, make sure there were no DTC's before
swapping the ECM with a new one, and then check the vehicle again. If DTC's were found, examine this first
3. before swapping ECM.
RE-TEST THE ORIGINAL ECM: Install the original ECM (may be broken) into a known-good vehicle and check
4. the vehicle. If the problem occurs again, replace the original ECM with a new one. If problem does not occur, this
63
is intermittent problem (Refer to “Intermittent Problem Inspection Procedure” in Basic Inspection Procedure).
Adjustment
• After replacing the ECM of the vehicle with the immobilizer, the following procedure must be performed.
1) [If installing a used ECM]
1. Perform "ECM Neutral Mode" procedure using GDS. (Refer to "Body Electrical System - "Immobilizer System - Repair procedures")
After finishing "ECM Neutral Mode", perform "Key Teaching" procedure using GDS. (Refer to "Body Electrical System - "Immobilizer
2. System - Repair procedures")
[If installing a new ECM]

2) Perform "Key Teaching" procedure using GDS. (Refer to "Body Electrical System - "Immobilizer System - Repair procedures")
• After replacing the ECM of the vehicle with the smart key system (button start), the following procedure must be performed.
1) [If installing a used ECM]
1. Perform "ECM Neutral Mode" procedure using GDS. (Refer to "Body Electrical System - "Smart key System - Repair procedures")
After finishing "ECM Neutral Mode", turn IGN ON then OFF using the smart key or start button. Then the ECM learns information on the
2. smart key automatically.
[If installing a new ECM]

2) Turn IGN ON then OFF using the smart key or start button. Then the ECM learns information on the smart key automatically.
• Perform TCM learning after replacing the PCM. (Refer to Automatic Transaxle Control System - "Adjustment")
64
Kia Soul: ETC (Electronic Throttle Control) System. Description and Operation
Description
The Electronic Throttle Control (ETC) System consists of a throttle body with an integrated control motor and throttle position sensor (TPS).
Instead of the traditional throttle cable, an Accelerator Position Sensor (APS) is used to receive driver input. The ECM uses the APS signal to
calculate the target throttle angle; the position of the throttle is then adjusted via ECM control of the ETC motor. The TPS signal is used to
provide feedback regarding throttle position to the ECM. Using ETC, precise control over throttle position is possible; the need for external
cruise control modules/cables is eliminated.
1. Dry bearing 5. Magnet

2. DC motor 6. Hall IC
3. Non-contact hall sensor 7. Yoke
4. Gear 8. Stator
Schematic Diagram
65
66
Kia Soul: ETC (Electronic Throttle Control) System. Troubleshooting

Fail-Safe Mode
Item Fail-Safe
ETC Motor Throttle valve stuck at 7°
TPS 1 fault ECM looks at TPS2
TPS 2 fault ECM looks at TPS1
TPS TPS 1,2 fault Throttle valve stuck at 7°
APS 1 fault ECM looks at APS 2
APS 2 fault ECM looks at APS 1
APS APS 1,2 fault Engine idle state
When throttle value is stuck at 7°, engine speed is limited at below 1,500rpm and vehicle speed at maximum 40
~ 50 km/h (25 ~ 31 mph)
67
Kia Soul: ETC (Electronic Throttle Control) System. Specifications

Specification
[TPS1]
C.T 7 ~ 13 0.35 ~ 0.65
W.O.T 88.6 ~ 94 4.43 ~ 4.70
[TPS2]
C.T 87 ~ 93 4.35 ~ 4.65
W.O.T 6 ~ 11.4 0.3 ~ 0.57
[ETC Motor]
Item Specification
Coil Resistance (Ω) 0.3 ~100 [20°C(68°F)]
68
Kia Soul: ETC (Electronic Throttle Control) System. Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
69
70
Kia Soul: ETC (Electronic Throttle Control) System. Repair procedures

Inspection
Throttle Position Sensor (TPS)
1. Connect the GDS on the Data Link Connector (DLC).
Start the engine and measure the output voltage of TPS 1 and 2 at C.T. and W.O.T.
Specification: Refer to “Specification”

2.
ETC Motor
1. Turn the ignition switch OFF.
2. Disconnect the ETC module connector.
3. Measure resistance between the ETC module terminals 1 and 2.
Check that the resistance is within the specification.

4.
Removal
Remove the resonator and the air intake hose.

2. (Refer to Engine Mechanical System - “Air Cleaner”)
3. Disconnect the ETC module connector (A).
4. Disconnect the coolant hoses (B) and vapor hose (C).
Remove the mounting bolts (D), and then remove the ETC module from the engine.
5.
Installation

Note that internal damage may occur when the component is dropped. If the component has been dropped, inspect
• before installing.
Electronic throttle body mounting bolt:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
1.
Adjustment
ETC module learning procedure

When installing new ETC module or re-installing it, ETC module learning procedure must be performed.
71
1. Hold the ignition key or the start button at the IG ON position during 5 seconds.
2. Turn ignition swich OFF and then start the engine.
DTC codes (P0638, P2110) might be displayed if ETC module learning procedure does not performed after
replacing ETC module.
Kia Soul: Manifold Absolute Pressure Sensor (MAPS). Description and Operation
Description
Manifold Absolute Pressure Sensor (MAPS) is a speed-density type sensor and is installed on the surge tank. It senses absolute pressure of
the surge tank and transfers the analog signal proportional to the pressure to the ECM. By using this signal, the ECM calculates the intake air
quantity and engine speed.
The MAPS consists of a piezo-electric element and a hybrid IC amplifying the element output signal. The element is silicon diaphragm type
and adapts pressure sensitive variable resistor effect of semi-conductor. Because 100% vacuum and the manifold pressure apply to both
sides of the sensor respectively, this sensor can output analog signal by using the silicon variation proportional to pressure change.
72
Kia Soul: Manifold Absolute Pressure Sensor (MAPS). Specifications

Specification
Pressure
[kPa (kgf/cm², psi)] Output Voltage (V)
20.0 (0.20, 2.9) 0.79
46.7 (0.47, 6.77) 1.84
101.3 (1.03, 14.7) 4.0
73
Kia Soul: Manifold Absolute Pressure Sensor (MAPS). Troubleshooting

