Kia - Spectra - Workshop Manual - (2005)

GROUP VOLUME Engine 3 MODEL Spectra NUMBER 021 DATE January 2005 TECHNICAL SERVICE BULLETIN SUBJECT: 2002-2004 SPECTRA ECM UPGRADE This bulletin provides information related to a Spectra 1.8L Engine Control Module (ECM) upgrade. Some 2002 through 2004MY Spectra 1.8L vehicles built between 5/14/01 and 6/1/04 may experience a Malfunction Indicator Lamp (MIL) condition with DTC P0121. Use the procedure in this bulletin to reprogram the (ECM) software for 2002 through 2004MY Spectra 1.8L vehicles with the DTC P0121 concern. Note: The 2002-2004 Spectra ECM Upgrade should only be performed on Spectra vehicles when the vehicle exhibits the conditions described in this Technical Service Bulletin. ROM ID INFORMATION TABLE: Model Affected ECM P/N ECM ROM ID 0K2NA 18881 Previous F2D8NS3C New F2D8NS5C 0K2NA 18881A F2D8NS4C F2D8NS6C Spectra 03MY 39111 2Y610 F3D8NS1C F3D8NS2C Spectra 04MY 39111 2Y620 F4D8NS0C F4D8NS1C Spectra 02MY Use the 32MB blue reprogramming card that was sent to your dealer October 2004. Download the latest Hi-Scan Pro reprogramming software for the 32MB (blue label) reprogramming card from the Kia Service Information System (KSIS). The “Downloads” page is accessed by first logging onto KSIS, then by clicking on the “Downloads” link located in the left-hand navigation frame. Dealers can also order a CD (optional) by calling 866 KIA-TOOLS and ordering P/N 111220BC. BEFORE STARTING THE PROCEDURE: Check the production date on the FMVSS door label to make sure that the vehicle is within the correct production range. File Under: Engine Circulate To: X General Manager X Service Advisor(s) X Technician(s) X Service Manager X Body Shop Manager X Parts Manager Fleet Repair Page 2 of 7 SUBJECT: 2002-2004 SPECTRA ECM UPGRADE NOTICE • • • • • • • A fully charged battery is necessary before reprogramming can take place. DO NOT connect a battery charger to the vehicle during reprogramming. Make sure the blower motor is ‘OFF’ during programming. All reprogramming must be done with the ignition key in the ‘ON’ position. Be careful not to disconnect any cables connected to the vehicle or Hi-Scan Pro during the reprogramming procedure. DO NOT start the engine during reprogramming. DO NOT turn the ignition key ‘OFF’ or interrupt the power supply during reprogramming. When the reprogramming is completed, turn the ignition key ‘OFF’ and wait 20 seconds before starting the engine. ONLY use approved reprogramming software designated for the correct model, year and engine size. Failure to do so may create other drivability issues due to the use of the incorrect ECM/PCM calibration. AUTOMATIC REPROGRAMMING PROCEDURE: OBD II Cable 1. Connect the DLC cable to the Hi-Scan Pro main body and tighten the 2 bolts securely. 2. Remove the current system software card from the Hi-Scan Pro and insert the 32MB blue label reprogramming sofware card with the ECU program into the Hi-Scan Pro top slot. 3. Plug the DLC cable from the Hi-Scan into the data link connector located under the dash on the driver’s side as shown. OBD II Connector Location TSB: Engine 021 January 2005 Page 3 of 7 SUBJECT: 2002-2004 SPECTRA ECM UPGRADE 4. Turn the ignition key to the "ON" position. 5. Turn the Hi-Scan Pro on and press "ENTER." ITEM SELECTION 20.MS 2.7 INTERMITTENT HESITATION. 21.SPECTRA 1.8 02-04MY TPS MODIFY. NOTICE Do NOT interrupt the reprogramming at any time. The ECM may be rendered inoperative if the software does not download completely. 6. Select option "21.SPECTRA 1.8 02-04MY TPS MODIFY." and press ENTER . 7. Select option "01.SPECTRA 02-04MY TPS MODIFY [AUTO MODE] and press "ENTER." 22. RIO 1.6D 04MY MAF SENSOR IMPROVE. 23. SOFTWARE DOWNLOAD. F1 : CARD INFORMATION SPECTRA RE-PROGRAMMING 01. 1.8 02-04MY TPS MODIFY [AUTO MODE] 02. 1.8 02-04MY TPS MODIFY [ERROR MODE] F1 : MODULE INFORMATION 8. Enter "0525" as the password for automatic reprogramming mode and press "ENTER." SPECTRA RE-PROGRAMMING 01. 1.8 02-04MY TPS MODIFY [AUTO MODE] 02. 1.8 02-04MY TPS MODIFY [ERROR MODE] ENTER YOUR PASSWORD : 0525 F1 : MODULE INFORMATION TSB: Engine 021 January 2005 Page 4 of 7 SUBJECT: 2002-2004 SPECTRA ECM UPGRADE 9. The Hi-Scan Pro will reprogram the ECM automatically. (See the “ROM ID Information Table” on the front page for the previous and new ECM IDs) RE-PROGRAMMING F_D8NS_C _ F_D8NS_C DOWNLOAD DONE! PROGRAM DOWNLOAD 10. When "REPROGRAMMING COMPLETED" message is displayed; press ENTER and turn off the ignition for 20 seconds. RE-PROGRAMMING 11. Start engine to check for proper operation. 