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Section 5 • Transmission

1. From heater To heater Cooling l SG From the reservoir E Water outlet pipe Outlet fitting Bypass fitting RH b Thermostat housing Li From radiator To radiator e The cooling system on the Sorento is a Self bleeding system revised version 3 3B Ignition System Ignition Failure Sensor Charging System Starter The Sigma 3 5 V6 engine uses a distributor less ignition system with the ECM controlling and monitoring ignition system functions Three ignition coils are located above cylinders 2 4 and 6 cylinder bank 2 three spark plug wires connect the coil assemblies to cylinders 1 3 and 5 The coils feature integrated power transistors The coils are also physically smaller than those in the Sedona 3 5L The ignition system in the 2003 Sorento is a wasted spark system For fault detection purposes an Ignition Failure Sensor is employed The Ignition Failure Sensor IFS monitors the coil primary waveform When the primary circuit is turned OFF by the ECM the collapse of the mag netic field induces a high voltage in the secondary winding An inductive spike is then in turn induced in the primary winding of the coil This inductive spike is detected by the IFS which then generates a digital Ignition Detect Signal The output from the IFS is routed to the ECM and the vehicle tachom eter By monitoring the digital output of the IFS the ECM can detect the
2. When brake pedal is not depressed shift lever should shift smoothly to P position from other positions Shift lever must operate smoothly without catch ing at all positions If shift lever is shifted into P position ignition key must turn to LOCK position smoothly i s Install direction i K Guide Pin is tc____ Inserted into Shift R Lock CAM revised version 3 9 TCM Logic The basic part of all electronic control systems is the TCM The TCM is an electronic device that receives information stores information and com municates information To a TCM certain voltage and current values mean something and based on these values the TCM is informed The TCM receives information from a variety of input devices that send voltage signals to the TCM These signals tell the TCM the current condition of a particular part or the conditions that a particular part is operating in After the TCM receives these an Sig CA signals it stores them and interprets the signals by comparing the values to data it has in its memory If an action is required the TCM will send out a volt age signal to the device causing it to respond to the appropriate component This entire process describes the operation of an electronic system Information is received by a mi croprocessor from input sensors the TCM processes the information then sends commands to the output devices It monitors its own work and checks to see
3. l FATC without AQS To change from metric to signals to the ECM standard hold the AMB and Down TEMP buttons at the same time for three seconds FATC Contro Temperature Unit Display OFF Switch Panel Functions The user can switch between metric and stan dard temperature display units by holding the AMB button down and pressing the TEMP down button for three seconds The default display at battery re connect is in metric units TEMP Switch The TEMP switch allows temperature settings to be raised or lowered The range is 62 to 90 F in one degree increments AUTO Switch The AUTO switch is used to place the system in automatic mode The FATC system will auto matically adjust blower speed mode door position intake air mode temperature and A C compressor operation based on the desired temperature selected by the user DEFROST Switch Pressing the DEFROST switch results in the mode door transitioning to defrost mode In addi tion the A C compressor will be activated if condi tions permit and the intake actuator will switch to fresh air mode Blower speed and temperature must be selected manually in this mode A C Switch The A C switch permits manual ON OFF selec tion of the A C compressor 8 revised version 3 Selecting the OFF switch shuts the blower down and deactivates the A C compressor clutch The temperature door will revert to automatic control The mode door will be in AUTO or manual mode d
4. to R as well as shifting 1 2 3 4 Note The TCM has no information of real current engine torque but through the calibration work at each condition in the actual vehicle for up and down shift the TCM determines the value by how much the engine torque has to be reduced Line pressure control improves shift quality due to controllable line pressure while shifting N to D N to R as well as shifting 1 2 3 4 Note Line pressure control changes according to the current gear position TPS value oil temperature Should a driver accidentally shift to R while driving forward the TCM does not engage the re verse gear until certain conditions are satisfied This safety feature was designed into the TCM logic to prevent an accidental shift from Drive to Reverse while driving revised version 3 Adaptive Shift Control Purpose e Optimal shift control according to the road and driving condition Functions e Up hill mode To prevent frequent gear shifting and improve performance and fuel consumption e Down hill mode Use engine braking as a brake for improved driving stability Output speed _ gt Accelerator pedal_ gt Engine torque Road slope C Acceleration TCM Calculate related information Adaptive Shift Control Uphill Mode When the accelerator pedal is depressed while the vehicle is driving uphill if the TCM were to up shift it woul
5. FAN OFF 216 225 244 A C CUT 194 203 216 225 L ECT dec ECT deg F A CON SYS Pressure Control gt 50 MPH Vehicle Speed V CONDENSER Hi E CONDENSER Ht L aN LOW R COOLING i E g K P Py 25 28 164 221 270 455 Pressure psi 2 revised version 3 The 2003 Sorento is fitted with a Mitsubishi Electronics Company Engine Management System MELCO utilizing a 32 bit ECM with a separate TCM The ECM and TCM communicate via a Controller Area Network CAN Sequential Multiport Fuel Injection is incorporated and a dis tributorless ignition system is used The 2003 Sorento 1s certified as a Low Emissions Vehicle LEV The Evaporative Emissions Systems employs an On Board Refueling Vapor Recovery ORVR valve along with a rollover valve and sup ports Smm leak detection via a vacuum leak check method Three 3 way catalytic converters one at each exhaust manifold one underneath the vehicle have been fitted The 2003 Sorento does not use Exhaust Gas Recirculation EGR Engine manage ment system monitoring functions are conducted in compliance with OBD II regulations 2 IDLE SPEED CONTROL MOTOR yh TPSIKITH IDLE Sy v3 MIP SENSOR 73 AIR FLOW SENSORI v4 WITH ATP YS AIR CLEANER iF JEL L y 4 mS NZ uB INLET a SSS N T CANISTER FLEL TANK H S ka FLEL TEM SENSOR Ba lL fet Pur FUEL LEVEL Nees 7 Taan a annaig 3 PURGE VENT SOLENOID vibe ay A I AE 0 V A ID VALVE rb CAM P
6. FUEL 2 The Crankshaft Position Sensor CKP is of the Hall Effect type The CKP is mounted adjacent to the crankshaft sprocket underneath the lower timing cover A three blade trigger wheel is mounted be hind the crankshaft sprocket The ECM determines engine speed through the CKP output in addition to detecting misfires The automatic transmission also requires engine speed information CKP signals are shared with the TCM via the CAN Crankshaft Position Sensor CKP The Hi Scan Current Data display for CKP information is limited to RPM data only connectors shown A single Knock Sensor KS is used on the 2003 Sorento and employs a shielded signal circuit Knock sensor failures will not illuminate the MIL a DTC P0325 will be stored Knock Sensor KS 6 revised version 3 SECTION 4 FUEL 2 Fuel Tank Pressure Sensor FTPS Fuel Level Sensor FLS and Fuel Temperature Sensor FTS A Fuel Tank Pressure Sensor FTPS is located on the fuel delivery module The ECM evaluates FTPS signal information for purge and close valve operation in addition to testing the EVAP system for the presence of a leak e The FTPS is monitored as a Comprehensive Component However EMS design requires that specific enable conditions be met before the FTPS output voltage is checked e Battery voltage must be gt 1OVDC IAT at initial engine start must be above 41 F e Load value must be between 25
7. 3497cc 10 0 1 600 12V 70AH 1 0 1 1 mm PFRSN 11 Platinum NGK RC1OPYPB4 Copper Champion revised version 3 3 Lubricant Volume SAW Metric Engine Oil 5 8 quarts 5 5 liters Transmission Oil 9 quarts 8 5 liters Coolant 3 gallons 11 4 liters Brake Fluid 1 4 quarts 1 3 liters Fuel 21 1 gallons 80 liters Differential Fluid w o LSD Differential Fluid w LSD Refrigerant complies with SAE J639 Maximum operating charge Refer to Fuses in the Owner s Manual Index revised version 3 Classification API Service SD or above Dextron III SAE J1703 FMVSS 116 DOT 3 or DOT 4 87 Octane as recommended in Owners Manual GL 5 SAE 90 GL 5 SAE 85 90 Refrigerant R 134a 33 ounces Tire Size Wheel Size 245 70 R16 6JJX15 Light Bulb Wattage Headlamps High Low 55 55 Front turn signal position lights 28 8 Front fog lights if equipped 27 Rear turn signal lights 27 Stop and tail lights 27 8 Back up lights 27 License plate lights 5 Interior Lights 10 Dome light 10 Rear cargo area light if equipped 10 High mounted stop light if equipped 21 Door courtesy lights 5 Maximum Pressure 35 PSI VEHICLE IDENTIFICATION NUMBER POSITION Vehicle Description Section Manufacturer N Kia Motors Corp Vehicle Type D MPV Model J Sorento Series CY 4WD D 2WD Body Type 5 7 4 Door SUV 2 3 4996 5984 GVWR Lbs Engine Restraint 3 3 5L V6 Dua
8. GENERAL INFORMATION Exterior Sorento Exterior Color Matrix and Interior KMA Colors Interior Color LX EX Beige 44 Code Exterior Color Midnight Black W W UD D3 C9 wi p1 G6 M IN E ZG Option on EX only Normal Schedule 1 Normal Maintenance Maintenance Schedule Maintenance intervals Number of Months or Kilometers Mil m s o as ors E em e H H H H ee Engine Oil Replace every 7 500 miles or 12 months Engine Oil Filter Replace every 7 500 miles or 12 months Automatic TranemissionFid i 1 ot Pot pot pot fe ta te Engine Timing Bet PE ro AirCleanerElement PE ER TT S ER SeakPios EER Notes Inspect R Replace 1 For California This maintenance is recommended but not required 12 revised version 3 Normal Maintenance Maintenance Schedule Intervals anecon H ws E rane ol cc G Pp pe et re R R R RS CHH H HT H H HTHH HHS HZ1 _ o Tsere orrea HR R HHHH 993 RR HR HHR meae raer TTT SS Front Differential Fluid if equipped er Orla ae ron wee oo es ne Ce ee SS SSS Notes Inspect and if necessary adjust R Replace 1 This maintenance is required in all states except California However we recommend that it also be performed on California vehicles 2 This maintenance is recommended by Kia However it is not necessary for emission warranty coverage or manufacturer recall liability Schedule 1 Normal Ma
9. Seat belt Buckle Switch Switch Type The 2003 Sorento uses two Front Impact Sen sors to aid the SRSCM in determining impact se verity These sensors are mounted to the frame rails behind the front bumper Depending on the velocity and severity of the collision the SRSCM will deter mine the deployment characteristics of the airbags and seatbelt pretensioners e Stage 1 one squib fires e Stage 2 second squib fires within 100 millisec onds of first squib e Stage 3 squib one and two fire simultaneously The Side Impact Sensors provide the SRSCM with input signals required to determine the severity of impacts from the sides Based on these signals the SRSCM may deploy either the left or right side cur tain air bags These sensors are mounted at the base of each B pillar 6 revised version 3 Seat Track Sensor Service Reminder Indicator SRI The 2003 Sorento uses Seat Track Sensors to determine the distance that each front seat is away from the air bag If the seat track sensor detects that the seat is close to the air bag module the SRSCM will cause the air bag to deploy with squib 1 and 2 firing simultaneously to reduce the risk of injury to the occupant When the ignition is turned on and operating volt age is applied to the SRSCM a bulb check will be done for the Service Reminder Indicator SRI During this initialization phase the lamp will blink six times in six seconds and t
10. The CCV is a normally open valve and is electrically closed for the purposes of sealing the EVAP system for leak monitoring pur poses Canister CCV Resistance Values e 23 26 ohms 68 F 10 revised version 3 SECTION 4 FUEL AND Low to medium speed torque is boosted with a variable intake manifold controlled by the ECM via a Variable Intake Control System VICS The VICS consists of an actuator operated by engine vacuum and a solenoid which is turned ON open at Jd or OFF closed by the ECM ground controlled to E Eal pa allow vacuum to operate the VICS actuator A vacu TR um chamber with a check valve is fitted to ensure a stable supply of vacuum to the VICS actuator The system is designed to direct intake airflow through long runners below 3500 100 RPM Above 3500 RPM the ECM activates the vacuum control so lenoid which in turn allows manifold vacuum to operate the VICS actuator intake airflow is then a Variable Intake Control System VICS SURGE TANK redirected through shorter intake runners CON VALVE ACTUATOR Wi VAC TANK PRI PORT SEC P RT E C U Purge Gas Inflow Port aN Bi il Tw Vacuum Source VICS Actuator Vacuum Cont Solenoid on off type revised version 3 11 SECTION 4 FUEL 4 The Main Relay supplies power to sensors and actuators which require 12VDC and provides main battery power to the ECM keep alive memory 19 maintained throug
11. readings located on the power steering pump The PSPS loading caused by turning the steering wheel at low engine speeds PSPS status ON OFF is viewable in Hi Scan Current Data The Vehicle Speed Sensor VSS is a Hall Effect unit The ECM uses the digital output signal in addi tion to the speedometer cruise control unit and the speed sensitive power steering EX only VSS sig nals are not utilized by the automatic transmission nor by either one of the transfer case control units EST TOD separate sensors are employed to per mit the TCM and EST TOD to detect vehicle speed e Vehicle Speed information is available in Hi Scan Current Data revised version 3 A Power Steering Pressure Switch PSPS is provides an ON OFF signal which allows the ECM to make engine speed adjustments due to increased p P E Lat S L a L EST Unit Show n z SECTION 4 FUEL AND Fast Idle Air Valve FIAV Fuel Injectors The ECM controls idle speed via a stepper mo tor installed on the throttle body Battery voltage is supplied to the ISC motor at two of the six termi nals the remaining four pins are for ECM control signals A Fast Idle Air Valve FIAV facilitates cold engine idle up functions by opening or clos ing based on coolant temperature At 140 degrees Fahrenheit the valve is fully closed It is possible to make field adjustments to the base idle speed using the Hi Scan Pro Place