Signal Waveform
74
Kia Soul: Manifold Absolute Pressure Sensor (MAPS). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
75
76
Kia Soul: Manifold Absolute Pressure Sensor (MAPS). Repair procedures
Inspection
Measure the output voltage of the MAPS at idle and IG ON.
Specification: Refer to "Specification"

2.
Removal
2. Disconnect the manifold absolute pressure sensor connector (A).
Remove the installation bolt (B), and then remove the sensor from the surge tank.
3.
Installation

• Insert the sensor in the installation hole and be careful not to damage.
Manifold absolute pressure sensor installation bolt:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
1.
77
Kia Soul: Intake Air Temperature Sensor (IATS). Description and Operation
Description
Intake Air Temperature Sensor (IATS) is included inside Manifold Absolute Pressure Sensor and detects the intake air temperature.
To calculate precise air quantity, correction of the air temperature is needed because air density varies according to the temperature. So the
ECM uses not only MAPS signal but also IATS signal. This sensor has a Negative Temperature Coefficient (NTC) Thermister and it's
resistance value changes in reverse proportion to the temperature.
Kia Soul: Intake Air Temperature Sensor (IATS). Specifications

Specification
Temperature
-40 -40 40.93 ~ 48.35
-20 -4 13.89 ~ 16.03
0 32 5.38 ~ 6.09
10 50 3.48 ~ 3.90
20 68 2.31 ~ 2.57
40 104 1.08 ~ 1.21
50 122 0.76 ~ 0.85
60 140 0.54 ~ 0.66
80 176 0.29 ~ 0.34
78
Kia Soul: Intake Air Temperature Sensor (IATS). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
79
80
Kia Soul: Intake Air Temperature Sensor (IATS). Repair procedures

Inspection
2. Disconnect the IATS connector.
3. Measure resistance between the IATS terminals 3 and 4.

4.
Removal
2. Disconnect the intake air temperature sensor connector (A).
Remove the installation bolt (B), and then remove the sensor from the surge tank.
3.
Installation

Intake air temperature sensor mounting bolt:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
1.
81
Kia Soul: Engine Coolant Temperature Sensor (ECTS). Description and Operation
Description
Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for detecting the engine coolant
temperature. The ECTS uses a thermistor that changes resistance with the temperature.
The electrical resistance of the ECTS decreases as the temperature increases, and increases as the temperature decreases. The reference
+5V is supplied to the ECTS via a resistor in the ECM. That is, the resistor in the ECM and the thermistor in the ECTS are connected in
series. When the resistance value of the thermistor in the ECTS changes according to the engine coolant temperature, the output voltage
also changes.
During cold engine operation, the ECM increases the fuel injection duration and controls the ignition timing using the information of engine
coolant temperature to avoid engine stalling and improve drivability.
82
Kia Soul: Engine Coolant Temperature Sensor (ECTS). Specifications

Specification
Temperature
-40 -40 48.14
-20 -4 14.13 ~ 16.83
0 32 5.79
20 68 2.31 ~ 2.59
40 104 1.15
60 140 0.59
80 176 0.32
Kia Soul: Engine Coolant Temperature Sensor (ECTS). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
83
Kia Soul: Engine Coolant Temperature Sensor (ECTS). Repair procedures

Inspection
2. Remove the ECTS (Refer to "Removal").
After immersing the thermistor of the sensor into engine coolant, measure resistance between the ECTS
3. terminals 1 and 3.

4.
Removal
Disconnect the engine coolant temperature sensor connector (A).
2.
3. Disconnect the ignition coil connector (A) and CMPS connector (B).
84
Unfasten the harness bracket (C) and Make a gap for removing high pressure fuel pipe by moving the bracket
(C).
4.
5. Remove the vacuum pipe mounting bolts (A).
Remove the engine coolant temperature sensor (B).
6.
Fill with engine coolant.

7. (Refer to Engine Mechanical System -"Coolant")
Installation

• Apply the engine coolant to the O-ring.
Engine Coolant Temperature Sensor mounting :

29.4 ~ 39.2 N.m (3.0 ~ 4.0 kgf.m, 21.7 ~ 28.9 lb-ft)
1.
85
Kia Soul: Crankshaft Position Sensor (CKPS). Description and Operation

Description
Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of the most important sensors of the engine control system. If
there is no CKPS signal input, the engine may stop because of CKPS signal missing.
This sensor is installed in ladder frame and generates alternating current by magnetic flux field which is made by the sensor and the target
wheel when the engine rotates. The target wheel consists of 58 slots and 2 missing slots on 360 CA (Crank Angle).
Kia Soul: Crankshaft Position Sensor (CKPS). Specifications

Specification
Item Specification
Coil Resistance (Ω) 774 ~ 946 [20°C (68°F)]
86
Kia Soul: Crankshaft Position Sensor (CKPS). Troubleshooting

Waveform
87
This example shows a typical Crankshaft Position Sensor(CkPS) and Camshaft Position Sensor(CMPS) waveform at idle.The PCM controls
the injection and ignition timing by using these signals.
Generally CkPS signal is used to detect the piston's position and CMPS signal is used to detect the Top Dead Center of each cylinder.
88
Kia Soul: Crankshaft Position Sensor (CKPS). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
89
90
Kia Soul: Crankshaft Position Sensor (CKPS). Repair procedures

Inspection
Check signal waveform of CKPS and CMPS using a GDS.
Specification: Refer to “Waveform”

1.
Removal
Remove the engine room under cover.

2. (Refer to Engine Mechanical System - "Engine Room Under Cover")
Disconnect the crankshaft position sensor connector (A) and remove the sensor (B) after removing the
installation bolt.
3.
Installation

• Apply the engine oil to the O-ring.
Crankshaft position sensor installation bolt:

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
1.
91
Kia Soul: Camshaft Position Sensor (CMPS). Description and Operation

Description
Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element.
It is related with Crankshaft Position Sensor (CKPS) and detects the piston position of each cylinder which the CKPS can't detect.
The CMPS is installed on engine head cover and uses a target wheel installed on the camshaft. The Cam Position sensor is a hall-effect type
sensor. As the target wheel passes the Hall sensor, the magnetic field changes in the sensor. The sensor then switches a signal which
creates a square wave.
Kia Soul: Camshaft Position Sensor (CMPS). Troubleshooting

Wave Form
92
93
Kia Soul: Camshaft Position Sensor (CMPS). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
94
95
Kia Soul: Camshaft Position Sensor (CMPS). Repair procedures

Inspection
Check the signal waveform of the CMPS and CKPS using the GDS.
Specification: Refer to “Wave Form”

1.
Removal
DON’T remove the camshaft position sensor while the engine is running or right after engine is turned off. The part
• and engine oil is hot and can cause burns.
[Bank 1 / Intake]
2. Disconnect the camshaft position sensor connector (A).
Remove the mounting bolt (B), and then remove the sensor.
3.
[Bank 1 / Exhaust]
2. Disconnect the camshaft position sensor connector (A).
Remove the mounting bolt (B), and then remove the sensor.
3.
Installation
96
• Apply the engine oil to the O-ring.
• Be careful not to damage the sensor housing and the connector.

