KIA Sportage 2000 ELECTRCAL TROUBLESHOOTING AND VACUUM HOUSE ROUTING MANUAL

2OOO
SPORTAGE
ELECTRICAL
TROUBLESHOOTI
NG
ANDVACUUMHOSEROUTING
MANUAL
CONTENTS
Air Conditioner:
. . . . .. . . 1 1 9
A / T C e a rS e l e c t i o lnn d i c a t o r . . . . . . . . . . . . . . .
ElectronicTime and Alarm
ControM
l odule......
Engine Coolant Temperature
F a \ l e nB e l l \ I n d r e r l { ) r . . . . . . . . . . . . . . . . .
C o n n e , . t oCrl a r s r f r e a l r o n . . . . . . . . . . . . . . . . . . . . . . .
lgnition Key Warning,FastenBelts Indicator,and Light On Waming. ......................
...
.........73
......2-13
..............73
(Continued)
CONTENTS
p r ' r z| , o h r .
SequentialMultiport Fuel Injection
r, nT nnHar
snPA't^mcrcr
\r rr u^Pn, t, ,Eo' i h' i r. .(. . . . . . . . . . . . .
............110-3
. . . . . . . . . . . . . . . .2. 5
.
"81-4
....... ...........110-2
. . . . . . . . . . . . . . . . . I. t. 0
.........
HOWTO USETHISMANUAL
Symbols
Normallyopen
switch
nt'ifft"""
f I
|
L -
.l
Only gart of
lcomponentshown,
| remaindershown
J elsewhere
PARKBRAKE<SWITCH
Closedwith
parkingbrake+on,
Multi-position
sw[cn
Component
name
Component
details
'lt
',
G--7->.
Ganged switch
conlac$
Dashedline shows
mechanical
connection-
Fuse
Relay,shown wilh no current
through relay coil. When current
Jlowsthrough coil, contactarm
changesposition.
Snowsvotlagers
ignilionin ON.
Solenoid
or coil
ldentitication
\
Current.ating
HOrnor
speaker
Circuit
Breaker
Ij
il-";-i
r-{F-----.1
Fusedesignation
L_(_:>iCurrenlrating
2
Indicator
light.
llluminates
a symbolor
(lnquotes.)
words(s).
i6***
i
r_L_____.i
SPORTAGE
Wireand
B L K. . . . . .. . . . . . . . .b l a c kconneclor
B L U. . . . . . . . . . . . . . b. .l u ecolors
B R N. . . . . . . . . . . . . .b. r o w n
uLH
[flr1f3:
. . . _ . . . . . ._ . ._ C t e a r
G R N . . . . . . . . . . . .g. r. e. e n
G R Y. . . . . . . . . . . . . .g. r. a y
L T B L .U. . . . . . . . . l i g h t b l u e
LTGRN. . . . . . . . lightgreen
O R G . . . . . . . . . . . .o. r. a n g e
P N K. . . . . . . . . . . . . . p. .i n k
R E D. . . . . . . . . . . . . . .r .e. d
W H T . . . . . . . . . . . . .w
. .h. i t e
Y E L . . . . . . . . . . . . .y. e
. .l l o w
Polentiometer
rsonecotor
ll wirernsularion
colorstripe.
I withanother
"'"'""
I fiflJ;;0,il[.,
I
Wavy line meansthe wire is
broken by the binding of the book
but continueson the nextpage.
-----S
fol"'"'
I A.,o*r"un.*',"
to anolher
I connects
andshowsthe
I circuit
flow.
direclion
of current
I
I
Diode.Posilive
currentflowsin
arrowdirection.
iscontinued
Circuit
whereindicaled;
arrowshowsdirection
llowandis
ol current
repeated
wherecircuit
continues.
2-1
HOWTO USE THIS MANUAL
V-:
Manual
Transmission
Dashedlinemeanscircuit
notshowncomplete,
bul is
completewhereindicaled.
I
-a
I
RFI(BadioFrequency
lntederence)
is
shielding
arounda wire.TheShielding
always
connecled
to ground.
I
!
F-|
Automalic
Transmission
Choicebracket.
Showsditt€rences
in wiringlor
opiions.
1 Componenicase
| groundedto vehicle.
t
l
L-J
G103
I
Wire attachedto
vehicleJorground.
vi:x:",
3
f\ """
G103
Connector
I
I
!
I
wireindirectly
connected
lo
ground;mayhaveoneor
moresplices
in line.
G103
,|--if"'r"{'l[$il,
I
|
r
.f..onn".,o.on
|
|
L-J
2-2
lead
| component
| (pigtait).
l
tlr"onn"oo,
I I
l{_4
L-i:r
lattachedlo
lcomponent.