12. 4 5 T 10 11 12 13 14 15 16 17 18 9 1 24 revised version 3 SECTION 5 TRANSMISSION DTCS In case a driver turns the OD OFF switch on or not shift down until the vehicle speed is reduced changes a shift lever to the 2L range while driving This will prevent the engine from over revving in 4th gear in D range at high speed the TCM will Engine Over run Inhibition Control DTC Detected Condition and Fail Safe Subject to change Code Description Fail Safe P0707 Output speed gt 1130 Engine RPM gt 1500 Judge D range system mechanically operates P0708 2 or more signals are detected for more than 10 sec D gt 2 gt L gt R gt N gt P operation priority P0722 1st 3rd gear No output while 45 input pulses detected Gear shift by using input speed sensor signals 4th gear 1500 output RPM drop and 0 RPM detected No lock up 4th fear ETR LPC Reverse Squat control Short to GND OFF detected for 300 msec after ON DCCSV OFF Open short to B ON detected for 50 msec after OFF 1st gear hold if output RPM lt 375 Open B short P0748 Open short to GND AD value lt 15 for 70 msec 4th Gear hold Short to B AD value gt 1000 for 500 msec P0753 Short to GND OFF detected for 300 msec after ON Lock up inhibited Open short to B ON detected for 50 msec after OFF Gear hold D range 4th 2 range 3rd L range 1st P0758 Short to GND OFF detected for 300 msec after ON Lock up inhibited O
13. 70 Engine speed must be above 1438 RPM Vehicle speed must be above 18 64 MPH FTPS output values e 2 2 2 8VDC with key on engine off and fuel cap loosened e FTPS data expressed as mmHG or millimeters of mercury can be seen in Hi Scan Current Data The ECM employs the Fuel Level Sensor FLS and the Fuel Temperature Sensor FTS during the 5mm leak detection portion of the EVAP test Both sensors are located on the fuel delivery module The FTS is a negative co efficient sensor e FTS failures will cause the ECM to disable the 5mm portion of the EVAP test e FLS failures will not illuminate the MIL a DTC will be stored and the ECM will assume 50 fuel level as a default value EVAP monitoring will not be affected by an FLS failure e FLS output value volts will increase as fuel is added to the tank range is 0 SVDC FTS Output Values 3 2 3 8V 32 F e 2 3 2 9V 68 F 1 5 2 1V 104 F Fuel Tank Pressure Sensor revised version 3 Fi Manifold Absolute Pressure Sensor MAP Power Steering Pressure Switch PSPS The ECM uses the Manifold Absolute Pressure Sensor MAP signal to adapt the fuel system to variances caused by changes in altitude The MAP is located on the passenger side of the intake plenum near the throttle body MAP Output Values e 0 8 2 4V idle warm engine e Hi Scan Current Data displays MAP voltage and vacuum inHG or inches of Mercury
14. ANALOGPIATA a lrn SNITCH d POSITION ENCCOER 2 FRONT SPEED SENSOR ONG 7 SFEED EENSCR GROUND _ MOTOR OUTPUT nran MOTOR OUTPUT LOv HD i ce aa GRE iiil 0 i POSTMON ENCODER 1 CONNECTOR w POSTICN ENCCOER 3 o REAR SPEED SENSOR o POSTION ENCODER 4 ELECTRONIC T F CONTROL UNIT OK201 47 TCO VEHICLE SIDE CONNECTOR FEMALE SCAN TOCL SENSOR OR SOLENOID 23 5 _____SENSORORSOLENOID T pe T NL N C Te a a a a a Par2s Ene peedinputsensorrngoberomence HS S Taare nan e a a 7 a 7 a 7 P0740 Torque converter clutch circuit malfunction P0743 Torque converter clutch circuit electrical C C r2 Poras Pressure soenoe T 1 1 A 1 1 A 1 1 P1121 Throttle sensor signal invalid P1630 CAN communication BUS OFF P1631 No ID from ECU LB LB OB o eee Only for 4WD OB a Ea 20 P0710 Transmission fluid temperature sensor circuit malfunction P0604 Internal control module random access memory error P0601 Internal control module memory checksum error Fault type e TYPE A DTC stored on the Ist driving e TYPE B DTC stored on the 2nd driving e TYPE C only fail safe Not DTC stored Warning lamp W L O D OFF lamp MIL Warning O Supported To be performed at the same time as DTC store Not supported 8 2 2 3 4 9 6 T 8 9 21 23 4 2 revised version 3 23 SEC
15. Floor mats LX Cargo tray all PIO 4 wheel drive all Rear spoiler EX Alloy wheels LX Roof rack LX Leather package EX AM FM 6 in dash disc CD EX Tow package EX Model Includes Two tone exterior Sunroof Roof rack Fog lamps Body color outer mirror dual power heated Bright machine finished aluminum wheels Moquette velour seat trim Wood grain center fascia console accents Power driver s seat Leather wrapped steering wheel Chrome plated inner door handles Chrome shifter shaft Brushed metal style PRNDL base plate Overhead console adds Multi meter outside temp compass altimeter barometer Rear cargo cover cargo net Electro chromatic rearview mirror Homelink in rear view mirror Keyless entry system two remotes Delphi premium AM FM stereo radio cassette CD player with separate amplifier 10 speakers steering wheel audio controls Bright stainless steel scuff plates Luxury Package available on EX grade only Optional 4WD torque on demand type Chrome outside door handles Chrome rear garnish Auto climate control Heated front seats Leather package Wood grain leather steering wheel Wood grain accent shift knob Auto headlamps Delphi premium AM FM 6 in dash disc CD with separate amplifier 10 speakers steering wheel audio controls Tow Package TP all Trailer hitch receiver ball mount ball PIO Wiring harness with 4 wire connector PIO revised version 3 SECTION 1
16. PF os Ss Large felt lined coinholder bin Ps Ss Under seat storage bin O O OJO OJO Rear quarter panel storage bins Digital clock in dash Tachometer Horn Dual Electrochromatic rear view mirror with homelink programmable garage door opener no Lux installation Remote keyless entry W Door lock panic rear glass open no Lux installation Power windows with one touch drivers express down feature Power door locks two turn entry system Assist grips Four positions Roof mounted rear LH amp RH Assist grip mounted rear LH amp RH Garment hooks Tilt steering wheel Rear cargo cover Cargo net ACC Cargo net hooks Under rear cargo floor storage compartments Rear cargo lamp w on off switch Driver and passenger sunvisors slide out dual covered amp illuminated vanity mirrors o Manual Air conditioning Automatic 2 Front 1 Second row 1 Cargo area 12 volt power points Cruise control with steering wheel controls 4 Floor mounted cargo tie down hooks also used for cargo net on EX Driver s foot rest Sunglass storage map lights garage door opener pocket Overhead Console Multi meter outside temp compass altimeter barometer not on FATC vehicles Center console with armrest dual storage top small items bottom CD Cassettes Dual rear cupholders rear console Dual center console cupholders Straight into dash not in steering column illuminated ignition switch Lockage large
17. Sensor Circuit Malfunction P1115 Water Temp Signal Malfunction from ECU to TCU P0717 Input Speed Sensor Circuit No Signal P0716 C OO C ee Input Speed Sensor Circuit Range Performance P1795 Transfer High Low L4 Switch Malfunction O o woas OOOO S o G S rr oomo S o S S H HTH HH H HTH HH Fault Type Type A DTC stored on the 1st driving Type B DTC stored on the 2nd driving Type C only failsafe not DTC stored Warning lamp O D OFF lamp SECTION 5 SPECIAL SERVICE TOOLS SN Group Type ToolNumberName illustration Unique Remark 37 OO OO CO Ba i D CO C on CO 2 C3 26 TRA Auto Trans TRA Auto Trans TRA Auto Trans TRA Auto Trans TRA Auto Trans DS Driveline Systems DS Driveline Systems DS Driveline Systems revised version 3 03 40LEi 03 40LEi 03 40LEi 03 40LEi 03 40LEi 09452 21000 Oil pressure gauge adapter 09452 21500 Oil pressure gauge 09452 21600 Oil pressure gauge adapter 09452 32100 Oil seal installer 09452 32300 Oil pressure gauge adapter 09432 33700 Bearing outer race installer 09517 21000 Oil seal installer 09532 32000 Oil seal installer use with 09452 21500 09452 21600 09452 32300 use with 09452 21600 09452 21000 09452 32300 use with 09452 21500 09452 21000 09452 32300 use with 09452 21000 09452 21500 09452 21600 use wi
18. compartment Mass Air Flow Sensor MAF Note MAF failures resulting from physical damage to the sensing element will cause a fixed output value of about 1 0 VDC MAF Output e 1 4 1 6VDC at idle e MAF values are displayed in Hi Scan Current Data as voltage airflow and calculated load IAT Output 3 2 3 8V 32 F e 2 3 2 9V 68 F 1 5 2 1V 104 F s 0 5 0 9V 178 F e IAT voltage and intake air temperature values are displayed in Hi Scan Current Data revised version 3 3 SECTION 4 FUEL AND Throttle Position Sensor TPS Engine Coolant Temperature Sensor ECT The Throttle Position Sensor TPS consists of a potentiometer together with an idle switch which is installed on the throttle body assembly TPS in formation is shared with the TCM via the Controller Area Network CAN In addition a Pulse Width Modulated PWM version of the TPS signal is transmitted by the ECM to the torque on demand transfer case control unit TCCM TPS Values s 0 3 0 9V idle s 4 0 4 6V WOT e The Idle Switch is monitored separately from the TPS signal and has its own DTC P0510 e TPS percentage voltage and idle switch status can be viewed in Hi Scan Current Data The Engine Coolant Temperature Sensor ECT is installed in the water outlet fitting and sup plies the ECM with coolant temperature information in addition to controlling the temperature gauge on the instrument cluster
19. compass will point at an angle east or west of true north To compensate for this Magnetic Declination must be taken into consideration Magnetic Declination is the angle between magnetic north and true north 3 Select the degree of correction from the map above ex ample Chicago Illinois would be 0 degrees 4 Press the UP or Down key on the Multimeter panel until the appropriate correction is indicated in the display 5 Press and hold the MODE SET key until the display changes back to its normal view Position Correction Relative Altimeter Barometer Outside Temperature Position correction should be performed if the displayed bearing differs from the actual bearing of the vehicle or if the battery has been disconnected 1 Start the vehicle access the compass function and hold the MODE SET key until the DRT indi cator flashes 2 Turn the vehicle slowly 360 degrees or more within 128 seconds Bearing correction is auto The Relative Altimeter displays the difference in altitude traveled For example if a customer lives in Denver Colorado at elevation 5 280 and sets the relative altimeter to zero before leaving on a trip to Pike s Peak at elevation 14 100 When the customer arrives at Pike s Peak the difference in elevation 8 830 will be displayed on the relative altimeter The range is 9800 feet To reset the altitude reading to the current altitude press and hold the MODE
20. e 12 revised version 3 a ae In Car Sensor The In Car Sensor is located in the lower center console to the left of the FATC panel This Negative Temperature Coefficient thermistor communicates vehicle interior temperature information to the FATC control unit In Car Sensor Characteristics Temp F Resistance 64 3 4 70 2 98 TI 2 3 83 2 2 90 Resistance checks are between terminals I and 2 Ambient Sensor Haas Ha gt Triple switch CONDENSER R Receiver amp Drier AIC Relay Blower Relay Junction Box top In Car Sensor and bottom schematic of In Car Sensor i z L e newt Photo Sensor TC C aa az X Hi Speed Blower Relay In car Sensor amp Humidity Sensor Module Power TR Humidity Sensor The Humidity Sensor is part of the In Car Sensor __ B R assembly The FATC control unit analyzes humidity A G Key Sensor to determine the need for A C compressor operation eine aay Sensor schematic which will reduce fogged windows revised version 3 13 SECTION 9 BODY ELECT CLIMATE CONTROL SENSORS FATC System Photo Sensor Sensors The Photo Sensor located near the driver side defrost duct uses a photovoltaic diode to transmit light level information to the FATC control unit This compensates for changes in solar radiation by adjust ing the blower speed and discharge temperature 63 7 TH SRE sa Salle Leck ee ee S 6
21. if its commands resulted in the expected results e 40 ad 20 yy x1000rpm A Output M _ ROM gt SNOW lamp 2WD E E CAN data to ECM e e oe CAN data to TCM gt SNOW signal 2WD Input A T range switch P gt 10 revised version 3 TCM Input and Output Terminal Voltage Table Accurate at time of printing data used for world market Input amp Output Signal Condition 13 SCSV 1 Driving Friden Vbatt DV 1st 2nd speed operation P N 1st 2nd 3rd 4th speed q N lo 1 9A MAX SCSV 2 Driving Fisa ent Vbatt DV 2nd 3rd speed operation P N 1st 2nd 3rd 4th speed q y lo 1 9A MAX SW OFF Yaw 3 2V CD Cylinder Rev SNSR Pulse V vow over drive clutch drum a PulselCO cylinder rev l Driving Var Vio 31 O D OFF Switch D OS Inhibitor Switch P a a TTT a a Inhibitor Switch R S T R Ignition OFF Vbatt Battery Lock Up Solenoid Driving Frequency Vbatt DV over 28 MPH Lo 1 9A MAX Gaia control Input amp Output Signal Condition a R T R H Switch OFF p 0 3 2V Brake SW Switch ON Vbatt 2 0 Vbatt SCSV1 Shift Control Solenoid Valve No 1 SCSV2 Shift Control Solenoid Valve No 2 lt Input speed sensor lt Output speed lt Torque converter solenoid valve Pressure control solenoid valve OTS Oil Temp Sensor Input amp Output Signal Condit
22. over 275 F In this mode lock up control will not operate and engaging time for low speed will occur at a lower RPM Snow mode was called Hold mode on the Sportage When this mode is selected using a button on the shifter the vehicle starts from second gear to prevent the spinning of driving wheels on the slip pery surface Snow mode is only available for 2WD vehicles only When the ATF temperature exceeds 275 F the TCM changes the shift pattern automatically to fur ther avoid ATF temperature increase This hot mode situation can happen while the vehicle is moving up a steep slope or while towing The TCM changes the shift pattern into a High ATF Temperature shift pattern extending the low gear range while rendering the damper clutch non op erational High Shift Pattern e ATF temp gt 275 F resulting in a High ATF Tem perature shift pattern e ATF temp lt 248 F will result in a normal shift pattern revised version 3 13 The Damper Clutch or lock up clutch is engaged for less fuel consumption while driving and to re duce exhaust gas emissions When the shift lever is moved from N to D the Squat Control operation temporarily shifts to 3rd gear to reduce shifting shock and a squatting vehicle Engine torque reduction control improves shift quality due to sending torque reduction request sig nal from TCM to ECM and reducing engine torque while shifting N to D N