• Be careful not to damage the O-ring.
Camshaft position sensor mounting bolt:

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
1.
Kia Soul: Knock Sensor (KS). Description and Operation

Description
Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine damage. Knock Sensor (KS) is installed
on the cylinder block and senses engine knocking.
When knocking occurs, the vibration from the cylinder block is applied as pressure to the piezoelectric element. When a knock occurs, the
sensor produces voltage signal. The ECM retards the ignition timing when knocking occurs. If the knocking disappears after retarding the
ignition timing, the ECM will advance the ignition timing. This sequential control can improve engine power, torque and fuel economy.
Kia Soul: Knock Sensor (KS). Specifications

Specification
Item Specification
Capacitance (pF) 950 ~ 1,350
Resistance (MΩ) 4.87
97
Kia Soul: Knock Sensor (KS). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
98
Kia Soul: Knock Sensor (KS). Knock Sensor (KS).

Removal
Remove the engine room under cover.

2. (Refer to Engine Mechanical System - "Engine Room Under Cover")
Disconnect the knock sensor connector (A).
3.
4. Remove the mounting bolt (A), and then remove the sensor (B) from the cylinder block.
99
Installation

Knock sensor mounting bolt:

18.6 ~ 24.5 N.m (1.9 ~ 2.5 kgf.m, 13.7 ~ 18.1 lb-ft)
1.
Kia Soul: Heated Oxygen Sensor (HO2S). Description and Operation

Description
Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed both upstream and downstream of the Manifold Catalytic
Converter. The sensor output voltage varies in accordance with the air/fuel ratio.
The sensor must be hot in order to operate normally. To keep it hot, the sensor has a heater which is controlled by the ECM via a duty cycle
signal. When the exhaust gas temperature is lower than the specified value, the heater warms the sensor tip.
100
Kia Soul: Heated Oxygen Sensor (HO2S). Specifications

Specification
HO2S [Bank 1/Sensor 1]
Item Specification
Heater Resistance (Ω) 2.4 ~ 4.0 [20°C(68°F)]
HO2S [Bank 1/Sensor 2]

A/F Ratio (λ) Output Voltage(V)
RICH 0.6 ~ 1.0
LEAN 0 ~ 0.4
Item Specification
Heater Resistance (Ω) Approx. 9.0 [21°C(69.8°F)]
Kia Soul: Heated Oxygen Sensor (HO2S). Troubleshooting

Signal Waveform
101
102
103
Kia Soul: Heated Oxygen Sensor (HO2S). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
104
105
Kia Soul: Heated Oxygen Sensor (HO2S). Repair procedures

Inspection
2. Disconnect the HO2S connector.
3. Measure resistance between the HO2S terminals 2 and 5 [B1/S1].
4. Measure resistance between the HO2S terminals 3 and 4 [B1/S2].

5.
Removal
Disconnect the connector (A), and then remove the sensor (B).
Note that the SST (Part No.: 09392-1Y100 or 09392-2H100) is useful when removing the heated oxygen sensor.
[Bank 1 / Sensor 1]
2. [Bank 1 / Sensor 2]
106
Installation

DON’T use a cleaner, spray, or grease to sensing element and connector of the sensor because oil component in them
• may malfunction the sensor performance.
Sensor and its wiring may be damaged in case of contacting with the exhaust system (Exhaust Manifold, Catalytic
• Converter, and so on).
Heated oxygen sensor mounting:

39.2 ~ 49.1 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
1.
107
Kia Soul: Rail Pressure Sensor (RPS). Description and Operation

Description
Rail Pressure Sensor (RPS) is installed on the delivery pipe and measures the instantaneous fuel pressure in the delivery pipe. The sensing
element (Semiconductor element) built in the sensor converts the pressure to voltage signal. By using this signal, the ECM can control
correct injection amount and timing and adjusts the fuel pressure with the fuel pressure regulator valve if the target pressure and the actual
pressure calculated by the RPS output signal are different.
Kia Soul: Rail Pressure Sensor (RPS). Specifications

Specification
Kia Soul: Rail Pressure Sensor (RPS). Troubleshooting

Signal Waveform
108
Kia Soul: Rail Pressure Sensor (RPS). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
109
Kia Soul: Rail Pressure Sensor (RPS). Repair procedures

Inspection
Measure the output voltage of the RPS at idle and various engine speed.
Condition Output Voltage (V)
Idle Approx. 1.2
1,500 rpm 2.2 ~ 2.5
2. 6,300 rpm Approx. 3.0
Removal
Release the residual pressure in fuel line (Refer to the Fuel Delivery System - Repair Procedures - "Release
2. Residual Pressure in Fuel Line").
Remove the Alternator.

3. (Refer to Engine Electrical System - "Alternator")
Disconnect the rail pressure sensor connector (A), and then remove the sensor (B) from the delivery pipe.
4.
110
Installation

Rail Pressure Sensor mounting:

29.4 ~ 34.3 N.m (3.0 ~ 3.5 kgf.m, 21.7 ~ 25.3 lb-ft)
1.
Kia Soul: Accelerator Position Sensor (APS). Description and Operation

Description
Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the rotation angle of the accelerator pedal. The
APS is one of the most important sensors in engine control system, so it consists of the two sensors which adapt individual sensor power
and ground line. The second sensor monitors the first sensor and its output voltage is half of the first one. If the ratio of the sensor 1 and 2 is
out of the range (approximately 1/2), the diagnostic system judges that it is abnormal.
Kia Soul: Accelerator Position Sensor (APS). Specifications

Specification
Output Voltage (V) [Vref = 5V]
Accelerator
Position APS1 APS2
C.T 0.7 ~ 0.8 0.28 ~ 0.48
W.O.T 3.85 ~ 4.35 1.8 ~ 2.3
111
Kia Soul: Accelerator Position Sensor (APS). Schematic Diagrams

Circuit Diagram
(M/T)
112
(A/T)
Kia Soul: Accelerator Position Sensor (APS). Repair procedures

Inspection
2. Turn the ignition switch ON.
Measure the output voltage of the APS 1 and 2 at C.T and W.O.T.