^-t-
laa
l- G103
i*j
oashedhnereans
comorere
our''s
whereindicated
comPlele
Ground J0nctionConneclor.Wavy
linesmeanolhergroundcircuits
are connectedto sameground
point.SeeGroundDistribution
ior
complele representation.
SPORTAGE
CIRCUITSCHEMATICS
Each schematicis anangedso currentflows from power
at thetop of the pageLogroundar rhebottomof thepage.
The "HOT" labels(! at rhelop ol a fusetell you when
the ignition switch suppliespower to that fuse.
Each circuit is shown completely and independentlyin
one schematic.Othercircuitsgettingtheir power from the
samepoint, groundingat the samepoint, are not shown.
However, if other circuits actuallv share some wires.
thosewireswill be shownalso.
Wires that connectto anothercircuit are shown with an
anowheadpointinqrn the direction of currentflow. Next
to the arrowhead(!)is the nameof the circuit or componentthat sharesthat wiring. You can quickly checkshared
wiring by checkingthe operationof components.
"See
Power Distribution" @rn"unr there are more connections here to other circuits shown in the Power
Distribution schematic.
Groundsymbol (dot and 3 lines)@overlapping the componentmeansthe housingof the componentis grounded
to the vehicle frame or to a metal part connectedto the
trame.
".,,..
I
lt
r
X----I
s 2 1 04
aa4>
Fuse8ox
Detal:'j
ATKYEL
1 INSTRUMENT
CLUSTER
"-:x",.
___J__:
i llsg'-'*"
*:.t'
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OIL PRESSURE
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O p e n sw t h o r l p r e s s u r e
KrA163A-2{.S
2-3
HOWTO USETHISMANUAL
PowerDistribution
The PowerDistribution schematicshowsthe wiring from
the Battery and Generatorto the StarterSolenoid.Fuse
Box, Ignition Switch and Light Switch. The first component after a fuse is also shown.
The PowerDistributionschematicrefersto FuseBox DetailsandLight SwitchDetailsschematics.
By usingthese
three (3) schematics,power distribution wiring can be
followed from the Batteryand Generatorto the first component after a Maxi Fuse, Fuse and Light Switch. The
ability to follow the power distributionwiring to the first
componentin eachcircuit is extremelyhelpful in locating
short circuits which causefusesto open.
"Hot
The fusesin the sampleschematicbelow are
At All
Times," sinceBattery voltageis always appliedto them.
POWERDISTRIBUTION
I
Glo4
l*"
cros
I
I FUSERELAYBor
o,(- - 1A crre
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1
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,']C RETAY
PAe 63
2-4
t t l
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t
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L-J
GEI.IERATON
p4. 30 I
Klar$A-2-!s
SPORTAGE
FUSEBOX DETAILS
The FuseBox Details schematicshowsall the wiring between a fuse andthe componentsconnectedto the output
of the fuse.The FuseBox Detailsschematicis extremely
helpful in locating a shon circuit that causesa fuse to
open.This schematicmay aid troubleshootingan inoperative circuit by showing a secondcircuit using the same
fuse.If the secondcircuit works. then the fuseandcertain
wires of the inoperativecircuit are good.
FUSEBOX DETAILS
F
I
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I
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rrr
t
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r
t
1
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1
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li"_;1",,
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KtA163A-2-GS
2-5
HOWTO USE THIS MANUAL
LIGHTSWITCHDETAILS
The Light Switch Details schematicshowsall the wiring
betweenthe light switch and the componentsconnected
to the outputofthe light switch.The Light Switch Details
schematicis extremelyhelpful in locating a shon circuit
on the output side of the light switch.
LIGHTSWITCHDETAILS
ENGINE
I COMPAFTMENT
FUSE/FELAY
I BOX
I
HEAOLIGHT
COiIBINAnON
swtTcH
LIGTIT
swttctt
. . Ftastf
.l-l ToPAss
SwlTCH
-
--
---
-J
8
16
INSTFUiIENT
CIUSTEB
C252
psge 8l
i ot
aE^
aotcttoR
1
BIGHT
HEADIIGHI
D
pags 81
!
2-6
crou
4 czooiczor
* czoorozor
Ktat63a.2-7-S
SPORTAGE
GROUNDDISTRIBUTION
This sampleGround Distribution schematicshowsall of
the componentsthat sharethe sameground point.
GROUNDDISTRIBUTION
SHIELDING
3!i:8"
sHrElgrNG
p.oe re
corlrRo!