23. presence of an ignition system malfunction A P0350 DTC is generated and stored upon detection Two drive cycles are required for MIL illumination The ignition system monitoring functions are conducted under 4000 RPM IFS fail ures can cause a P0320 DTC this DTC is a one trip code The charging system on the 2003 Sorento uti lizes a generator with a built in voltage regulator The ECM does not control the field circuit operation as on Sedona Generator e 13 5v 120 amps A reduction drive type starter is used The starter motor current draw should be 90 amps or less IFS revised version 3 SECTION 3 gt The 2003 Sorento battery Battery Cooling Engine cooling and condenser fans are ECM Condenser Controlled through a series of three fan relays Fan Control located in the engine compartment fuse and re lay box Both fans feature high and low speeds which are actuated based on the ECT vehicle speed the A C switch position and the A C sys tem triple pressure switch position A C ON A C OFF Vehicle Speed V lt 50 MPH Vehicle Speed V lt 28 MPH CONDENSER om 4 CONDENSER pe E SaN OFF FAN OFF ban Hi Hi COOLING LOW E COOLING LOW pa FAN OFF FAN OFF 216 225 244 A C CUT 194 203 207 216 ECT deg ECT deg F gt 50 MPH Vehicle Spead V lt 28 MPH Vehicle Speed V lt 50 MPH Hi Hi CONDENSER gt CONDENSER yf ic OFF n FAN OFF Hi Hi COOLING LOW L b COOLING LOW Pe E FAN OFF
24. revised version 3 SECTION 7 STEERING AND S Fail Safe Functions Provisions have been made for fail safe capability during certain circumstances VSS failure will cause the EPSCM to allow maximum current 1A to flow at all speeds the result will be consistent light steer ing effort Solenoid signal failure will have the op posite effect an interruption in solenoid current will result in heavy steering effort at all speeds Front Suspension The 2003 Sorento uses a double wishbone and coil over front suspension with a sway bar The up per ball joint is integral while the lower ball joint can be serviced separately Camber and caster are adjustable through eccentrics incorporated in the frame mounting locations of the lower control arms The toe adjustment is facilitated by threaded tie rod ends Rear Suspension The rear suspension consists of a rear differential axle with coil springs and shock absorbers attached to the frame by a five link type system A sway bar is used to minimize body roll Rear alignment is not adjustable Self Levelizer Self leveling shock absorbers are available as an option on the EX trim level When additional load is added to the vehicle a pumping action is cre ated from the relative movement between the axle and the vehicle body This pumping action results in an increase in vehicle height due to the build up of high pressure oil within the shock assembly As load is reduced the vehi
25. temperature coming from the torque converter where the transmission s oil temperature is the highest Oil viscosity varies depending on the oil tempera ture This affects parts lubrication and shift feel so the TCM needs to change its shift pattern and lock up control to reduce oil temperature when it gets too high The TCM has a high mode hot mode and low mode shift pattern As a fail safe if an oil temperature sensor circuit is open or short the TCM judges the oil temperature to be 392 F and inhibits the lock up control and the high oil temperature shift pattern is then adapted revised version 3 5 The Input Speed Sensor CO detects A T in put speed from the rotation speed of the over drive direct clutch and transmits this to the TCM The input speed sensor will supply default data for gear shifting in case the output speed sensor fails It also informs the TCM of the damper clutch operating status when the lock up solenoid is ON The CO monitors the rotation of the Over Drive Direct Clutch ODDC The ODDC is engaged at Input Speed Sensor CO first through the third gear When the transmission is 1100 shifted into fourth gear the ODDC disengages and 1000 the direct clutch s revolution begins to stop In this E ann way the TCM receives feedback about fourth gear engagement or disengagement lt 800 The input speed signal is a substitute data source ae 700 for gear shifting in case the output
26. the vehicle into an idle RPM adjusting mode and then manipulate the Speed Ad justing Screw SAS as needed ISC Resistance Values e Terminals 5 4 5 6 1 2 2 3 29 38 ohms 68 F ISC Step Data Viewable in Hi Scan Current Data e 120 steps are possible the initial position is 80 steps set during 10 12 second power latch time at key OFF Idle Speed Target Data e P N range A C OFF 800 100 RPM e P N range A C ON 900 100 RPM s D Range A C OFF or ON 750 100 RPM The ECM sequentially activates the six fuel injectors through individual ground controlled cir cuits During initial engine cranking the injectors are actuated simultaneously until the 1 cylinder is detected via the CMP signal Each injector has four individual spray ports Injection time in milliseconds for each cylinder bank can be seen with the Hi Scan Current Data function Injector resistance 13 16 ohms at 68 F f _ Idle Speed Control ISC Fast Idle Air Valve FIAV revised version 3 9 SECTION 4 FUEL 4 The ECM controls the Purge Solenoid Valve Solenoid PSV using a duty cycle signal to facilitate canis ter purging The PSV is also operated during EVAP ee leakage monitoring Purge PSV Resistance Specification e 30 34 ohms 68 F The Canister Close Valve CCV is located on the GI EVAP canister which is underneath the vehicle for CCV ward of the fuel tank
27. to the new systems is also included First view the 2003 Sorento Technical Highlights video Then carefully read through this publication in its entirety Read study and review Enroll at a local Training Center for more Sorento training 2 revised version 3 M dS Z L LR Yes mmo T Va PATT DHAS d A GOE p y S A HT eT TTT TTT Sy PEEN PHH ETS ER UAA AEL x N 11 B SL CLS qe dG TOU re A Aig MANAGEMENT TTT TTU E SA 5 re Pon TS S 02 o E s Take the test on line at www kiauniversity com There are two Trim Levels for the 2003 Sorento LX and EX Both trim levels feature the Sigma 3 5 V6 engine and the 30 40LEI 4 speed automatic transmission The general specifications given here are for general information only and are subject to change Please check the Sorento Service Manual for the latest information Item Overall length Overall width Overall height without roof rack Overall height with roof rack Wheelbase Ground clearance Approach angle Departure angle Item GVWR Curb weight Weight distribution Item Bore X Stroke Displacement Compression ratio Battery CCA Capacity Alternator 13 5V 120A Starter 12V 1 2kw Spark Plug Gap Type Inches 179 8 73 3 68 1 ales 106 7 8 2 28 4 26 7 Pounds 4x4 5 644 Ax2 5 423 4x4 4 255 4x2 4 057 4x4 54 46 4x2 56 44 Gasoline Engine 3 66 x 3 38 inches 213 4 cubic inches
28. transmit ter for 1 second turn signals will blink once again 5 Remove the jumper wire turn the ignition switch OFF and remove the key revised version 3 5 SECTION 9 BODY ELECTRICAL The rear wiper functions are separate from the ETACS An ECU for rear wiper functions is located in the tailgate The rear wiper system features ON intermittent and momentary activation The rear washer obtains fluid from the front reservoir The 2003 Sorento rear tailgate glass can be opened independently from the rear tailgate func tionality is incorporated into the rear wiper ECU to automatically park the rear wiper if the rear tailgate glass is opened To restore normal operation the rear wiper switch must be cycled from OFF to ON should the rear tailgate glass be opened with the rear wiper switch ON Rear Wiper System H un amp RSs H 0 Wiper SW mal P Z 9 ee Washer SW N U om wd O e ma Limit SW Rear window open SW Rear Wiper System Circuit E Wiper Motor 6 revised version 3 SECTION 9 BODY E Full Auto Temperature Control FATC Manual Body Electrical The 2003 Sorento is available with a manual or an optional Full Auto Temperature Control FATC system Both systems use R 134a and are of the ex pansion valve receiver dryer type as are all Kia A C systems A swash plate type compressor is fitted and a parallel flow condenser is employed e The R 134a capacity 1 32 pounds e
29. 003 Sorento has a wheel base of 106 7 inches There is plenty of room for cargo inside and an optional roof rack available The tailgate has a flip open type glass that is controlled from the driver s door panel switch The rear wiper is computer controlled to prevent wiper operation when the glass is opened The spare tire is located under the rear cargo area of the vehicle It is lowered using the handle that is located under the cargo area panel The jack is lo cated behind the trim panel on the passenger side of the rear cargo area The rear washer bottle shares the front water bottle located under the hood Gusset Plate L L r E cx U K SORENTO Le d AOE revised version 3 The Electronic Time and Alarm Control Sys tem ETACS directs the operation of various body electrical functions Availability of features varies with vehicle trim level ETACS Input amp Output Diagram Inputs Controller Actuator Battery back up voltage Ignition 1 amp 2 power voltage Alternator L Terminal AUTO HEADLIGHT EX Washer Switch Wiper Motor Relay Wiper INT Switch Defogger Relay Wiper INT Volume Resistor Seat Belt Warning Lamp Rear Defogger Switch Chime Belt Seat Belt Switch Power Window Relay DRV PASS Door Switch Central Door Lock Relay All Door Switch each door S W Key Illumination Lamp Main Door Switch door lock unlock TNS Relay TNS Switch Room Lamp Vehicle Speed Signal Tail Gate Glass Actuat
30. 774 E BRB J left Photo Sensor Z TSA eaae characteristics S Te e i right Photo Sensor Over 0 45V 5 operation 5 2144 i i 1 U 10 20 30 40 50 80 70 LUX x10 000 Characteristics Ambient Sensor The Ambient Sensor is located forward of the condenser fan shroud The Negative Co Efficient characteristics of this sensor are utilized by the FATC control unit to detect ambient outdoor tem perature these values are then taken into consider ation during AUTO mode operation FATC GROUND VOLTAGE DETECTION YOSNAS Resistance Between B7 amp A7 Temp F Resistance 4 24 4 14 13 8 32 8 1 REFERERANCE VOLTAGE 50 4 9 68 3 1 86 2 1 4 14 revised version 3 Self diagnostics and fail safe functionality are 3 Hold the A C switch down and press the Mode designed into the FATC system Diagnostic Trouble switch more than three times within five sec Codes are retrieved using the switches on the FATC onds All graphic segments will blink two times control panel at the rate of four cycles per second The letters DTC Retrieval HHCC will then appear and blink at the same rate At that point self diagnostics will initiate 1 Turn the ignition switch to the ON position After all DTCs are displayed the codes will be 2 Set the temperature to 77 Degrees Fahrenheit 25 displayed two additional times before the FATC degrees Celsius unit exits the self d
31. ATED EVAP test Large Leak Test 1mm and gt 1mm leak Fuel Level 15 85 ECT gt 140 F IAT lt 140 F Vehicle Speed gt 19 MPH FTPS Voltage 1 0 3 5V ECT at start lt 140 F Load Value 25 70 Engine Speed gt 1500 RPM Small Leak Test 5mm e Fuel Temp 32 113 F e ECT at start lt 140 F e IAT lt 140 F e Time after start 192 seconds 3min 12 sec e FTPS Voltage 1 0 3 5V e Fuel Level 15 85 e Vehicle speed lt 37 5 MPH Thermostat Monitoring The engine must reach 170 6 F within a specified time period following engine start The amount of elapsed time before thermostat monitoring takes place will vary depending on MAF VSS and engine load values 10 30 min Thermostat Monitoring Enable Conditions s ECT at start 20 140 F e IAT decrease after start lt 9 F e ECT at start IAT at start lt 9 F e VSS gt 10 MPH revised version 3 13 SECTION 4 FUEL AND EMISSIONS Hi Scan Pro Diagnosis The 2003 Sorento is fitted with two Data Link Connectors DLC A 20 pin DLC is installed in the engine compartment in addition to the J 1962 16 pin connector OBD II DLC Forty five Current Data items are available for viewing and or flight recording The following additional functions are supported Actuation Testing Injectors may be individually cancelled with the engine running The fuel pump PSV CCV and radiator fan high low speeds can be activated with key ON and engine NO
32. Compressor oil capacity 5 29 ounces Discharge valve above and right Compressor Suction valve The ECM controls the compressor clutch opera tion Once an A C request is received the ECM will then signal the A C relay if all conditions are correct Cooling Condenser fan speeds and ISC position are also managed by the ECM based on A C system operation A single climate control panel is fitted on vehicles with the manual system The knob on the left con trols the blower 4 speed The center knob is for mode selection a button in the center of the knob controls fresh air recirculation mode operation The knob on the right is used to adjust discharge air temperature and incorporates a button for A C compressor operation requests Note Cable controls are not used in the 2003 Sorento R 134A parallel flow type condenser Discharge valve Suction valve Manual air conditioner revised version 3 Fi The optional FATC system features completely automatic control over discharge air temperature i mode door operation blower speed and A C com ial lt bt pressor operation A variety of sensors feed data to KACA a central control panel Circuitry within the control panel in turn manages blower speed temperature mix door position mode door position intake ac tuator fresh air recirc and A C compressor request Full Auto Temperature i al vy Control FATC ET Ax I a D