3.
Removal
1. Turn the ignition switch OFF and disconnect the negative (-) battery terminal.
2. Disconnect the accelerator position sensor connector (A).
Remove the mounting nuts (B).
3.
113
Remove the cap (A)
4.
Remove the mounting bolt (A), and then remove the accelerator pedal module.
5.
Installation
Accelerator pedal module mounting nut:

12.8 ~ 15.7 N.m (1.3 ~ 1.6 kgf.m, 9.4 ~ 11.6 lb-ft)
Accelerator pedal module mounting bolt:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
1.
Kia Soul: Fuel Tank Pressure Sensor (FTPS). Description and Operation
Description
Fuel Tank Pressure Sensor (FTPS) is a component of the evaporative emission control system and is installed on the fuel tank, the fuel
pump, or the canister. It checks the purge control solenoid valve operation and detects a leakage of the system.
114
Kia Soul: Fuel Tank Pressure Sensor (FTPS). Specifications

Specification
Pressure [kPa (kgf/cm², in H2O) Output Voltage (V)
-6.67 (-0.068, -26.8) 0.5
0 2.5
+6.67 (0.068, 26.8) 4.5
Kia Soul: Fuel Tank Pressure Sensor (FTPS). Schematic Diagrams

Circuit Diagram
(M/T)
115
(A/T)
Kia Soul: Fuel Tank Pressure Sensor (FTPS). Repair procedures

Inspection
Measure the output voltage of the FTPS.

2.
Removal
2. Remove the rear seat cushion.
3. Remove the fuel pump service cover (A).
116
4. Disconnect the fuel tank pressure sensor connector (A).
Remove the fuel tank pressure sensor (B) after releasing the hooks vertically.
5.
Installation

• Insert the sensor in the installation hole and be careful not to damage when installation.
117
Kia Soul: Injector. Description and Operation

Description
The GDI injector is similar to a standard injector, but sprays fuel at a much higher pressure directly into the combustion chamber and has a
swirl disc to get the fuel swirling as it exits the nozzle. This aids in atomization of the fuel.The ECM controls both the feed circuits (high side)
to feed voltage to the injectors and the ground circuits (low side) to energize the injectors. Also, the feed for 2 injectors comes from the same
driver set. As the ignition coils are paired with cylinders (1-4 and 2-3), the injectors are also set up in pairs.
Kia Soul: Injector. Specifications

Specification
Item Specification
Coil Resistance (Ω) 1.5 ± 0.075 [20°C(68°F)]
Kia Soul: Injector. Troubleshooting

Signal Waveform
The three waveforms below are taken from the #1 and #4 injectors. The top waveform is from the high side (feed side) of the #1 and #4
injectors, while the middle waveform is from the low side (ground side) of the #1 injector and the bottom waveform is from the low side of the
#4 injector.
The middle waveform is the same as the top waveform because there is no ground for the circuit. With no current flowing in the circuit, the #1
injector is not energized and fuel does not flow.
The bottom waveform shows that ground is supplied and there is a voltage drop across the #4 injector. With current flowing in the circuit, the
#4 injector is energized and fuel flows.
118
Kia Soul: Injector. Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
119
120
Kia Soul: Injector. Repair procedures

Inspection
2. Disconnect the injector connector.
3. Measure resistance between the injector terminals 1 and 2.

4.
Removal
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may
be injury caused by leakage of the high pressure fuel. Before repairing the high pressure system, be sure to
release the residual pressure in fuel line as step 2 in below procedure.
Release the residual pressure in fuel line.

2. (Refer to Fuel Delivery System - Repair Procedures - "Release Residual Pressure in Fuel Line")
Remove the delivery pipe & injector assembly

3. (Refer to Fuel Delivery System - "Delivery Pipe")
Disconnect the injector connector (A)
4.
Remove the fixing clip (A), and then and then separate the injector (B) from the delivery pipe.
5.
Installation
121
1. Combustion seal
2. Rubber washer
3. Support disc
4. O-ring
• Do not reuse the used injector fixing clip.

• Apply engine oil to the injector O-ring.

• Do not reuse the used injector O-ring.
• Do not reuse the used bolt.
• When inserting the injector, be careful not to damage the injector tip.
• Do not reuse the support disc.

• Do not reuse the injector rubber washer.
When replacing the rubber washer, the steal plate (A) part should be faced the cylinder installation part and the rubber
• plate (B) part should be faced the injector body part.
122
• Do not reuse the combustion seal.

Replacement
The injector combustion seal should be replaced new one to prevent leakage after removing the injector.
Remove the combustion seal (A) with a wire cutter.
Grip the sealing ring carefully, pull it to form a small loop and then cut it.
1. Be careful not to damage the surface of the valve sleeve with the wire cutter.
Before the assembly of the sealing ring the groove must be cleaned using a clean cloth.
Any coking of the injector sealing surface must be carefully removed with a brass-wire brush.
2.
123
The surfaces of the new sealing ring must be clean and free of grease.
Place the seal installing guide (B) (SST No.: 09353-2B000) on the tip of the injector not to damage the injector tip
(A).
Push the sealing ring (C) with thumb and index finger over the conical assembly tool until it snaps into the
groove.
The complete assembly must not take longer than 2 to 3 seconds.
3.
To size the sealing ring the injector is first introduced into the sizing tool (A) (SST No.: 09353-2B000) and then
pressed and at the same time rotated 180° into the sizing tool.
4.
Pull the injector out of the sizing tool by turning it in the reverse direction to that used for the press-in process.
5. Check that the seal ring has not been damaged during assembly to the injector and that no circumferential scratches
124
are present.
Do not reuse the combustion seal.
The seal must be completely free of grease and oil.
Check the combustion seal (A) installation.
6.
Kia Soul: Purge Control Solenoid Valve (PCSV). Description and Operation
Description
Purge Control Solenoid Valve (PCSV) is installed on the surge tank and controls the passage between the canister and the intake manifold.
It is a solenoid valve and is open when the ECM grounds the valve control line. When the passage is open (PCSV ON), fuel vapor stored in
the canister is transferred to the intake manifold.
Kia Soul: Purge Control Solenoid Valve (PCSV). Specifications

Specification
Item Specification
125
Kia Soul: Purge Control Solenoid Valve (PCSV). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
126
Kia Soul: Purge Control Solenoid Valve (PCSV). Repair procedures

Inspection
2. Disconnect the PCSV connector.
3. Measure resistance between the PCSV terminals 1 and 2.