'=i'=i
f =l f=l
f=t f=t
i-l
c23::ffi!]L_j j-J l-J
f=t f=l
i-J i-J
SBtELO
f-t
i-,
ENGINE
t
L--------J
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t
2A
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c211
2-7
HOWTO USE THIS MANUAL
COMPONENT
LOCATION
A component location index follows each schematic.
With the exceptionof obviouscomponentslike headlights, the index lists the location of every component,
connectorand ground in the schematic.The index also
gives referencesto componentlocation photographslocatedin Section201.
COMPONENT
LOCATION
INDEX
(Refer to Section201 for photographs.)
Component
BrakePedalSwitch................................Under
VP,belowsteering
column..
Actuator.........................Left
Cruise
Control
rearof engine
compartment
CruiseControlClutchPedal
Position
Switch...
..Onpedalsupport
bracket....
PhotoNo.
.................................49
.....................................29
................48
(C128).................Left
DataLinkConnector
rearof engine
compartment....
.................................21
Engine
Control
Module............,............Behind
lowerrightsideof l/B nearrightkickpanel
...........
........................62
G200...................
2-8
......Lefl
kickpanel,
belowpassenger
compartment
fuse/relay
box...................42
SPORTAGE
FIVE-STEP
TROUBLESHOOTING
Test Light and DVOM
1. Verifythe Problem
On circuits witbout solid-statedevices,use a test light to
checkfor voltage.A test light is madeup of a l2-volt bulb
with a pair of leadsattached.After groundingone lead,
touch the other lead to various points along the circuit
where voltage should be present.The bulb will go on if
there is voltage at the point being tested.If you need to
know how much voltage is present,use a digital volt/
ohmmeter(DVOM).
Tum on all the components
in the problemcircuit to
checkthe accuracyof the customercomplaint.Notethe
symptoms.
Do not begindisassembly
or testinguntil you
havenarroweddowntheproblemarea.
2. Analyzethe CircuitSchematic
Lookup theschematic
for theproblemcircuit.Determine
howthecircuitis supposed
io workby tracingthecurrent
pathsfrom the powersourcethroughthecircuitcomponentsto ground.Also,tracecircuitsthatsharcwiringwith
theproblem
circuit.Thenames
of circuitsor components
thatsharethesamefuse,ground,or switch,andsoon,are
referredto in eachcircuitschematic.
Try to operateany
sharedcircuitsyou didn'tcheckin step l. If the shared
circuitswork, the sharedwiring is OK, and the cause
mustbe in thewiringusedonly by theproblemcircuit.If
severalcircuitsfail at thesametime.thefuseor eroundis
a likely cause.
Basedon the symptomsand your understanding
of the
circuit'soperation,
identifyoneor morepossiblecauses.
Test Light and DVOM
Self-Powered
Use a self-poweredtest light to checkfor continuity.This
tool is madeup of a light bulb, battery,and two leads.To
test it, touch the leadstogether;the light shouldgo on.
Use a self-poweredtest light only on an unpoweredcircuit. First, disconnectthe battery,or removethe fuse that
feedsthe circuit you are working on. Selecttwo points in
the circuit betweenwhich you want to check continuity.
Connect one lead of the self-poweredtest light to each
point. If there is continuity,the test lighfs circuit will be
completed,and the light will go on.
3. Find the Cause
Make circuit tests to check the diagnosisyou made in
step 2. Keep in mind that a logical, simple procedureis
the key to efficient troubleshooting.Test for the most
likely causeof failure first. Try to maketestsat pointsthat
are easily accessible.
4. Repairthe Problem
Oncethe specificproblemis identified,makethe repair.
Be sureto usepropertoolsandsafeprocedures.
5. Checkthe Repair
Tum on all componentsin the repaired circuit in all
modesto make sure you've fixed the entire problem. If
the problemwasan openfuse,be sureto testall of the circuits on that fuse. Make sure no new problemstum up
and the original problemdoesnot recur.
TESTLIGHT
SELF-POWERED
KtAt63A,2-9-S
TESTEQUIPMENT
s NoflcE
Most chcuitsincludesolid-statedevices.Test
the voltagesin these circuitsonly with a
1o-megaohm
or higherimpedancedigitalmultimeter.Never use a test light or analogmeter
on circuits that containsolid-statedevices.
Damageto the devicesmay result.
2-9
HOWTO USETHISMANUAL
FusedJumperWire
Use a jumper wire to bypassan open circuit. A jumper
wire is made up of an in-line fuse holder connectedto a
set of test leads.It shouldhavea five amperefuse.Never
use a jumper wire acrossany load. This direct battery
shon will blow the fuse.