33. FF for a period of 10 seconds 1 second when the driver or front passenger door is opened KEY HOLE ILLUMINATION IGN KEY ETACSCM Keyhole Illumination Circuit 2 revised version 3 The interior lights will immediately reduce to 75 brightness once all doors are closed The lighting will then fade out within a 5 6 second time period IGN Key SAV Lamp 4Door SW BATT 12V T Gate SW Remote Controller ETACSCM T gate glass SW Interior Light Delay Out Circuit Turning the key in the driver door lock cylinder to the UNLOCK position will unlock the driver door only All doors will unlock if the key is turned to the UNLOCK position a second time within three seconds Turning the key to the LOCK position will lock all doors Ignition Switch Prrrrrrrrtrrrtirrt KKK KR KEK N To Drive Door Switch Power window operation is possible for 30 sec onds after the ignition switch is placed in the OFF or areena aR LOCK position providing the driver front passenger ow ote L door remains closed Power Window Timer Circuit revised version 3 3 In addition to the audible warning produced with the key in the ignition cylinder and the driver door in the open position the door locks will automati cally cycle to the UNLOCK position if an attempt is made to lock the doors with the key in the ignition However the doors can be manually locked which will cancel the lock out pr
34. H INHIBI A SMT TL CONTROL UNIT Hess GROUND VARIATION 1 7P N 7327 8928 YAZAK I OIL TIMPLRATURE SENSOR IGHITION W WHI 12 revised version 3 SECTIONS Shift Control Driving Control High ATF Temperature Control Shifting is based on inputs to a computer from various sensors such as engine temperature engine speed throttle position oil temperature and gear se lector position The TCM compares the information from the sensors against the shifting instructions programmed into it The TCM then controls the ap propriate solenoid valves to provide optimum shift timing However main shifting is made by the TPS and the output speed sensor signal which can be calcu lated as vehicle speed The input speed sensor signal is used to monitor the fourth gear engagement In case of TPS sensor failure the current data display in the HSP will display 0 Maximum line pressure is applied to the operating components to protect the transmission and torque reduction con trol will not operate In case of output speed sensor failure input speed data is used for shifting Damper clutch control line pressure and torque reduction control will not oper ate Normal shift pattern in D range up shifting and down shifting is available in all ranges 1 gear lt gt 4 gear except when 4 low mode is selected by a driver The shift pattern for hot oil mode starts when the old temperature is
35. IS 8 Z 9 Failsafe function YT gla o a a Sis g that always 9 9g2 2225 3 S leads to keep S O 8 BB B w e gt gic alive function S Z j 83 Sal S Sls 52 6 8 lS SSF ajma EB Power supply reversible gt low voltage 9 4V gt Uz xixixi Za 111 o WSS heel speed sensc ohm rr ll a 9 9 non ohm FDFP im I 2 WSS failure s i lo reversible gt high frequenzy BLS brake light switch Zt UE Taxi T l N PM __pump motor faiure er XX ia MR motor relay failure ae T xx 9 VR __sventil relay sticking fn T T H 1 h T XX A revised version 3 G Switch sensor failure A T T EERE FE EPS Electronic Power Steering EPS Condition in Parking and Very Low Speed 7 STEERING AND The 2003 Sorento is equipped with an Engine RPM Sensing power assisted rack and pinion steer ing system Vehicle Speed Sensing power steering is also available EPS found on EX trim levels only In the case of the RPM sensitive system the power steering gear and control is a one piece unit very similar to the system installed on the Sedona The turning radius is 36 4 feet Operations Shared by Both Systems The power steering pump driven by the crank shaft pulley through a drive belt develops the An Electronic Power Steering Control Module analyzes the signal from the VSS and varies the amount of fluid passing through the steering rack by varying the amount of current applied to a solenoid
36. LE SIDE CONNECTOR t FF l FEMALE RELY ae FRAD SOLENCID enrere SELECTOR SWITCH ROTATY SWATCH TYPE 209 revised version 3 pack to apply the clutch In this manner the clutch application pressure 1s achieved by using an inclined plane rather than just a magnet like an AC clutch The duty cycle application of the magnet allows for almost infinite control of the drive to the front axle Active Torque Transfer System ATT kaai SRA LE L ag The third available powertrain configuration for the 2003 Sorento is an intelligent full time four wheel drive system that utilizes an Active Torque Transfer system ATT commonly known as Torque on Demand TOD The TOD system uses a transfer case with a magnetically operated multiple disc clutch pack to provide the appropri ate amount of torque to each axle in response to the operator s driving technique and operating surface conditions Using many vehicle sensor inputs including front and rear output Hall effect speed sensors mounted in the TOD transfer case unlike the EST which only has a rear output sensor the TCCM monitors the speed of each propeller shaft and the driving condi tions If no rapid speed increase is detected for the front or rear axle without a corresponding speed increase for the other axle the TCCM causes very little pressure to be applied to the TOD clutch pack and the drive ratio is maintained at approximately 100 torque to the rear axle and
37. OSITION SENSOR Ko L 44 PLAGE CONTROL SOLENO RZ ALOR ny Xe Z 1 OXYGEN SENSORIBANK Z SENSOR 1 Ya WATER TEMP SENSOR f W arr pl Mice 2 wt 772 2 meu epar 2 SENSOR 24 viO KNOCK SENSOR x 1 v1 1 OXYGEN SENSOR BANK 1 SENSOR 17 j 5 vj 2 YEH SENSOR BAMK 1 SENSOR 2 v CRANK ANGLE SENSOR revised version 3 l Fuel delivery on the 2003 Sorento is ECM con trolled Fuel pressure from the in tank pump is man aged via a pressure regulator installed on the fuel rail 49 50 PSI unregulated pressure 39 PSI regu lated A fuel return line after the regulator leads to the fuel tank A fuel pump priming pulse is not em ployed The fuel filter is located in the fuel tank and is installed on the delivery module assembly Access to the fuel delivery module is facilitated by folding the bottom of the rear seat forward and removing the access plate on the passenger side The fuel pump relay is located in the engine compartment fuse and relay box Fuel Delivery A Fuel Cut Sensor inertia switch is installed in the circuit located on the passenger side inner fender near the air box between the fuel pump relay and the fuel pump The normally closed switch is physically located on the passenger side of the en gine compartment Within the switch a steel ball on a cone shaped seat is held in place via the force cre ated by a magnet fitted under the cone shaped seat The steel ball will overcome this magnetic force when a s
38. SET switch for one second or more which will set the relative altimeter to zero Pressing the UP or DOWN switch for one second will allow the units to be changed from metric to standard and vice versa The altimeter data is derived from a baromet ric pressure sensor which may affect altitude read ings at the same location depending on pressure variance Note The altimeter will retain its value at key OFF The Barometer displays atmospheric pressure in Hectopascals 1013 hPa is equivalent to 29 92 inches of mercury or 14 7 psi air pressure at sea level Note The sensor used for the Altimeter and Barometer functions is self contained within the Multimeter Ambient outside temperature is displayed in Cel sius or Fahrenheit units pressing the UP or DOWN keys for one second or more changes the display units matically performed the DRT indicator will cease flashing when completed This should be done at speeds of 12 5MPH or less Completion of this procedure may require more than one complete 360 degree turn Note the DRT indicator will flash during nor mal driving if abnormal data is detected for a dura tion of 5 minutes revised version 3 17 Passenger Airbag Module PAB Left and Right Side Curtain Airbag Module The 2003 Sorento is equipped with the new Sie CAB mens Smart Air Bag System This new Smart System Seat Belt Pretensioners Driver DBPT and Pas features the ability to cotto the deploym
39. T running EVAP Testing The Hi Scan Pro can be used to initiate an off board EVAP system test The vehicle must be in Park or Neutral and not moving VSS 0 for this test to function properly During the test the engine speed will be set around 2500 RPM Five minutes should elapse between EVAP test sequences and the engine should be warmed up ECT gt 176 F Fuel level should be between 15 and 85 capacity A blocked vent on the FTPS will give a false reading ECU ROM ID Displays the ROM ID of the ECM Idle RPM Adjust Mode The Hi Scan can be utilized to place the vehicle into an idle RPM adjust mode The Speed Adjust ing Screw SAS on the throttle body can then be manipulated to adjust base engine RPM see the Vehicle Emission Control Information Label under the hood for the correct specification Special Service Tools Tool Number amp Name Mustration Us Fuel Pressure Kit Adapter D Connection of fuel pressure gauge to delivery pipe for measurement of fuel pressure 09353 24100 Fuel Pressure Gauge amp Hose 14 revised version 3 SECTION 5 The Sorento automatic transmission is the Aisin Warner 30 40LE1 Model a four speed Electronical ly Controlled Automatic Transmission ECAT with a lock up torque converter Unlike the Sportage which uses a throttle cable to control hydraulic pres sure the Sorento uses a pressure control solenoid valve Various internal and external changes ha
40. TION 5 TORQUE ON Failure Effect Fail Safe W Lamp EEPROM Default calibration data TPS loss of signal P1726 TOD TPS idle TOD determined by wheel OFF slip only TPS out of range P1727 TOD TPS idle by wheel OFF EMC open shorted to battery P1728 TOD halted 2WD EMC shorted to ground P1729 TOD halted 2WD Front speed sensor voltage P1730 TOD 4H mode fail Rear speed OFF low sensor EMC Touch off level fixing 4L Mode fail EMC Maximum level fixing OFF 4H mode fail Front speed sensor EMC Touch off Front speed sensor voltage P1731 TOD high Rear speed sensor voltage P1732 TOD low rear speed sensor voltage high P1733 TOD Vehicle speed sensor refer P1734 TOD ence voltage low Vehicle speed sensor refer level fixing 4L Mode fail ence voltage high P1735 TOD EMC Maximum level fixing OFF Shift motor open shorted to Electric motor shifting No shifts Shift motor open shorted to Electric motor shifting No shifts OFF level fixing 4L Mode fail EMC Maximum level fixing OFF 4H mode fail Zero speed sensor EMC Touch off OFF vf Shift system timeout Electric motor shiftin No shifts General position encoder fault Electric motor shifting O 4H 4L 4H 4H 4L 4H EE Position 2 shorted to ground Electric motor shifting No shifts 4H 4L 4H OFF Position 3 shorted to ground Electric motor shifting No shifts 4H 4L 4H Position 4 shorted to ground Electric motor shifting No shifts 4H 4L 4H 1 2 J
41. The ECT is fitted with gold plated terminals The ECT is a negative temperature co efficient thermistor ECT Output Values e 3 2 3 8V 32 F e 2 3 2 8V 68 F e 1 5 2 1V 104 F e 0 4 0 8V 178 F e ECT temperature is viewable in Hi Scan Current Data A revised version 3 SECTION 4 FUEL AND Heated Oxygen Sensors HO2S Camshaft Position Sensor CMP Four Zirconia type Heated Oxygen Sensors HO2S are installed on the 2003 Sorento two up stream two downstream The front HO2S provide exhaust gas oxygen content information to the ECM for air fuel ratio control in the closed loop mode For catalyst monitoring purposes the rear heated oxy gen sensor signals are compared to the front HO2S e Fuel trim values under typical normal operating conditions 12 5 e HO2S voltage values and heater data can be seen for each sensor In addition Hi Scan Current data provides Fuel Trim long term short term infor mation for each bank A Hall Effect Camshaft Position Sensor CMP is installed adjacent to the exhaust camshaft sprocket on cylinder bank 2 underneath the upper timing cov er The trigger wheel has four blades the blade for the number cylinder is longer than the other three The ECM Signal utilizes output from the CMP in conjunction with CKP output to ensure proper in jector sequencing Timing Mark Camshaft Position Sensor revised version 3 5 SECTION 4
42. Wiring Diagram e B GREEN TA BROWN SPEED aL TET IGHTION 1 z K L i i C t panar ZK Om L r K em N X 7 FACM INHIBITOR SY XP Ped LRAG U ae S ea ee TEH R T EY ees ph DED L e mb Pa p motor causes a gear change in the transfer case that will provide a gear reduction for the transfer case output When the gear change has been completed successfully the 4L Indicator Light will illuminate steadily on the instrument panel If the vehicle had previously been in 2H the FRRD will automatically engage the front differential and axles To prevent dirt or moisture from being forced into the front differential with a failure of the clutch seals the FRRD system utilizes pressurized air to activate the internal dog clutch rather than vacuum control In the event of a suspected malfunction the High Scan Pro is a valuable diagnostic tool HIFT S ORSR NTE ITCRA PF VELLOA AWITE G ORANGE n AnaoLeT 7 SAU JEAN TANAY MOTOR TABLE _ eso 1aawG f 18aWG Bt k S S G G DB E ag KA gt T F3 C POSITIONN 4 MOTOR dL SWITCH SPEED SENSOR POSITIONN 3 MOTOR PETIR SVATA AT CLUTSM INTERLDCK EVATI T 2H SWITCH DIAGNOSTIC DISPLAY dL DISPLAY aH DISPLAY S M TRANSFER CASE CONTROL MODULE l Mahad U 4 ea iTr i lblolg ilk mip s L BHRHHHEIH SCAN TOOL i VEHIC
43. ance onm Temperature Celsius 3 3 3 7 ohm 68 F High Line Pressure Pressure Control Solenoid Valve Low Current High Low revised version 3 SECTION 5 Shift Solenoid No 1 amp No 2 Wiring Shift Lock Device Installation The wiring for the Shift Solenoid No 1 No 2 the Lock up Solenoid and SLT are assembled in one connector and are installed in the A T case 3 Procedure to install the lock cam Make sure to move shift lever to position P and install lock cam as figure Procedure for adjusting shift lock cable Check that lock cam is located in position Install shift lock cable in position as figure Temporarily install shift lock cable to A T lever assembly as shown in figure Securely insert cable end into fixing pin of cam After checking that a portion of cable end touches cable fixing pin of Rock cam fix shift lock cable to A T lever Checking that procedure for installing the shift lock is correct When the brake pedal is not depressed push but ton of the shift lever at P position cannot be op erated Shift lever cannot be shifted to the other positions from P Push button can be operated at the other positions except P When brake pedal stroke is 30 mm with shift lever at P position push button should be operated without catching and shift lever can be shifted smoothly to other positions from P