4.
Removal
2. Disconnect the purge control solenoid valve connector (A).
3. Disconnect the vapor hoses (B) from the purge control solenoid valve.
Remove the purge control solenoid valve (C).
4.
127
Installation

• Use care to keep foreign material out of the valve.
Kia Soul: CVVT Oil Control Valve (OCV). Description and Operation
Description
Continuous Variable Valve Timing (CVVT) system advances or retards the valve timing of the intake and exhaust valve in accordance with
the ECM control signal which is calculated by the engine speed and load.
By controlling CVVT, the valve over-lap or under-lap occurs, which makes better fuel economy and reduces exhaust gases (NOx, HC) and
improves engine performance through reduction of pumping loss, internal EGR effect, improvement of combustion stability, improvement of
volumetric efficiency, and increase of expansion work.
This system consist of
-the CVVT Oil Control Valve (OCV) which supplies the engine oil to the cam phaser or cuts the engine oil from the cam phaser in accordance
with the ECM PWM (Pulse With Modulation) control signal,
- the CVVT Oil Temperature Sensor (OTS) which measures the engine oil temperature,
-and the Cam Phaser which varies the cam phase by using the hydraulic force of the engine oil.
The engine oil getting out of the CVVT oil control valve varies the cam phase in the direction (Intake Advance/Exhaust Retard) or opposite
direction (Intake Retard/Exhaust Advance) of the engine rotation by rotating the rotor connected with the camshaft inside the cam phaser.
Kia Soul: CVVT Oil Control Valve (OCV). Specifications

Specification
Item Specification
128
Kia Soul: CVVT Oil Control Valve (OCV). Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
129
Kia Soul: CVVT Oil Control Valve (OCV). Repair procedures

Inspection
2. Disconnect the OCV connector.
3. Measure resistance between the OCV terminals 1 and 2.

4.
Removal
2. Disconnect the CVVT oil control valve connector (A).
Remove the mounting bolt (B), and then remove the valve from the engine.
3. [Bank 1 / Intake]
130
[Bank 1 / Exhaust]
Installation

• Apply engine oil to the valve O-ring.
CVVT oil control valve installation bolt:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
1.
131
Kia Soul: Variable Intake Solenoid (VIS) Valve. Description and Operation
Description
Variable Intake manifold Solenoid (VIS) valve is installed on the intake manifold. The VIS valve controls the vacuum modulator which
activates a valve in the intake manifold. The ECM opens or closes this valve according to engine condition (Refer to below table).
Engine condition VIS valve Operation
Increasing engine performance in low engine speed by reducing

Medium speed Closed intake interference among cylinders
Minimizing intake resistance by shortening intake manifold length and

Low / High speed Open increasing area of air entrance
132
Kia Soul: Variable Intake Solenoid (VIS) Valve. Specifications

Specification
Item Specification
Coil resistance (Ω) 30.0 ~ 35.0 [20°C(68°F)]
Kia Soul: Variable Intake Solenoid (VIS) Valve. Schematic Diagrams

Circuit Diagram
(M/T)
(A/T)
133
Kia Soul: Variable Intake Solenoid (VIS) Valve. Repair procedures

Inspection
2. Disconnect the VIS valve connector.
Measure resistance between VIS valve terminals 1 and 2.

3.
Removal
2. Disconnect the variable intake solenoid valve connector (A).
3. Disconnect the vacuum hoses (B) from the valve.
Remove the valve (C) from the surge tank.
4.
Installation
134

• Use care to keep foreign material out of the valve.
Kia Soul: Fuel Pressure Control Valve. Description and Operation

Description
Fuel Pressure Regulator Valve is installed on the high pressure fuel pump and controls fuel flow flowing into the injectors in accordance with
the ECM signal calculated based on various engine condition.
Kia Soul: Fuel Pressure Control Valve. Specifications

Specification
Item Specification
Coil Resistance (Ω) 0.47 ~ 0.51 [20°C(68°F)
135
Kia Soul: Fuel Pressure Control Valve. Troubleshooting

Signal Waveform
136
Kia Soul: Fuel Pressure Control Valve. Schematic Diagrams

Circuit Diagram
(M/T)
137
(A/T)
Kia Soul: Fuel Pressure Control Valve. Repair procedures

Inspection
2. Disconnect the fuel pressure regulator valve connector.
3. Measure resistance between the fuel pressure regulator valve terminals 1 and 2.

4.
Removal
Refer to Fuel Delivery System - "High Pressure Fuel Pump"
Installation
Refer to Fuel Delivery System - "High Pressure Fuel Pump"
138
Kia Soul: Canister Close Valve (CCV). Description and Operation

Description
Canister Close Valve (CCV) is normally open and is installed on the canister ventilation line. It seals evaporative emission control system by
shutting the canister from the atmosphere during EVAP leak detection process.
Kia Soul: Canister Close Valve (CCV). Specifications

Specification
Item Specification
Coil Resistance (Ω) 19.5 ~ 22.5 [20°C(68°F)
Kia Soul: Canister Close Valve (CCV). Schematic Diagrams

Circuit Diagram
(M/T)
139
(A/T)
Kia Soul: Canister Close Valve (CCV). Repair procedures

Inspection
2. Disconnect the CCV connector.
3. Measure resistance between the CCV terminal 1 and 2.