Short Finder
Short findersare availableto locateshortsto ground.The
short finder createsa pulsing magneticfield in the shoned circuit and showsyou the locationof the shortthrough
interior trim. Its use is explained in the following troubleshooting
tests.
KtAl63A-2n0-S
TROUBLESHOOTING
TESTS
Testingfor Voltage
E@
v
lll#r
--\l
This test measuresvoltage in a circuit. When testingfor
voltageat a connector,you may not have to separatethe
two halvesof the connector Instead,probethe connector
from the back.Always check both sidesof the connector
becausedirt and corrosion betweenits contact surfaces
can causeelectricalproblems.
l.
Connect one lead of a test light to a known good
ground,or if you are using a voltmeter,be sure you
connectits negativelead to ground.
2. Connectthe otherleadof the testlisht or voltmeterto
the point you want to check.
El"*''""
'r\l
3. If the test light glows, thereis voltagepresent.lf you
are using a voltmeter, note the voltage reading. It
should be within one volt of measuredbattery voltage.A lossof morethan one volt indicatesa problem.
VOLTMETER
(ORTEST
LIGHT)
pl'o'-'"o'o
KtA163A-2nr-S
2-10
SPORTAGE
Testingfor Continuity
This testchecksfor continuitywithin a circuit.When tes!
ing for continuity at a connector,you may not have to
separatethe two halvesof the connector Instead,probe
the connectorfrom the back.Always check both sidesof
the connectorbecausedirt and corrosionbetweencontact
surfacescan causeelectricalproblems.
BLOWER
swrTcH
1. Disconnect the negative cable from the vehicle
battery.
2. If you are using an ohmmeter,hold the leadstogether and adjustthe ohmrneterto read zero ohms.
3. Connectone lead of a self-poweredtestlight or ohmmeter to one end of the circuit you wish to test.
4. Connectthe other lead to the other end.
Kta163A-2-12.S
5. If the self-poweredtest light glows, there is continuity. If you are using an ohmmeter,low or no resistancemeansgood continuity.
Testingfor VoltageDrop
This test checksfor voltagedrop along a wire, or through
a connectionor switch.
l.
Connectthe positiveleadof a voltmeterto the end of
the wire (or to the side of the connectoror switch)
closestto the battery.
2. Connectthe negativeleadto the otherend of the wire
(or the other side of the connector or switch).
3. Operatethe circuit.
4. The voltmeterwill show the differencein voltagebetween the two points.A difference,or drop of more
than 0.5 volts, may indicatea problem.Checkthe circuit for looseor dirty connections.
Testingfor a Short to Groundwith a Test
Light or Voltmeter
l.
Removethe open fuse and disconnectthe load.
2. Connecta test light or voltmeter acrossthe fuse terminals.Make surevoltageis being appliedto the battery side fuse terminal.Check the schematicto seeif
"ON" position.
the ignition switch needsto be in the
3. Beginning near the fuse box, wiggle the hamess.
Continuethis processat convenientpoints about six
inches apart while watching the test light or voltmeter.
4. When the test light blinks or the voltmeter needle
moves,there is a short to ground in the wiring near
that Doint.
VOLTMETER
(oR TEST
LIGHT)
FUSE
BOX
(FUSE
REMOVED)
SHORTTO
GROUND
El'*''"'
'Ib?s'%*n'""o
[u'o""o'*:^,*^
2-11
HOWTO USE THIS MANUAL
BATTERY
DISCONNECTED
FUSE
BOX
(FUSE
REMOVED)
SHORTTO
GROUNO
OHMMETER l-l-l
(oR SELF.
| |
|
L/
LoAr,
DrscoNNEcrED
B
SOLENOID
2-12
l.
Removethe openfuse anddisconnectthe batteryand
load.
2. Connectone leadof a self-poweredtest light or ohmmeter to the fuse terminal load side.
3. Connectthe other lead to a known good ground.
SryITCH
ii'J+:IEBD
l-td
".rf
Testingfor a Shortto Groundwith a
Self-Powered
TestLight or Ohmmeter
KrA163A-2n
5.S
4. Beginning near the fuse box, wiggle the hamess.
Continuethis processat convenientpoints about six
inchesapartwhile watchingthe test light or ohmmeter.
5. If the self-poweredtest light blinks or the ohmmeter
needlemoves.thereis a shonto groundin thewiring
nearthat Doint.
SPORTAGE
Testingfor a Short to Groundwith a
Short Finder
l.
Removethe open fuse.Leavethe batteryconnected.
2. Connectthe shortfinder betweenthe positivebattery
terminal and the load side fuse terminal.
BATTEBY
3. Close all switches in series with the wire you are
troubleshooting.