44. approximately 0 to the front axle The clutch piston is a ball ramp type of piston As the driving end is rotated it causes the driven end to also rotate and applies minimal drive to the clutch pack even when not activated When the magnetic clutch is activated by the ECM the duty cycle application of the magnetic field seems to put a drag on the rotation of the driven end of the piston As the driven end resists rotation the driving end relatively shifts under the driven end causing the driving end to walk under the driven end and the ball ramp design causes the piston to grow longer The wedge effect of the two halves of the piston causes the piston to apply pressure to the clutch regardless of the road surface the vehicle is operated on When the TCCM detects a rapid speed increase at the rear axle without a corresponding speed increase for the front axle the program of the TCCM inter prets this as the rear wheels slipping and activates the magnetic clutch control to apply variable pres sure to the TOD clutch pack in the transfer case That causes a split in the de livery of drive torque to the axles that may achieve up to a 50 50 split of the available torque between the front and rear axles If the TCCM then detects a sudden increase in front axle speed without a corresponding increase in rear axle speed the TCCM s program interprets this as the front wheels slipping and will reduce the application
45. assures auto matic air bleeding of the system Features e DOHC e 10 1 compression ratio e Idle speed 800 RPM 100 Items Sigma 3 5 L Displacement 3 497 cc Bore x stroke 93 x 85 5 mm Compression ratio 10 1 Firing order 1 2 3 4 5 6 Basic ignition timing 10 BTDC Idle RPM 800 100 HLS End Pivot Type x Fuel Pressure regulated 47 48 psi Injector type 4 hole Injector timing 17 BIDC Spark plug PFRSN 11 Spark plug gap 1 0 1 1 mm Oxygen sensor ZrO2 Coolant control Inlet Control Air flow sensor Hot Film EMS MELCO End Pivot Type Hydraulic Lash Adjusters Aluminum heads Cast iron cylinder block Aluminum upper oil pan revised version 3 SECTION 2 ENGINE 1 Variable Intake System 2 Exhaust Manifold 3 Thermostat Housing 4 Engine Block 5 Bracket 6 Dipstick Tube DeB Power steering pulley Tensioner pulley s hee dave bi Accessory mounting bracket e Three tensioners Water pump pulley 5 Tensioner pulley U RAT Air conditioner FE Ja a a pulley ZROH i LL L L h l LATE Sheet SS K C a oo A oa S Tensioner pulley 2 revised version 3 Crankshaft pulley SECTION 2 E Timing Belt Timing mark Camshaft sprocket Tensioner arm Tensioner pulley Auto tensioner Crankshaft sprocket To the reservoir Timing mark Timing mark D aog Pa Camshaft position sensor Idler pulley Engine support bracket Crankshaft position Sensor
46. cle height will momentarily increase a release device operates high pressure oil is released and the vehicle height will decrease The self levelizer system is not dependent on ex ternal sensors or pump assemblies Oil suction tube Oil reservoir Pump rod Damping Piston High pressure Gas chamber Diaphragm Piston rod revised version 3 Release bore Rebound stop Bypass for level control Inlet valve Pump chamber Outlet valve SECTION 7 STEERING The 2003 Sorento is equipped with P245 70R16 tires Steel wheels are standard on the LX alumi num wheels are standard on the EX aluminum wheels are optional on the LX The spare tire is a full size unit mounted beneath the rear of the vehicle A cable operated winch assembly is fitted to facilitate spare tire removal Wheels and Tires installation Special Service Tools SST Steering and Sus pension SST Steering and Sus pension SST Steering and Sus pension A revised version 3 09431 11000 Front oil seal installer 09432 21601 Bearing installer 09565 31300 Yoke plug wrench socket SECTION 8 BODY Overview The 2003 Sorento s body has a powerful and pres tigious look featuring a body on frame construction with nine cross members A gusset plate has been added for additional rigidity The front view of 2003 Sorento is wide and ag gressive featuring a large size radiator grill The 2
47. color Fog lamps Multi reflector head lamps Head lamps Auto lamps Body color Bumpers Bodyside cladding fender Two tone flares Body color S Rear garnish Manual fuel door amp gas cap with tether Rear split hatch liftgate w flip open glass operated with remote or inside release Skid plates front end fuel tank C S S gt x lt revised version 3 E SECTION 1 GENERAL INFORMATION INTERIOR Features and Options Double raschel cloth seat and door trim Seat upholstery amp trim inserts Moquette velour cloth seat and door trim gt lt Leather 8 Way manual adjustment driver 8 Way power adjustment driver Front seats Heated driver amp passenger Lumbar adjustment driver W Tilt adjustable headrests 60 40 split flat folding rear seats Rear seat Fold down armrest Removable headrest all three positions Leather wrapped Steering wheel Leather wrapped wood grain Black PRNDL shift shaft knob Shifter Brushed metal style PRNDL chrome shaft black knob Brushed metal PRNDL chrome shaft wood grain accent knob Color keyed Inside door handles Chrome Color keyed Scuff plates Bright stainless steel Wood grain center fascia console accents Fabric headliner rm Cut pile carpet 8 revised version 3 Features and Options Dome lights with fade out feature illuminated entry and exit and I P dimmer switch master control PF os Ss In door safety courtesy lights
48. conds Take at least one minute to idle in neutral between tests Stall RPM C1 Sigma 3 5 2520 RPM D range only Co F2 R range only D amp R both ranges Time Lag Test This is the same procedure as stall except there is no throttle application Time lag is the time until slight shock can be felt when the shift lever is shifted from N to D and from N to R while engine is idling The time lag test can inspect the hydraulic condition clutch brake condition The technician must wait one minute between tests Wheels must be locked during this test Measure time lag by using stop watch from mo ment shift lever is shifted from N to D and N to R until moment slight shock is felt Procedure Check ATF fluid level Hook up transmission pressure tester to test port on the side of the transmission Check for oil leaks at test port after starting ve hicle Take left foot and apply brake firmly Set parking brake Shift transmission into D range Take right foot and apply throttle pressure for no more than five seconds The test is the same for reverse except technician must wait at least one minute between testing C Stall RPM Possible Cause 1 C2 slip 2 F2 slip 3 Less line pressure 1 C2 slip 2 B3 slip 3 Less line pressure 1 Less engine power 2 Poor OWC of inside T C oor oil pump Time lag spec N to D no mor
49. d result in poor acceleration Uphill mode prevents frequent up shifting to maintain driving force during acceleration There are two up slope modes which change shift patterns e Hill One mode engages when the road slope ex ceeds 8 gradient for two seconds e Hill One mode disengages when the road slope is 5 5 or less for one second gt Optimal gear shifting e Hill Two mode engages when the road slope ex ceeds 15 gradient for two seconds e Hill Two mode disengages when the road slope is 12 or less for one second The sensors used to determine optimal gear shift ing are the VSS TPS and MAF If the vehicle speed remains constant while TPS angle and load increase the TCM will assume the vehicle is traveling uphill and will respond with either the up slope one or slope two modes The mode with which the TCM responds depends on the TPS angle and engine load Uphill Two Uphill One revised version 3 LS Adaptive Shift Control Coast Down Control Adaptive Shift Control Down Slope Mode While driving downhill the engine brake operates automatically according to the accelerator position and braking conditions at a certain slope degree e Down Slope mode engages when road slope ex ceeds 4 5 gradient down slope occurs for longer than 1 second e Down Slope mode disengages when road slope is 3 5 or less If the vehicle speed increases while TPS angle is at zero a
50. de Terminal 4 Terminal 6 FRE S REC S Located in the bottom of the heater case the POTENTIOMETER CHARACTERISTICS Temp Door Actuator controls the position of the temperature blend door A potentiometer within the actuator assembly detects door position and provides a feedback signal to the FATC control unit When 5V between terminal 2 1 above voltage is obtained between terminal 5 1 4 7V 0 3V COOL WARM 1O revised version 3 The Mode Door Actuator controls direction of airflow based on signals from the FATC control unit MODE S W connector 14213 4 5 6 7 VENT A12 4 D m BILEVEL A2 a R i l FLOOR A13 f naz i DEFA k GROUND Bi LEV FLOOR MIX DEF G Ground Inspection e Apply 12V to mode actuator terminal 7 and ground terminal 6 e Verify that the mode actuator operates as below when grounding terminals 5 4 3 2 and 1 in se quence Vent Bi Level gt Floor gt Mix gt Def revised version 3 11 Sensors Fin Thermo Sensor The Fin Sensor is a negative temperature coef ficient thermistor installed on the evaporator core It is monitored by the FATC control circuitry to prevent evaporator freezing The A C compressor will shut down if evaporator temperature drops below 33 F Compressor re activation will resume between 38 3 39 2 F Characteristics a G E E E a e H a a o a sa BT s os e 48 w
51. defective parts Turn the ignition key to the ON position and Nare Please consult the Service Manual before ser turn on the Hi Scan Pro vicing the supplemental restraint system Special Deployment tool 095A 34100 A Service s Deployment of undeployed airbag module Tools e SRSCM Deployment Adapter Harness DAB 0957A 38100 PAG 0957A 34200 Diagnosis check wire 0957A 38000 Dummy 0957A 38200 Dummy adapter DAB SAB 0957A 38300 PAB BPT 0957A 38400 Dummy adapter 0957A 38300 Adapter to connect PAB Dummy adapter 0957A 38400 Adapter to connect BPT Dummy adapter 0957A 38100 Use with 0957A 34100A 8 revised version 3 Kia Motors America Ine PO Box 52470 Irvine CA 92619 2410 Student Learning Guide UKO30 PS 001
52. e SRSCM also monitors the front seat belt buckle switches and seat track posi tion sensors controls operation of the SRI stores Diagnostic Trouble Codes in non volatile memory and stores information regarding component de ployment crash information The SRSCM has emergency energy reserves to provide deployment energy for a short period if ve hicle voltage is low or lost in a crash The SRSCM also provides a signal after a deployable crash to unlock the vehicle doors The SRSCM must be replaced if any of the airbags deploy However the SRSCM may be reused if only the pretensioner has deployed After six pretensioner deployments an internal fault code is generated in the SRSCM and the SRSCM must be replaced Warning The battery must be disconnected for 10 minutes prior to disconnecting the SRSCM con nector or performing any repair testing procedure on the SRSCM systems Note These capacitors hold a charge for a period of time after the battery has been disconnected Please consult the Service Manual for proper procedures Failure to do so may result in severe injury In addition the SRSCM must be in stalled with the correct orientation to ensure that the sensors are positioned along the longitudinal center line of the vehicle The bolts should be torqued ac cording to sequence Refer to the Service Manual for correct specifications and additional information 2 revised version 3 Note These capacitors hold a charge fo
53. e all the wheels lose their grip on the ice and they cannot achieve the desired frictional force which would increase the G value Therefore the G sensor allows the ABSCM to recognize all wheel slip tendencies by measuring the low G value Even if all wheel speeds are reduced because of one or two wheels locking up if the G sensor value remains high ABSCM corrects the reference vehicle speed that comes from only the locked wheel Normal Operation In normal conditions equal brake pressure is de livered from the master cylinder to each caliper via an inlet valve which is normally an open type Unless the ABS mode has been actuated the pump motor does not operate The purpose of the accumulators is to save brake fluid for a constant fluid supply to the pump during pump operation in ABS mode During EBD opera tion when the pump does not run the accumulator stores fluid which comes from the outlet valve The purpose of dampers is to absorb pressure fluc tuation and noise while the pump motor operates O C O O 15 Ignition Switch E 21 Stop Switch O O 14 Stop a CE 7 diagnosis A L Signal ground re 30 Acceleration longitudinal 10 Sensor V 5V 28 TOD Signal 13 4WD ECU ABSCM External Wiring Diagram revised version 3 a UL 7 m HID MU Z R IUT Wheel Speed Sensor RL M D Oa OD N H H HTH H TH HTH E H H HTH E H H HTH H H H HTH tise H H HTH H C0045 WSS RL continuity WSS connector wir
54. e harness C0045 WSS RL plausibility Wire check short air gap tooth C0050 WSS RR continuity WSS connector wire harness C0050 WSS RR plausibility Wire check short air gap tooth C0930 Acceleration sensor Connector sensor failure wire open C0060 Solenoid Valve LF AV Short MV line open C0065 Solenoid Valve LF EV Short MV line open C0070 Solenoid Valve RF AV Short MV line open EV C0075 Solenoid Valve RE O l Short MV tine open C0080 Solenoid Valve RL AV O g i Short MV line open O ow S eO S o pen caso enO S o oS O o ene S o pen enone HTH cis Valve relay Brake switch WSS frequency error ECU malfunction EBD amp Parking ABS Warning Lamp Brake Lamp e ECU failure e Wheels sensor failure open or short e Low high voltage e Solenoid valve failure e Parking brake e Low brea e While diagnosis Short G bar failure e Short G Bar Failure e Acceleration sensor e Acceleration sensor revised version 3 3 Electronic Brake Distribution EBD The Electronic Brake force Distribution EBD system is a sub system of the ABS system and con trols the effective adhesion by the rear wheels It further utilizes the efficiency of highly devel oped ABS equipment by controlling the slip of the rear wheels in the partial braking range The brake balance which is controlled electronically is moved even closer to the optimum eliminating the need for the proportioni