4.
5. Disconnect the vapor hose connected with the canister from the CCV.
6. Connect a vacuum pump to the nipple.
7. Ground the CCV control line and apply battery voltage to the CCV power supply line.
Apply vacuum and check the valve operation.
Specification: Vacuum maintained

8.
Removal
3. Disconnect the canister close valve connector (A).
4. Disconnect the ventilation hose (B) from the canister close valve.
5. Remove the canister close valve (C) after removing the bolts.
140
Installation

141
Kia Soul: Fuel Delivery System
 Components and Components Location

 Repair procedures
 Fuel Tank. Repair procedures
 Fuel Pump. Repair procedures
 Fuel Filter. Repair procedures
 Fuel Pump Motor. Repair procedures
 Fuel Sender. Repair procedures
 Fuel Pressure Regulator. Repair procedures
 Fuel Line. Repair procedures
 Filler-Neck Assembly. Repair procedures
 Accelerator Pedal. Repair procedures
 Delivery Pipe. Repair procedures
 High Pressure Fuel Pump. Repair procedures
142
Kia Soul: Components and Components Location

Components Location
[Fuel Tank]
1. Fuel tank 8. Fuel tank pressure sensor (FTPS)

2. Fuel pump 9. Canister close valve (CCV)
3. Fuel filter 10. Fuel level sender (FLS)
4. Fuel pressure regulator 11. Fuel filler hose
5. Canister 12. Ventilation tube
6. Fuel tank air filter 13. Vapor tube
7. Fuel tank band 14. Fuel pump plate cover
[Fuel Pump Assembly]
143
1. Head Assembly
2. Fuel Filter 6. Reservoir-cup
3. Fuel Pressure Regulator 7. Fuel Sender
4. Fuel Pump Motor 8. 2-Way & Cut Valve
5. Pre-filter 9. ORVR Valve
[High Pressure Fuel Line]
144
1. High Pressure Fuel Pump 3. Delivery Pipe

2. High Pressure Fuel Pipe 4. Injector
be injury caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.
145
Kia Soul: Repair procedures

Fuel Pressure Test (Low pressure system)
Residual Pressure in Fuel Line").
When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS
1. after completion of “Release Residual Pressure in Fuel Line” work.
Install the Special Service Tool (SST).

Disconnect the low pressure fuel feed tube from the low pressure inlet of high pressure fuel pump.
There may be some residual pressure even after “Release Residual Pressure in Fuel Line” work, so cover the
hose connection with a shop towel to prevent residual fuel from spilling out before disconnecting any fuel
(1) connection.
Install the special service tool for measuring the fuel pressure in between the low fuel feed tube and the low pressure
inlet of high pressure fuel pump (Refer to the figure below).
2. (2)
Inspect fuel leakage on connections among the low fuel feed tube, the low pressure inlet of high pressure fuel
3. pump, and the SST components with IG ON.
Measure Fuel Pressure.

Start the engine and measure the fuel pressure at idle.
Fuel Pressure: 480 ~ 520 kPa (4.89 ~ 5.30 kgf/cm², 69.6 ~ 75.4 psi)
If the fuel pressure differs from the standard value, repair or replace the related part (Refer to the table below).
Fuel
Pressure Cause Related Part
Fuel filter clogged Fuel Filter
Too Low Fuel leakage Fuel Pressure Regulator
(1) Too High Fuel pressure regulator stuck Fuel Pressure Regulator
Stop the engine, and then check for the change in the fuel pressure gauge reading.
Standard Value: The gauge reading should hold for about 5 minutes after the engine stops
4. (2)
146
If the gauge reading should not be held, repair or replace the related part (Refer to the table below).
Fuel Pressure Related

(After Engine Stops) Cause Part
Fuel Pressure Drops Slowly Leakage on injector Injector
Fuel Pressure Drops Immediately Check valve of fuel pump stuck open Fuel Pump
(3) Turn the ignition switch OFF.
When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS
Test End
Remove the Special Service Tool (SST) from the low pressure fuel feed tube and the low pressure inlet of high
(1) pressure fuel pump.
6. (2) Connect the low pressure fuel feed tube and the low pressure inlet of high pressure fuel pump.
Release Residual Pressure in Fuel Line
Whenever the high pressure fuel pump, fuel pipe, delivery pipe, or injector is removed immediately after shutting
off the engine, an injury may be caused by the release of highly pressurized fuel. Release the residual pressure
in the high pressure fuel line by referring to the "Residual fuel pressure release procedure" below before
removing any high pressure fuel system components.
Wear safety glasses and fuel resistant gloves.
1. Turn the ignition off and disconnect the battery negative cable.
Remove the fuel pump fuse (A).
2.
3. Disconnect the electrical connector from the high pressure fuel pump.
4. Reconnect the battery negative cable.
Run the engine for about 20 seconds to lower the pressure in both the high or low pressurelines. The engine
5. may shut off within the 20 second period. If not, turn the engine off.
6. Proceed with the service or repair. Use rags to cover opening and catch spills when opening up the high
147
pressure system.
Reinstall / re-connect all components in reverse order of removal. Start engine and confirm proper operation, and
7. make sure there are no fuel leaks.
8. After completing, clear DTC(s) using GDS scan tool (the procedure described above will cause DTC to set).
Kia Soul: Fuel Tank. Repair procedures

Removal
2. Remove the rear seat cushion.
Remove the fuel pump service cover (A).
3.
4. Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B).
Disconnect the fuel feed tube quick connector (C).
5.
6. Lift the vehicle and support the fuel tank with a jack.
7. Disconnect the center muffler hangers (A).
148
Disconnect the fuel filler hose (A).
8.
Disconnect the vapor tube quick-connector (A).
9.
10. Remove the parking brake cable RH bracket mounting bolts (A) to obtain space for removing the fuel tank.
149
Remove the fuel tank from the vehicle after removing the fuel tank band (A).
11.
Installation
1. Fuel tank band mounting bolt: 39.2 ~ 54.0 N.m (4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lb-ft)
Kia Soul: Fuel Pump. Repair procedures

Inspection
[Fuel pump]
1. Turn ignition switch OFF and disconnect the negative (-)battery cable.
2. Remove the fuel pump assembly.
Check that motor operates properly when applying battery voltage to terminals 2 and 4 of fuel pump connector
(A).
3.
150
Pin No. discription