4. Tum on the short finder. It sendspulsesof currentto
the short. This creates a pulsing magnetic field
aroundthe wiring betweenthe fusebox andthe short.
5. Beginning at the fuse box, slowly move the short
finder meter along the circuit wiring. The meter will
show current pulsesalong the interior trim. As long
as the meter is betweenthe fuse and the shon. the
needlewill move with eachcunent pulse.Once you
move the meterpastthe point of the short,the needle
will stop moving. Check around this area to locate
the causeof the shortcircuit.
FUSE
gox
<!>
'l'-7.-l
=lP,T.??l
/8
CONNECTOR
CLASSIFICATION
The generallocation of connectorscan be identified by
using the chafi below.The specificlocation of eachconnector can be found in the component location photographsin section201.
Connector
Location
cl00 thrucl99
Engine compartment
C200rhruC299
Instrumentpanel
C300thru C399
Passengercompartment
C400thru C499
Luggagecompanment
C500thru C599
Left front door
C600thru C699
Right front door
C700thru C799
Left reardoor
C800thru C899
Right rear door
C900rhruC999
Headliner
C1000thruC1999
Engine compartment
C2000thru C2999
Instrumentpanel
MOVE
METER
ALONG
WIRE
|
rF-l |JI88E",
ll+l
i Flt's]re'"
.t... *U
i
NEEDLE
STOPS
MOVING
HERE
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Kla163A-2n
6-S
2-13
HOWTO USETHISMANUAL
CONNECTOR
TERMINAL
IDENTIFICATION
Wire Side Of
Female Terminals
The cavities (and wire teminals) in each connectorare
numbered starting from the upper right looking at the
male terminalsfrom the terminal side (or looking at the
femaleterminalsfiorn the wire side).Both views are in
the samedirection so the numbersare the same.All cavitiesarenumbered,
evenif theyhaveno wire terminalsin
them.
TerminalSide Of
Male Terminals
KtA163A-3.1.S
The connectorcavitynumberis listednextto eachterminal on thecircuitschematic.
The cavity/terminal
shownis
#4.
Kta163A,3-2-S
GENERALSERVICE
In-LineConnectors
Locking Tabs Are On Both
Sides Of The Connector
The fbllowing illustrationsshow typical electricalconnectorsand their disengagements.
.
Flel Bladed
Screwdriver
KtA153A-3-3-S
2-14
Insen a flat blade screwdriverin the locking tab and
twist.
SPORTAGE
.
Graspthe connectorhousingand pull until the locking
tab is on the ramp.
Tum the connector over and repeat the procedure on the
oppositeside of the connector
J
euttI
vie*l
Graspthe connectorhousingand pull apart.
PressIn On The ReleaseTab.
GraspThe ConnectofHousingAnd Pull Aparl.
Disconnectingthe Connector
The conneciorcan be disconnectedby pressingthe lock
lever Do not pull on the wires when disconnectingthe
connector.Be careful to hold the connectoritself when
disconnectinsit.
K|^r63a-+5-s
Inspection
When l testeris usedto check the continuity or to check
the voltage,insert the testerprobe from the wire hamess
side.
Klal63A-3-GS
2-15
HOWTO USETHISMANUAL
WIRINGCOLORCODES
Two-color wires are indicatedby a two-color code symbol. The first color code indicatesthe basecolor of the
wire and the secondindicatesthe color of the stripe.
CODE
COLOR
CODE
COLOR
BLK
BLACK
LT GRN
LIGHT GREEN
BRN
BROWN ORG
ORANGE
GRN
GREEN
RED
RED
BLU
BLUE
YEL
YELLOW
PNK
PINK
WHT
WHITE
KtAt53A-3-7-S
Thin InsulationWire
To reducethe weight of the wiring hamesses,
a thin coating of a high resistanceinsulationmaterialis used.
Klat634-$&5
ShieldedBraid Wire
The shieldedbraid wire is usedto preventmalfunctionsin
thosecircuitsthat are importantand susceptibleto outside
signalsor interference.For example:
.
Ignition coil signal
o HeatedOxygen sensor(H02S) signal
Insulation
KtA163A-3-95
2-16
SPORTAGE
REPLACEMENT
OF TERMINALS
'.-
Use the appropriatetools to remove the terminal, as
shownin the illustrations.
*NOTICE
Wheninstallinga terminal,be sureto pressit
in untilit lockssecurelvFemaleType
Insert a push-tool,or thin piece of metal such as a small
screwdriver,from the terminal side of the connector,and
then, with the locking tabspresseddown, pull rhe terminal out from the rear side of the connector.
MaleType
Refer to femaletype procedure.
2-17