55. e than 7 sec onds N to R no more than 1 2 seconds Take three measurements and take the average value Results Longer than spec from N to D lower line pressure forward clutch failure slipping num ber 2 one way clutch failure Longer than spec from N to R lower line pressure direct clutch failure slipping first and reverse brake failure slipping revised version 3 17 Automatic Transmission Line Pressure 3 Read the oil pressure as soon as the engine speed Trouble shooting Test becomes constant then release the accelerator Diagnosis 1 Connect the SST to line pressure inspection port pedal of transmission case Note Steps 4 and 5 must be performed within five seconds 2 Shift the selector lever to D range 6 Shift the selector lever to N range and run the 3 Read the oil pressure at engine idle speed P E E engine at idle speed for at least one minute 4 Depress the brake pedal firmly with the left and gradually depress the accelerator pedal with the right foot 7 Read the line pressures at engine idle and stall speed for R range in the procedure described above Te H 7 AUK RT RRR Evaluation of Line Possible Cause Pressure Test Condition Defective or stuck the throttle valve Defective or stuck the regulator valve Defective the oil pump OD clutch slipping In D and R ranges Fluid leakage in the D range li
56. eck gap at 0 3 1 2mm DIE H B SUES s B otherwise the ABS will detect wheel slip K Power Power consumption Outlet Valve E A 4 290 0 25Q Please consult your Service Manual for ABS service procedures Install location revised version 3 SECTION 6 BRAKES ABS Anti Lock Brake System ABS Acceleration Sensor The four wheels of an AWD all Wheel Drive 4WD vehicle are linked by the center differential so the engine braking force acts on all the wheels In the event one of the tires of an AWD vehicle begins to slip the torque of the tire that is beginning to slip is distributed to the other tires making the rotation speed of all the tires virtually identical Since the signals being sent to the ABSCM from the four ABS sensors at this time are similar the reference vehicle speed calculated by the ABSCM is less than the actual vehicle speed Using the calculated vehicle speed and acceleration as a basis for ABS control would result in error that would increase the danger of wheel slip In order to overcome the problem described above an AWD vehicle is equipped with an accel eration sensor G sensor located under the center console which is used to determine the actual decel eration of the vehicle For example if a driver slams the brake pedal on ice making all wheels lock up the vehicle begins to slide and the G value deceleration is low This is becaus
57. ed to protect all operating components of the transmission Also the torque reduction control will not operate The ECM sends the TPS a signal via a CAN bus communication line to the TCM Without the CAN communication an independent pin and wir ing would be needed to receive sensor information from the ECM The TPS information is used to con trol line pressure through the line pressure control valve Resistance values for this sensor are 3 3 3 7 ohms at 156 F Shift solenoids No 1 and No 2 are controlled by the signal from the TCM Shift Solenoid valve is the normally closed NC type When the solenoid is ON solenoid valve is open Tae ONC TPS output eet E Shift Control Solenoid Valve revised version 3 E This solenoid is a Normally Open NO type According to each lock up shift schedule the TCM sends signals to the lock up solenoid valve ON OFF control of the lock up solenoid by the TCM is based on the vehicle speed and the throttle opening According to the TPS opening angle the lock up solenoid valve controls the oil pressure to the prima ry regulator valve and generates proper line pressure which matches engine load tyr 19 mil 4 n le Levi 4 a beia 9 nP i The Line Pressure Control Solenoid SLT con trols linear throttle pressure by control signal from TCM and line pressure for clutches and brakes to reduce shift shock Resist
58. ent speed senger PBPT of the driver and passenger s front air bags with the Seat Track Sensors Diye DS rey aud Passer use of dual squib air bag modules Other features of this system are the side impact curtain airbags and ger PST front seat belt pretensioners The air bag systems are Front Impact Sensors Driver DFIS and Pas designed to supplement the seat belts to help reduce senger PFIS the risk and severity of injury to the driver and pas e Side Impact Sensors Driver DSIS and Passen sengers in the event of a collision ger PSIS The major components of this system are e Buckle Switches Driver DBSW and Passen e Supplemental Restraint System Control Module ger PBSW SRSCM e Driver Airbag Module DAB Please consult the Service Manual for recommended service procedures e Wiring Harness and Clock Spring e SRS Service Reminder Indicator SRI PAB PBPT D P SIS DJP STS E ee K ee x SRSCM pDBPT D P BSW revised version 3 SECTION 10 SUPPLEMENTAL SRS Control Module The SRS Control Module SRSCM is located on the floor behind the shift lever and hand brake Access the SRSCM connector by removing the rear panel of the center console The primary functions of the SRSCM are crash detection airbag and pre tensioner activation and monitoring the airbag and pretensioner systems The SRSCM determines when to deploy the airbag modules by sensing frontal and side impact forces Th
59. epending on the state of system operation at the time the OFF switch was pressed In addition the intake door will switch to the fresh air position MODE Switch By pressing the MODE switch the user can cycle through VENT B L FLOOR and MIX positions Blower speed and discharge temperature are manu ally controlled RECIRC Switch FRESH Switch The RECIRC and FRESH switches permit selec tion of the intake air source AMB Switch Ambient outdoor temperature is displayed for five seconds after the AMB switched is pressed AMB Sensor F N Sensor In car Sensor Photo Sensor Control Humidity Module Auto Switch Off Switch A C Switch AQS Switch AMB Switch Temp Switch Defroster Switch Blower The blower motor has six possible speed varia tions Instead of a conventional resistor assembly a power transistor is used for speeds one through five The power transistor is located in the heater case as sembly Display Blower Speed BLOWER RELAY HIGHSPEED g BLOWER RELAY amp Mix Door Intake Door Compressor CONDITION IG ON FATC ON Measure voltage BLOWER _ 7 7 MOTOR revised version 3 9 For high speed operation battery voltage is ap plied directly to the blower motor via a relay located x High Speed Blower Relay next to the blower motor A 12 volt motor is controlled using a reverse po larity circuit to select the source of intake air Mo
60. es the same as the Two Turn Unlock feature accessible from the driver door key cylinder interior illumination is also acti vated when the doors are unlocked A panic function is incorporated as part of the RKE circuitry Pressing the panic button on the transmitter for 2 7 seconds or more will result in hazard lamp and horn activation for 27 seconds The panic function can be cancelled by pressing the UN LOCK button on the transmitter pressing the panic button for 2 7 seconds or more will also cancel this function RKE Transmitter Programming The 2003 Sorento RKE system will accommodate a maximum of two transmitters Programming Procedure single trans mitter 1 Insert the ignition key and turn the switch to the ON position 2 Install a jumper wire between pins 5 and 6 of the 20 pin under hood DLC Aug Rp Je e o n a2 20pin D Connector No 5 battery B No 6 RKE set 3 Press the LOCK button on the transmitter until the turn signal lamps are extinguished lamps will blink twice 4 Release the LOCK button remove the jumper wire and turn the ignition key to the OFF posi tion Programming Procedure two transmit ters 1 Insert the ignition key and turn the switch to the ON position 2 Install a jumper wire between pins 5 and 6 of the 20 pin under hood DLC 3 Press the LOCK button on the first transmitter for 1 second turn signals will blink once 4 Press the LOCK button on the second
61. g GIANG Z eel CDS IGMITION 4 j revised version 3 IGHITION SW K BATTERY hy d T M Tt SPEED SENSOR AND CLUTCH GOIL CONNECTOR E i BG fale i j tlelelilk mio s eltinli li njali S NEUTRA EW BRAKE SL i i The TOD system s advantage over the part time four wheel drive system or other competitive hy draulically activated full time four wheel drive systems is the system s ability to constantly monitor the operation of both drive axles for slipping and the ability to electronically precisely adjust the amount of torque being delivered to each drive axle to an appropriate level This enhances the Sorento s driv ing safety and stability regardless of rapid changes in the driving surface from dry clean pavement to mud to ice or snow to water covered The driver never needs to worry about putting the vehicle into four wheel drive or taking the vehicle out of four wheel drive to minimize wear on powertrain parts or improve driving stability The TOD system monitors vehicle operation and instantly makes any necessary drivetrain adjustments Fail safe for auto mode is 0 100 power distribu tion for the front and rear axles Fail safe for low mode is 50 50 power distribution Registered trademark of the Borg Warner Corporation U S A gt MOTOR OUTPUT HILIAA gt MOTOR OUTPUT LTH gt EWC gt BATTERY x IGHITICN S11 ENOODER GROUND DIAGNOSTIC DISPLAY TPS
62. glove box with upper map pocket LCD odometer with two trip meters revised version 3 9 SECTION 1 GENERAL INFORMATION AUDIO SYSTEMS SAFETY gt lt m gt lt Features and Options Audio Systems AM FM CD 8 speakers 6 enclosures Delphi premium AM FM Cassette CD audio with separate amplifier 10 soeakers 6 enclosures Delphi premium AM FM 6 disk in dash CD with separate amplifier 10 speakers 6 enclosures Steering wheel audio controls O Antenna One pole Safety Battery saver Brake Front and rear disc Dual airbags Steering wheel instrument panel air bags no seam Side curtain airbags Rear child safety door locks High mounted stop lamp Fixed upper amp lower anchors for child safety seats LATCH system First aid kit in rear quarter panel storage bin KMA Two speed variable intermittent wipers Rear window defogger Rear window wiper washer intermittent Front windshield de icer hot wire Low fuel warning indicator Washer fluid low warning indicator 4 Wheel ABS Side impact protection Seat belts 3 Point emergency locking retractor all seating positions Adjustable anchors in front Pretensioner amp force limiter front seats Energy absorbing steering column ux ae ed as O S5 i e Fuel cut off system S Standard O Optional NOL available ACC Accessory Lux Luxury package TP Tow Package 1O revised version 3 Options ABS all Self Levelizer EX
63. h a separate connection The relay remains active for about 10 12 seconds at key OFF for adaptation value ISC initialization and fault status storage purposes The main relay is ECM controlled Main Relay A Controller Area Network CAN allows the ECM and TCM on the 2003 Sorento to exchange data using two common data lines rather than em ploying separate wiring for each shared signal CAN data is transmitted in digital format at a transmission rate of 500kbit second The ECM and TCM support individual DTC s for CAN communication failures P1630 is a TCM CAN code P1632 is an ECM Controller Area Net work DTC Controller Area Network CAN 12 revised version 3 SECTION 4 FUEL AND EMISSIONS OBD II Monitoring Functions The following monitoring functions are performed in accordance with OBD II regulations e Catalyst Efficiency Monitoring e Misfire Monitoring Note The misfire monitor function does not detect rough road conditions via a Chassis Acceleration Sensor Bosch or Wheel Speed Sensor Siemens rough road detection is accomplished internally by the ECM based on RPM and load values e Fuel system Monitoring Fuel Trim s EVAP Monitoring 0 5mm leak detection capability Note EVAP testing on the 2003 Sorento is similar to the Sedona vacuum The ECM will NOT initiate an EVAP test on its own with the vehicle stationary at idle speed The following are conditions for an ECM INITI
64. hen be turned off Dur ing the initialization phase the SRSCM will not be ready to detect a collision Deployment will be inhibited until the signals in the SRSCM circuitry Operating situation Return to normal from temporary fault 2Faults frequency gt 5 Active fault Normal 2 Faults frequency lt 5 Faults frequency gt 6 Active fault pees E dUd Np x i E ee Se eee On to off after 6 seconds finish initialization The SRI will illuminate continu ously if there is a loss of ignition voltage supply to the SRSCM or a loss of internal operating voltage The SRI will also remain illuminated continuously through the shorting bar in the wiring harness con nector if the SRSCM is disconnected The SRI will flash at approximately 1Hz should there be a loss of SRSCM operation Operating method ON OFF Turn it on continuously Blink 6 times Turn it on continuously revised version 3 E Diagnostic Trouble Codes for the 2003 Sorento Access Kia Vehicle Diagnosis for SRS ane lemental restraint syst displayed as B Dili Diagnosis PUP POMENA TESLAN Sy ater ALE Cpe ce ae e If a system fault is detected there is a possibility codes which must be retrieved using the Hi Scan that the fault is not in the component but in SRS Pro wiring or connector e Connect the Hi Scan Pro to the vehicle s under Caution Do not repair SRS components or wiring hood DLC Replace
65. hock equivalent to a 9 MPH collision is transmitted to the sensor through the body of the vehicle Once the ball has overcome the magnetic force it strikes a moveable contact the switch is thereby opened interrupting current flow to the fuel pump A switch on top of the sensor is installed to facilitate resetting normal fuel pump operation Continuity should be present between the two outer terminals once the reset switch has been pressed Fuel Cut Sensor 2 revised version 3 Input Output Input gt ECM Output Oxygen Sensor Bank 1 Sensor 1 Manifold Differential Pressure Sensor Ignition Oxygen Sensor Bank 1 Sensor 2 Knock Sensor Injector Oxygen Sensor Bank 2 Sensor 1 Fuel Level Sensor Idle Speed Cont Motor Oxygen Sensor Bank 2 Sensor 2 Fuel Tank Pressure Sensor Main Relay Control Mass Air Flow Sensor Fuel Temperature Sensor Fuel Pump Control Air Temperature Sensor Ignition Failure Sensor Cooling Fan Control Throttle Position Sensor Vehicle Speed Sensor Diagnosis OBD Camshaft Position Sensor Power Steering Sensor VICS Vacuum Solenoid Crankshaft Position Sensor Ignition Switch Coolant Temperature Sensor Battery Voltage The 2003 Sorento employs a Bosch hot film type Mass Air Flow sensor MAF which has an integrat ed Negative Temperature Coefficient NTC Intake Air Temperature Sensor IAT The MAF is located between the air cleaner and the throttle body on the passenger side of the engine