1 Fuel sender signal
2 Fuel pump (+)
3 Fuel sender ground
4 Fuel pump (-)
[Fuel sender]
1. Turn ignition switch OFF and disconnect the negative (-)battery cable.
2. Remove the fuel pump assembly.
Using an ohmmeter, measure the resistance between terminals 1 and 3 of sender connector (A) at each float
level.
Pin No. discription

1 Fuel sender signal
2 Fuel pump (+)
3 Fuel sender ground
3. 4 Fuel pump (-)
Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position Resistance (Ω) Capacity (ℓ)
E 197 ~ 203 4.3
1/2 64.2 ~ 68.2 26.4
4. F 6 ~ 10 51.3
Removal
2. Remove the rear seat.
3. Remove the fuel pump service cover (A).
151
4. Disconnect the fuel pump connector (A) and the fuel tank pressure sensor connector (B).
5. Disconnect the fuel feed tube quick connector (C) and the vapor tube quick-connector (D).
Remove the plate cover (E) after removing the mounting bolts.
6.
Remove the fuel pump from the fuel tank.
7.
Installation
Be careful of fuel pump direction when installing (Refer to the groove in the fuel tank).
1. Fuel pump plate cover mounting bolt : 2.0 ~ 3.0 N.m (0.2 ~ 0.3 kgf.m, 1.4 ~ 2.2lb-ft)
152
Kia Soul: Fuel Filter. Repair procedures

Removal
1. Remove the fuel pump. (Refer to Fuel Delivery System - "Fuel Pump")
Disconnect the electric pump wiring connector (A) and the fuel sender connector (B).
2.
Remove the head assembly (A) after releasing the cushion fixing clip (B).
3.
Disconnect the fuel tube connector (A).
4.
5. Remove the reservior-cup (B) after releasing the fixing hooks (A).
153
6. Disconnect the fuel tube quick-connector (A).
Release the fixing hooks, and then remove the pre-filter (B).
7.
Remove the fuel pressure regulator (A) and fuel pump motor (B).
8. Be careful of O-ring
Installation
154
Kia Soul: Fuel Pump Motor. Repair procedures

Removal
2.
3.
4.
5. Remove the reservior-cup (B) after releasing the fixing hooks (A).
155
Release the fixing hooks, and then remove the pre-filter (B).
7.
Remove the fuel pump motor (A).
Installation
156
Kia Soul: Fuel Sender. Repair procedures

Removal
2.
Remove the fuel sender (A) in the direction of an arrow.
3.
Installation
Kia Soul: Fuel Pressure Regulator. Repair procedures

Removal
2.
157
3.
4.
Remove the reservior-cup (B) after releasing the fixing hooks (A).
5.
7. Release the fixing hooks, and then remove the pre-filter (B).
158
Remove the fuel pressure regulator (A).
Installation
159
Kia Soul: Fuel Line. Repair procedures
Removal
• Be careful not to damage the fuel line during repair.
[Low pressure fuel line]
Release the residual pressure in fuel line. (Refer to the Fuel Delivery System - Repair Procedures - "Release
2. Residual Pressure in Fuel Line")
3. Remove the fuel tank. (Refer to Fuel Delivery System - "Fuel tank")
Open the low pressure fuel tube clip (A).
4.
Release the low pressure fuel quick-connector (A) using the clip remover (B).
5. When removing the low pressure fuel quick-connector, use a clip remover as shown in the image below.
160
Disconnect the vapor hose (A) and low pressure fuel quick-connector (B).
6.
Remove the under cover LH (A).
8.
9. Remove the under cover RH (A).
161
Remove the front muffler mounting nuts (A)
10.
11. Remove the center muffler and rear muffler.
Remove the rear heat protector (A).
12.
13. Remove the front heat protector (A).
162
Remove the low pressure fuel tube climp mounting nut (A).
Fuel tube clamp mounting nut : 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
14.
Unclip the fuel feed tube (A) and vapor tube (B) holders using a flat-head screwdriver.
15.
16. Open the holder (A)
163
Remove the fuel line (A) from the vehicle,
17.
[High pressure fuel line]
Release the residual pressure in fuel line. (Refer to the Fuel Delivery System - Repair Procedures - "Release
3. Disconnect the Engine Coolant Temperature Sensor connector (A).
164
4. Disconnect the ignition coil connector (A) and CMPS connector (B).
Unfasten the harness bracket (C) and Make a gap for removing high pressure fuel pipe by moving the bracket
(C).
5.
6. Remove the vacuum pipe mounting bolt (A)
7. Remove the vacuum pipe & high pressure fuel pipe function block mounting bolt (B).
Remove the high pressure fuel pipe flang nut ( C).

High pressure fuel pipe flang nut: 26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft) High pressure fuel pipe function
block mounting bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
8.
Remove the high pressure fuel pipe flang nut from the high pressure fuel pump with the special service tool
(A).[SST No.: 09314-3Q100 or 09314-27130]
9. High pressure fuel pipe flang nut: 26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft)
165
Remove the high pressure fuel pipe (A).
10.
Installation
166
Kia Soul: Filler-Neck Assembly. Repair procedures

Removal
Open the fuel filler door and unfasten the filler-neck assembly mounting bolts (A).
1.
2. Lift the vehicle
Remove the left rear wheel & tire and the wheel guard (A).
3.
4. Disconnect the fuel filter hose (A) and the ventilation hose (B).
Remove the filler-neck assembly from the vehicle after removing the bracket mounting bolt (C).
5.
Installation
167
Kia Soul: Accelerator Pedal. Repair procedures

Removal
1. Turn the ignition switch OFF and disconnect the negative (-) battery cable.
2. Disconnect the accelerator position sensor connector (A).
Remove the mounting nuts (B).
3.
Remove the cap (A)
4.
Remove the mounting bolt (A), and then remove the accelerator pedal module.
5.
installation
Accelerator pedal module mounting nut: 12.8 ~ 15.7 N.m (1.3 ~ 1.6 kgf.m, 9.4 ~ 11.6 lb-ft) Accelerator pedal module
1. mounting bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
168
Kia Soul: Delivery Pipe. Repair procedures

Removal
When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS
Disconnect the injector & RPS extension connector (A).
3.
4. Remove the intake manifold. (Refer to Engine Mechanical System - "Intake Manifold")
5. Remove the drive belt. (Refer to Engine Mechanical System - "Drive Belt")
6. Disconnect the alternator connector (A) and OCV connector (B)
Make a gap between the alernator (C) and the eninge assembly by pulling the alternator in the direction of arrow.
7.
8. Remove the injector foam (A).
169
Remove the high pressure fuel pipe (A) after loosen the flang nuts (B) and mounting bolt (C).
High pressure fuel pipe flang nut: 26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft) High pressure fuel pipe function
block mounting bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
9.
Remove the mounting bolts (A), and then remove the delivery pipe & injector assembly from the engine.
Delivery pipe mounting bolt : 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
10.
11. Disconnect the injector connector (A)
170
Remove the fixing clip (A), and then and then separate the injector (B) from the delivery pipe.
12.
Installation
• Do not use already used injector fixing clip again.
• Do not reuse the support disc.