12. Check for diagnostic trouble codes (DTCs) using the Hi-Scan Pro with system software card. Erase any diagnositic trouble codes. For automatic transaxle equipped vehicles, both the engine and transaxle section DTCs must be checked. Note: Refer to ECM Reprogramming Troubleshooting section on Page 7 if the download does not work properly. TSB: Engine 021 January 2005 RE-PROGRAMMING COMPLETED ! IGNITION KEY OFF! F1 : CARD INFORMATION Page 5 of 7 SUBJECT: 2002-2004 SPECTRA ECM UPGRADE MANUAL UPDATE PROCEDURE: If menu option "01.1.8 02-04MY MODIFY [AUTO MODE]" fails to download the new program, option "02.1.8 02-04MY TPS MODIFY [ERROR MODE]" must be used. Confirm all connections are established as shown, in the "AUTOMATIC UPDATE PROCEDURE" before continuing. 1. Turn the ignition key to the ON position. 2. Turn the Hi-Scan Pro ON and press "ENTER." ITEM SELECTION 20.MS 2.7 INTERMITTENT HESITATION. 21.SPECTRA 1.8 02-04MY TPS MODIFY. NOTICE 22. SOFTWARE DOWNLOAD. Do NOT interrupt the reprogramming at any time. The ECM may be rendered inoperative if the software does not download completely. 3. Select option "21.SPECTRA 1.8 02-04MY TPS MODIFY" and press "ENTER." 4. Select option "02.1.8 02-04MY TPS MODIFY [ERROR MODE]" for manual upgrade and press "ENTER." F1 : CARD INFORMATION SPECTRA RE-PROGRAMMING 01. 1.8 02-04MY TPS MODIFY [AUTO MODE] 02. 1.8 02-04MY TPS MODIFY [ERROR MODE] F1 : CARD INFORMATION TSB: Engine 021 January 2005 Page 6 of 7 SUBJECT: 2002-2004 SPECTRA ECM UPGRADE 5. Select the proper menu number by looking at the vehicle ECM label for the ECM part number (use mirror to see ECM label in vehicle). Compare the vehicle ECM part number to the part numbers in menu 01 through 04. Select the proper menu number and press "ENTER". 6. Enter the password according to each vehicle’s ECM part number and year for the manual upgrade and press "ENTER." SPECTRA RE-PROGRAMMING 01. SPECTRA 1.8 02 MY : 0K2NA 18881 02. SPECTRA 1.8 02 MY : 0K2NA 18881A 03. SPECTRA 1.8 03 MY : 39111 2Y610 04. SPECTRA 1.8 04 MY : 39111 2Y620 ENTER YOUR PASSWORD ECM P/N Password 0K2NA 18881 0K2NA 18881A 39111 2Y610 39111 2Y620 8881 8816 2610 2620 : **** F1 : MODULE INFORMATION NOTICE Be sure to input the correct password. If an incorrect password is selected, the correct ECM software will NOT be downloaded. 7. Check the new ECM ID displayed and verify that the correct ECM software has been downloaded by referencing the “ROM ID Information Table” on Page 1. RE-PROGRAMMING FORCED _ DOWNLOAD DONE! PROGRAM DOWNLOAD TSB: Engine 021 January 2005 F_D8NS_C Page 7 of 7 SUBJECT: 2002-2004 SPECTRA ECM UPGRADE 8. When the "REPROGRAMMING COMPLETED" message is displayed, turn the Ignition key off, wait 20 seconds, and then start the engine to check for proper operation. 9. Check for diagnostic trouble codes (DTCs) using the Hi-Scan Pro with system software card. Erase any diagnostic trouble codes. For automatic transaxle equipped vehicles, both the engine and transaxle section DTCs must be checked. RE-PROGRAMMING RE-PROGRAMMING COMPLETED ! IGNITION KEY OFF! F1 : CARD INFORMATION ECM REPROGRAMMING TROUBLESHOOTING: • • • • • "INVALID PASSWORD" — Enter the correct password for the automatic update mode again (0525). "REPROGRAMMING ERROR PLEASE WAIT FOR RETRY" — An error occurred during reprogramming, the Hi-Scan Pro will retry the reprogramming automatically. "THIS ECM IS DIFFERENT TYPE" — The ECM on this vehicle is not the type subject to this reprogramming procedure. "ALREADY REPROGRAMMED" — The reprogramming has previously been done on this vehicle. "REPROGRAMMING ERROR PLEASE CHECK SYSTEM" —In this case, you must reprogram manually by selecting menu option "02. 1.8 02-04 MY TPS MODIFY [ERROR MODE]". AFFECTED PRODUCTION RANGE: 2002 - 2004MY Spectra 1.8L vehicles with production dates from 5/14/01 through 6/1/04. WARRANTY CLAIM INFORMATION: Claim Type Causal P/N Qty. Cond. Code Cause Code Repair Description Labor OP Code Time Related Parts Qty. W 0K2NA 18881 0K2NA 18881A 39111 2Y610 39111 2Y620 0 N03 C40 ECM Reprogramming 39110F13 0.3 N/A 0 TSB: Engine 021 January 2005