66. iagnostic routine DTC Code Description Fail Safe EO Normal El In Car Sensor Fail 77 F Fixed E2 Ambient Sensor Fail 77 F Fixed E3 Fin Sensor Fail 28 F Fixed E5 Photo Sensor Fail E6 Temp Door Setting Temp 63 77 F Max Cool Potentiometer Fail Setting Temp 77 90 F Max Hot revised version 3 15 Compass The Multimeter on the 2003 Sorento is similar in exterior appearance to the Trip Computer on the 2002 Sedona Functionality however is significant ly different between the two units The Multimeter on the 2003 Sorento is fitted with compass altitude barometric pressure and temperature modes Using the Mode switch the user can cycle through the available functions The temperature feature will not be included on vehicles equipped with the Fully Automatic Temperature Control System The compass function provides bearing direction of travel information to the user It is known that a magnetic compass does not point to true geograph ic North Magnetic North is the direction in which a compass will point Over most of the surface of a Sa E S Deciralion degrees Annual change mini Declination Correction 1 Turn the ignition key ON and access the compass func tion DRT will be shown in the display 2 Press and hold the MODE SET switch for 4 seconds The display will change from a direction to a number fol lowed by an E or W the Earth this means that a
67. ich 1s aligned with the shift lever According to the location of the manual valve the hydraulic connection inside the valve body operates relevant parts Automatic transaxle vehicles have an A T neutral relay to detect the shift condition from Auto Mode to Low Mode TOD or 4H to 4L mode EST Due to the characteristics of the Transfer Case Con trol Module TCCM the N signal battery 12 volt from the inhibitor switch cannot switch directly revised version 3 For example if the L range is selected but there is no position signal coming from an inhibitor switch the TCM recognizes this as the D range It controls the ON OFF combination of the shift control so lenoid valves No 1 and No 2 according to the D range shift pattern Without the signal from the L range the transmission follows a D range shift pat tern up to the second gear The car transmission can not be shifted up to the third and fourth gears Neutral relay TCM TCCM IG1 B The Oil Temperature Sensor converts ATF tem perature variation into electronic signals to transmit to the TCM This information is necessary for shift control and Lock up control etc FS nT PASS E Resistance Specifications e At 32 F resistance should be 1 884 2 290 ohms e At 320 F resistance should be 19 2 22 2 ohms The oil temperature sensor is a Negative Ther mal Coefficient NTC type of thermistor which detects ATF
68. intenance continued Maintenance Intervals wome rs Ts Tze or km x 1000 12 24 48 Brake Lines and Connections O Parking Brake H T H a 2s ee Brake Fluid Clutch Fluid i equipped Sorna operon natmo _ Front Suspersonsetvens 1 _ Dresano HR cressfeoeynusenssats 1 S ee E Frente Reoromesranvions r H e CTH A C Refrigerant if equipped Inspect refrigerant amount annually A C Compressor if equipped Inspect operation annually G revised version 3 13 Sigma 3 5 Engine General Description The Sorento is equipped with a Sigma 3 5 Liter engine which is the same as the Sedona but with a different Variable Intake System The intake manifold utilizes a variable intake system which extends the torque curve by selecting designated intake runners to improve performance The block is made of cast iron The cylinder heads and upper oil pan are aluminum Hydraulic Lash Adjusters HLA eliminate the need for valve ad justments There are three drive belts with mechanical ten sioners The timing belt turns all four cam sprockets with a hydraulic timing belt tensioner The engine is mounted at 4 inclination higher in front in order to accommodate the front differential A fitting is provided on the thermostat housing link ing the front water jackets of both heads through a pipe to the surge tank This design
69. ion Remark Continually 10 4Kbps Logic 0 Vbatt 20 45 Li Pulse Logic 1 Vbatt 80 T 28 Diag Switch 49 Inhibitor Switch 2 PIR NIDIL Below 0 8V 50 Inhibitor Switch L PIRIN D 2 Below 0 8V 23 Cruise Control gt 3 5 S II 2 4 Continually 500Kbit s 41 CAN High Continually 500Kbit s 22 CAN Low S 8 8 8 p a L Z Ra Ez SCAN 1601 P u se N 2 2 2 EE WIR gio gt es 4 FR ANNE NAZAR Vialand aa ag SB OB TOP LANE SCAN T STOP LANP xe ea VIHICLE PELD up 6 60 IHAA PEV sine 0x701 8 10 DIAGNDSIS CONNECTOR RASID H JA PR LIED TAY ZO C L RN Beige ja a la r lefele lefele febli ellie ifmfalt obol peshasi ah Af Ham IR Le H ACC UNIT L fe 18 4 T C LM j Lr durn CLOCK WISE OWL ais viet 03 ECU STE a HE SEE SEE VARIATION 1 SEE VARIATION 1 Cor m TO UE Kae E m Sp N FOH2 1081 40 TATAK I R N 5 R ICU PIH NANT P aM ROL SOLCNOIO RESU KENTEL SOLENGID LATH IA casen OMN RIL SA UT CrL HOER Sra SL HS VEHICLE SPELD SZNS i if i THHIGIIGR WIH TR HIFI DONTADL 24 LRE WO HIFI CONTROL SACHOID WI ua LATH FOR EIL TEMPCRATURE SENSOR BIL TCMPERSILAL SC MTD CALIE CONTROL ARIH FOR CO Er TRS ACU TICN Z ZE 81 HS TS SW 0G D A OFF Lip S 1 2 E i EI FAIGA TRT WHIRIA wich N LATH TE PIAR 219 Z HME ARE alal a 2 P 7 TCCM ES AE TOO SS NE KEANNA SRS
70. ivated The FRRD system uses pressur ized air from an electrically operated air pump to activate and de activate a dog clutch in the front differential The electric air pump is located in front of and below the vehicle battery in the engine compartment When 4WD is selected the air pump energizes and expands the dog clutch activator to apply pressure to the clutch As the clutch engages it causes the ring gear carrier of the front differential to rotate which in turn rotates the front drive pinion This causes the front propeller shaft to rotate to syn chronize the speed of the shaft with the gears in the transfer case As the speed of all of the related com ponents synchronizes the Transfer Case Control Module TCCM activates the shift motor to en TCCM Location gage four wheel drive in the transfer case Once the four wheel drive engages the 4H Indicator Light will illuminate steadily on the instrument panel The vehicle may now be operated on soft or slippery sur faces with the rear wheels pushing the vehicle and the front wheels pulling to add safety and stability The part time four wheel drive system also has a low range feature to provide the operator with greater torque to turn the wheels when less vehicle speed is required To engage the 4L range of op eration the driver needs only 1 stop the vehicle 2 place the gear selector in N and 3 rotate the mode selection switch to the 4L position The shift
71. j pero Highlighta and New Model Introduction Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 General Information Engine Engine Electrical Fuel and Emissions Transmission amp Drivetrain Brakes Steering and Suspension Body Body Electrical Supplemental Restraint System This Technical Highlights publication provides information about the new fea tures systems and components used on the 2003 Sorento We have included the most accurate and up to date information 2002 Kia Motors Corporation Service Training Department available at the time of publication Due to constant improvement in our products the information and specifications presented in this manual are subject to change without notice All rights reserved This publication may not be reproduced in whole or in part without the written consent of Kia Motors Corporation revised version 3 SECTION 1 GENERAL INFORMATION This Sorento Technical Highlights publication serves two important purposes Used with the 2002 Sorento Technical Highlights video it s your key to a comprehensive understanding of all the new features systems and components that are included on the all new Sorento Secondly this manual is How to Use This Manual Watch the video your initial model introduction training for the 2003 Sorento Information about service procedures that are specific
72. l Airbag Check Digit Must be 0 9 or X Model Year 3 2003 Assembly Plant 5 Whasung For all vehicles manufactured between 4 27 2002 and 8 14 2002 the letter C indicates either 2WD or 4WD For all vehicles manufactured between 2 28 2002 and 8 14 2002 the number 5 indicates a 4 door SUV For all vehicles manufactured between 2 28 2002 and 8 14 2002 the number 2 indicates a GWVR of 2 271 2 720 kg 4 996 5 984 Ibs Vehicle Identification Section Chassis No Production Frame Sequence Number revised version 3 5 Features and Options 3 5 DOHC 6 cylinder 192 HP 4 Speed automatic Engine speed sensing Power Steering Vehicle speed sensing Steering linkage Rack amp pinion Hood blanket Front Wish bone w coil spring Suspension Rear 5 Link coil spring Fuel tank 80 liters 21 1 gallons 2 Speed transfer case 4WD Self levelizer 6 revised version 3 gt lt m gt lt Features and Options Styled steel S Wheels e Alloy bright machine finish face P245 70R16 domestic bound S ires P245 70R16 Michelin Full size spare tire under vehicle alloy steel if equipped with alloys S Mudguards ACC Windshield Solar control glass S Side glass B pillar back Privacy glass S Power sunroof tilt and slide Grille Black mesh insert w chrome surround S Body color S Door handles Body color chrome accent Dual power heated black S Mirrors Dual power heated body
73. m a J i i la i d Lal 7 ri T 1 p L LS i Y R p T 0 Ere Ed LL SE PS e EE t a w as a E Mig am Pw Ee boa P pe Tr T lad a MS i kiii ET Tia v L a ea lana pa HT a m 0 P lq m s L M L 1 RE ZT D E E TEN K Swi m L pern BS EES tata Os il i 7 a ee ITE ae i i Faas naf F eo T E t c ay Te Fae ee LEE A T 7 eS eee e i are d r a tot p n m 7 EE a ee RE i AC KASR E aK y ae af FA HEF C F ees a E ES eal eo pet yb A lt tiir Ran e MaL B K a f he r a T wailed P nE A T ie ES R moe 1 g 4 V m foes a oe 1 TE J N i i RE F e f L 4 revised version 3 SECTION 10 SUPPLEMENTAL Seat Belt Pretensioner Seatbelt Force Limiter The front Seat Belt Pretensioners are incorpo rated within the seat belt retractor and help to reduce the severity of injury during a collision When the seat belt pretensioner is activated it spools in the seat belt webbing tightening the seat belt and helps keep the occupant in position After the seat belt is tightened it then releases slightly during the colli sion through the use of the built in force limiter that provides the occupant with a controlled ride into the frontal airbags Only the front seats on 2003 Sorento have seat belt pretensioners During a collision the SRSCM will control the activation of the seatbelt pretensioners based on the severity of the collision The SRSCM sends an elec trical firing signal to the pretensione
74. nd the brake is applied the TCM will as sume the vehicle is traveling downhill and respond Coast Down Control is used for 32 and 2 gt 1 shifting When a vehicle starts and accelerates the one way clutch is engaged in Ist gear and 2nd gear Acceleration means engine speed rotates faster than the output speed Once a vehicle moves past the mo ment of inertia without acceleration output speed is faster than the engine speed At this moment the one way clutch rotates freely The TCM performs a Coast Down Control using the characteristics of the One Way Clutch OWC Coast Down Control prevents a shift shock caused by deceleration into a low speed gear With this con trol down shift engagement from 3rd to 2nd 2nd to Ist gears is reduced with the Ist the 2nd gears 16 revised version 3 3 gear extended more Therefore a down shift to 2nd gear or lst gear can occur before the OWC is engaged which will result in reduced shifting shock caused Coast Down Control Start Conditions e Brake switch is ON when the foot brake is ap plied e Engine is idle when the accelerator pedal is not used e D or 2 range Coast Down Control Cancellation Conditions e After one second after the brake is disengaged s TPS gt 0 SECTION 5 T Trouble shooting Diagnosis Stall Test Purpose To check the slip of components and overall per formance of the transmission Caution Do not test for longer than five se
75. ne pressure hydrau lic circuit Forward clutch slipping OD clutch slipping Below standard In D range only Fluid leakage in the R range line pressure hydrau lic circuit Direct clutch slipping Defective low amp reverse brake SP Defective or stuck the throttle valve Excessive line pressure at idle Defective or stuck the regulator valve In R range only 18 revised version 3 General Information The 2003 Sorento is available in three different powertrain configurations The first configuration is a conventional rear wheel two wheel drive powered by a Sigma 3 5L V6 gasoline engine coupled to an Aisin Warner 30 40 LEI four speed electronically controlled auto matic transmission The second configuration utilizes the same en gine and transmission to power the vehicle equipped with Electronic Shift Transfer EST a part time BOLT DRIVE SHAFT Airpump FRRD F H PINION Bessel o oro L fatu s gt dA v a ee ER kE 9 6 AB e RING GEAR ELECTRONIC SHIFT TRANSFER four wheel drive system The EST utilizes a Free Running Differential FRRD to adapt the front axle to Shift on the Fly SOF The driver can acti vate the high range of the four wheel drive system at speeds up to 50 mph 80km h When the driver rotates the Mode Selection Switch on the instrument panel from 2H to 4H the FRRD air pump motor is energized and the shift motor is act
76. ng valve A typical proportioning valve because it s a me chanical device is limited in its ability to achieve an ideal brake balance under varying conditions of vehicle weight and weight distribution Also a mal function of a proportioning valve manifests itself only by its failure to prevent rear wheel lock up The EBD is controlled by the ABS Control Mod ule which continuously calculates the slip ratio of each wheel and controls the brake pressure at the rear wheels to assure a greater adhesion coefficient at the front wheels If the EBD fails the EBD warning lamp parking brake lamp is illuminated EBD Modulation Range 1 Hold Mode Rear pressure hold when the rear slip tendency is higher than the front wheel i V front wheel Vv kph Range 2 Increase Mode S Rear pressure increase when rear wheel speed recovers to get a brake force puls Ja s i train I p Range 3 Decrease Mode bar Rear pressure decrease when rear wheel slip increase after hold mode Range 4 Out of EBD Control EBD control is finish ABS control of rear and front wheels begins res gt Z S 238 S oO L 2a 2 lt E g ABS disabled EBD enabled Failsafe function FER 2 P L l S gt 9 tee 9 T ABS and EBD disabled A se 5 Z lt ERE e 2 _ Le __ ABS and EBD enabled S lt E Failure Matrix a KS 2 x not possible Nov gt E S 1 A O Soke P l 2 c X