• Do not reuse the injector rubber washer.
• Do not reuse the combustion seal.

• Apply engine oil to the injector O-ring.

• Do not use already used injector O-ring again.
• Do not use already used bolt again.
171
• When insert the injector, be careful not to damage the injector tip.
Kia Soul: High Pressure Fuel Pump. Repair procedures

Removal
When removing the fuel pump fuse, a Diagnostic Trouble Code (DTC) may occur. Delete the code with the GDS
3. Remove the high pressure fuel pump form
Disconnect the fuel pressure control valve connector (A).
4.
Open the low pressure fuel tube clip (A).
5.
6. Release the low pressure fuel quick-connector (A) using the clip remover (B).
172
When removing the low pressure fuel quick-connector, use a clip remover as shown in the image below.
7. Remove the high pressure fuel pipe. (Refer to Fuel Delivery System - "Fuel Line - High pressure fuel line")
Remove the installation bolts (A), and then remove the high pressure fuel pump from the cylinder head
assembly.
Unscrew in turn the two bolts in small step (0.5 turns). In case of fully unscrewing one of the two bolts with the other
bolt installed, the housing surface of the cylinder head may be broken because of tension of the pump spring.
8.
Installation
173
Be sure to check the low pressure fuel hose quick-connector (A) is completely connected to the high pressure fuel
• pump until a confirmation 'click' sound is heard.
Be sure to re-check the low pressure fuel hose is completely connected to the high pressure fuel pump by pulling it
• after connecting.
• Be sure to install the high pressure fuel pipe (B) with the specified torques.
• Because fuel leak may cause fire, securely Inspect leakage of all fuel line connection parts at engine start condition.
Before installing the high pressure fuel pump, position the roller tappet in the lowest position by rotating the
• crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.
• Do not reuse the used bolt.
• Do not reuse the used high pressure fuel pipe.
When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns)
• after tightening them with hand-screwed torque.

First hand-tighten the fasteners fully until they are not fastened any more in order to have them inserted in place and
then completely tighten to the specified torque using a torque wrench. If not tightening the bolts or nuts in a straight
• line with the mating bolt holes or fittings, it may cause a fuel leak due to broken threads.
Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also
• apply engine oil to the groove on the location where the protrusion (C) is installed.
174
Use the special service tool [SST No.: 09314-3Q100 or 09314-27130] to install the high pressure fuel pipe.
High pressure fuel pump mounting bolt: 12.8 ~ 14.7 N.m (1.3 ~ 1.5 kgf.m, 9.4 ~ 10.9 lb-ft) High pressure fuel pipe flang
nut: 26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft) High pressure fuel pipe function block mounting bolt: 9.8 ~ 11.8
1. N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
175

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Kia Soul: Emission Control System

Kia Soul: Specifications

Coil Resistance (Ω) 22.0 ~ 26.0 [20°C(68°F)]

Fuel Tank Pressure Sensor (FTPS)

-6.67 (-0.068, -26.8) 0.5

+6.67 (0.068, 26.8) 4.5

Canister Close Valve (CCV)

Coil Resistance (Ω) 15.5 ~ 18.5 [20°C(68°F)]

Kia Soul: Components Location

1. PCV valve 5. Canister close valve (CCV)

4. Fuel tank pressure sensor (FTPS) 8. Catalytic converter (WCC + UCC)

1. PCV valve 2. Canister

5. Canister Close Valve (CCV)

8. Catalytic converter (WCC) 8. Catalytic converter (UCC)

Kia Soul: Description

Kia Soul: Schematic Diagram

Kia Soul: Troubleshooting

Symptom Suspect area

Engine struggles to start Malfunction of the Purge Control Solenoid Valve

Vapor hose damaged or disconnected

Rough idle or engine stalls Malfunction of the PCV valve

Rough idle Malfunction of the Evaporative Emission Control System

Excessive oil consumption Positive crankcase ventilation line clogged

Kia Soul: Crankcase Emission Control System

Kia Soul: Schematic Diagram

Kia Soul: Inspection

2. Reconnect the PCV valve to the vapor hose.

Kia Soul: Positive Crankcase Ventilation (PCV) Valve Operation Principle

Kia Soul: Positive Crankcase Ventilation (PCV) Valve Removal

Remove the PCV valve (B).

Kia Soul: Positive Crankcase Ventilation (PCV) Valve Inspection

Kia Soul: Positive Crankcase Ventilation (PCV) Valve Installation

Kia Soul: Evaporative Emission Control System

Kia Soul: Description

Kia Soul: Operation

Evaporative And ORVR Emission Control System

1. Fuel Filler Cap

Kia Soul: Schematic Diagram

Kia Soul: Components Location

1. Purge Control Solenoid Valve (PCSV)

Kia Soul: Inspection

[EVAP. Leakage Test]

Select "Evap. Leakage Test".

Kia Soul: Canister Removal

Remove the canister assembly.

Kia Soul: Canister Inspection

Kia Soul: Canister Installation

Canister mounting bolt:

Kia Soul: On-board Refueling Vapor Recovery (ORVR) valve Removal

Remove the fuel pump.

3. Remove the ORVR (A) after releasing hooks (B).

Kia Soul: On-board Refueling Vapor Recovery (ORVR) valve Installation

Kia Soul: Fuel Filler Cap Description

Kia Soul: Fuel Tank Air Filter Removal

2. Lift the vehicle.

3. Disconnect the canister close valve connector (A).

4. Disconnect the ventilation hose (B).

Kia Soul: Fuel Tank Air Filter Installation

• Install the component with the specified torques.