77. on Detects the oil temperature Detects input shaft revolution Connected to the control cable to change driving range Solenoid valves and sensors connection POSITION GEAR s1 s2 stfco c1 c2 e0 B1 82 B3fFo ri F2 RATIO O ME I ofr ofr oft r ore T a Ta ore Te l S on fon or on orr orr f orr orr ore orr onj or f or PO ofr reo fo Pero orf or or OFF cI T nn D L ee Mm co a eet Geet eet D 7 nm ES pes a mc mo Oo 2 Mm Oo ao oe eee ee ee oe T TI T TH T a U LA 7 AN XX 4 U Vast fo aT rif CTH rite i dcs OD INPUT SHAFT INPUT SHAFT OUTPUT SHAFT revised version 3 3 Electronic Control Parts and Their Operation AIT Neutral Relay Neutral Start Switch NSW The Neutral Start Switch NSW sends the auto matic transmission s shift lever position to TCM e The NSW only allows the engine to start in P and N The neutral start switch which is also called an inhibitor switch sends the shift position information to the TCM To start an engine the shift lever should be located in the N or P range In the case of a switch malfunction or switch open or short e If no signal is detected the TCM electrically controls the shift control solenoid valves accord ing to the shift pattern However hydraulic pres sure and engaged components are controlled by the manual valve location wh
78. or Tail Gate Switch Hazard Relay Tail Gate Glass Switch ETC ETC The multifunction switch serves as an input to the ETACS Front wiper and washer motor operation 1s controlled by the ETACS module M Function SAV we i OC rk T Washer amp Wiper Circuit revised version 3 The rear defogger timer provides for 20 min utes of rear defogger operation once the switch is pressed Due to the current consumption of the heater grid 15 20A the defogger should only oper ate while the engine is running To facilitate this the ETACS receives input from the L terminal of the generator If the generator is not charging the signal 1 will be low around 2 5v Under this condition the T rear defogger will not operate Once the L termi D RL nal signal goes high around 12V the ETACS will then allow the rear defogger to operate ee m Defogger System Circuit Defogger Relay The heated outside mirrors have the same operat ing parameters as the rear defogger The ETACS controls Seat Belt Warning Lamp and chime operation based on input from the driv er s seat belt switch The chime will sounds if the seat belt is not connected while starting the engine and if the seat belt is disconnected while the engine is running Seat Belt Warning Lamp IGN Key SAV IGN Key Seat Belt SAV ETACSCM Seat Belt Warning Circuit The Ignition Switch will illuminate with the key O
79. otection feature The headlights will shut down once the ignition switch is turned OFF Parking lamps will remain illuminated until the key is removed and the driver door is opened at that point all exterior lamps will be extinguished An Auto Light Sensor which is only available on the EX Luxury package detects the available light level and facilitates automatic activation of the exterior lamps There 1s a 500ms delay prior to lamp illumination a three second delay exists within the OFF function logic revised version 3 Ignition Switch To Drive Door Switch To Passenger Door Switch TORR LH amp RH Door Switch Lene e eee eens eee ee eens eeeeeeeesesenseseceseseeesesened Power Window Relay Ignition Key Reminder Lock out Protection Circuit ALTERNATOR Ba N C ie lapechabe a DIMMER SW LIGHT SW Orso RC TR TRS f st Ts Et e OEL ennO od Bas I Be El E Bee R be OFF H0 High CA La _ Gee E PL Ide Oto Ps O toto me lor 100A_ Fusible Link J 3 COU EE Driver s DRS J i t Battery Saver Function Circuit Light SW Ignition Switch Dimmer Passing SW Auto Light Function Circuit Remote Keyless Entry The 2003 Sorento Remote Keyless Entry Sys tem which comes standard on the EX permits operation of the door lock unlock functions from a distance of up to 16 feet from the vehicle The un lock function on the RKE operat
80. pen short to B ON detected for 50 msec after OFF Gear hold D range 4th 2 range 3 rd L range 1st P1121 TPS message FF H is received for 0 2 sec Judge TPS 0 Max line pressure No ETR LPC P0710 Short Abnormal sensor resistance detected for 5 min Judge ATF temp 200 C No lock up ETR LPC inhibited while shifting Open AD value is under 15 or over 1000 detected P1115 WT message FF H is received for 0 2 sec Judge the temp normal P0717 No input while 12 pulses of output signal are detected No lock up ETR LPC inhibited while shifting P0716 Input speed gt 7000 RPM detected P1630 BUS OFF is detected 0 2 sec after IG on No lock up maximum line pressure No ETR LPC P1631 No message received from ECM No lock up maximum line pressure No ETR LPC Output RPM gt 2260 TPS gt 5 Brake on gt 10 sec Ignore the brake signal Lock up available DTC List Subject to change DTC Description Fault Type P0707 Transmission Range Sensor Circuit Low Input P0708 Transmission Range Sensor Circuit High Input P0722 Output Speed Sensor Circuit No Signal S OOO R K e e I R o Torque Converter Clutch Circuit SL Malfunction a ee 0 Torque Converter Clutch Circuit SL Electrical BB Shift Solenoid A 1 Malfunction O ae Shift Solenoid A S1 Electrical A P0755 Shift Solenoid B S2 Malfunction P0758 Shift Solenoid B S2 Electrical P0748 Pressure Solenoid SLT Electrical P1121 Throttle Sensor Signal invalid P0710 ATF Temp
81. pressure on the TOD clutch pack in the transfer case to reduce the torque application for the front axle The changes in application pressure to Electro Magnetic Clutch h r 21 revised version 3 TOD Wiring Diagram Ze the TOD clutch pack are accomplished by activating the magnetic clutch using a duty cycle the shorter the duty cycle the less application pressure in the clutch pack The TCCM monitors the operation of the TOD system continuously The TCCM is mounted under the carpet on the passenger s side of the vehicle and communication with it to monitor operating param eters and DTCs may be gained using the High Scan Pro connected to either the 16 pin OBD2 connector under the instrument panel or the 20 pin diagnostic connector located in the engine compartment Similar to the Sorento part time four wheel drive system the TOD system also has a 4L mode avail able when higher torque and lower speeds are pre ferred Like the part time system the vehicle must be stopped the transmission placed in N and the selector switch moved to the 4L position During 4L operation there is no adjustable torque distribution in the TOD system and this mode should only be used on driving surfaces that will allow some slip ping of the drive wheels to minimize tension buildup between drive axles which potentially could damage drivetrain components or cause vehicle instability TABLE SP 24 SENSOR ne AND ECU if
82. r a period of time after the battery has been disconnected Disconnect the battery for 10 minutes before performing any service on the SRS system Please consult the Service Manual for proper procedures F P DAB tst STUTTA DAB 2nd le 9 PAB tst PAB 2nd SA peas PCAB ETACS m Door Unlock Diagnostic Case Line All firing current for airbag deployment must go through the Safing Sensor The safing sensor is a dual contact electromechanical switch which closes if the vehicle deceleration exceeds a specified threshold The operation of the sensor is completely inde pendent of all electronic components in the SRSCM and the firing current must flow across the safing sensor contact to activate the airbag modules and or seatbelt pretensioners This provides protection against an unwanted deployment of the airbag or seatbelt pretenionser firing circuits The SRSCM integrated electronic Accelerometer provides an electrical representation of the accelera tion experienced by the vehicle in the longitudinal direction This electrical signal is linearly propor tional to the vehicle acceleration in Gs and is used to determine the severity of the collision The Driver Airbag Module DAB is mounted on the steering wheel and is connected to the wir ing harness through the clock spring assembly this ensures a consistent connection without regard to steering wheel position The DAB 1s 60 liter
83. r squibs in the gas generator mounted on the seatbelt assembly The gas generator produces a force that moves the piston forward The piston shaft is a rack that engages with a gear set that drives a pinion gear The pinion gear then turns the spool to retract the webbing tighten ing the seat belt for the occupant Caution A pretensioner functions one time only Be sure to replace the seat belt pretensioner with a new one after activation The SRSCM need not be re placed unless six pretensioners have been activated The front seatbelt Force Limiter is designed to reduce the restraining force of the seatbelt webbing the occupant s chest experiences during a colli sion If the collision force reaches a certain value the torsion bar in the pretensioning seatbelt system deforms and allows a small webbing to be extracted from the seat belt thus reducing the restraining force on the occupant Rack Planet Gear revised version 3 Pinion The SRSCM monitors the buckle switches for the front seats to determine the threshold for activation Belted Buckled 4KQ 10 of the air bags and occupants seatbelt pretension Unbelted Unbuckled 1K amp 10 l S Type Micro Switch type ers During a low threshold collision the seatbelt pretensioners only may be activated provided that the seatbelts are buckled However if the seatbelts are not buckled then the air bags are deployed E Normal Close Unbuckled
84. s in size when fully inflated The DAB uses a module that has a dual squib inflator designed to deploy in stages depending on the severity and velocity of the colli sion The dual squib inflator design is used to tune the deployment characteristics of the driver airbag system into three stages e Stage 1 one squib fires e Stage 2 second squib will fire after the first squib e Stage 3 squib one and two fire simultaneously r ed et LTR ee Tes Pi ee eon T C T E revised version 3 6 SECTION 10 SUPPLEMENTAL RESTRAINT SYSTEM The Passenger Airbag Module PAB is installed as part of the instrument panel assembly The PAB features an invisible U pattern tear seam Deploy ment of the PAB will require replacement of the in strument panel Once the PAB is fully inflated there are no vent holes to deflate the airbag The PAB module also uses a dual squib inflator and deploys in stages like the DAB Passenger Airbag Module The side curtain airbags drop down from the headliner and can inflate on either sides of the ve hicle The curtain airbags operate independently of the DAB and PAB based on inputs to the SRSCM from the side impact sensors Curtain Airbag Module ROLL TYPE INFLATOR i s F ajo 0 L w ae sa tan a 4 5 dh R K Pia Les a age A Ce 4 i L a2 a P Rr N I 2 E iL Tra ee T E ee ae T L t See V N a 2 4 e p vd lt a ef a m i la 1 L is wy art L KaR E a
85. speed sensor D fails It also indicates the damper clutch s operating o 600 state when the lock up solenoid is ON E 500 When a damper clutch operates the damper clutch directly couples with the torque converter s 400 drive plate rotating at engine speed Thus input 40 0 40 80 120150 shaft speed is also the engine speed If the damper Temperature degree C clutch fails or hydraulic pressure is not applied be 560 680 ohm 68 F cause the lock up solenoid malfunctions the damper clutch will slip or not operate This will result in a speed difference between the engine speed and the input shaft speed The damper clutch operation can be checked by an input sensor signal The Output Speed Sensor detects the rotation of the output shaft The output speed signal operates in conjunction with the TPS data to get an accurate gear shifting pattern while driving If this sensor fails the MIL lamp comes on Gear shifting can be done normally using the input speed sensor signal Additionally the damper clutch con trol line pressure control and torque reduction con trol all will not operate Output Speed Sensor Resistance ohm 0 40 80 120 150 Temperature degree C 6 revised version 3 387 473 ohm 68 F The Throttle Position Sensor TPS is the most important component used to determine shift timing control If the TPS sensor fails the TPS data will default to 0 and maximum line pressure will be appli
86. ssure HIN 868 6m AVE 4 8 U WAM 411 4 U in the reaction chamber will increase and create FREQ 125 88 Hz DUTY 48 Speeds reaction torque which is working against the valve a a a a S speeds up to deflection Linear behavior of pressure vs torque 62 MPH gives precise steering while cornering at medium speed driving EPS Condition at Low Medium U zoon curs Reco menu Signal at solenoid pin 2 50 MPH solenoid current flow at this speed will be around 6A EPS The solenoid IS completely opened and the reac s SAmS GUR R 2 U Condition at t100 pressure is determined by the balance of the ori MIN 869 6mU AVE 2 4 U MAK 11 50 High Speed fices of solenoid valve and cut off valve Therefore FREQ 125 09 Hz DUTY 26 __ 75 MPH and the steering wheel torque IS controlled primarily by T a a a the amount of hydraulic reaction which gives the characteristic linear torque vs pressure behavior This linear behavior provides excellent steering response comparable to manual steering gears but with controllable steering effort level Above a certain torque which is determined by the reaction pressure the cut off valve opens and restricts further torque increase Then full hydraulic support is avail able in case of evasive maneuvers and wheel bursts above Signal at solenoid pin 2 75 MPH solenoid current flow will be about 4A at this speed 2
87. th 09500 21000 use with 09500 21000 use with 09500 21000 IL H E DS Driveline Systems DS Driveline Systems DS Driveline Systems DS Driveline Systems 09542 4A000 Oil seal installer 09532 31200B Oil seal installer OK993 270 A09 Drive pinion 09530 FM000 Limited slip differential test adapter use with 09500 11000 use with 09500 21000 use with OK993 270 A08 OK993 270 A10 revised version 3 27 The 2003 Sorento feature four wheel disc brakes which receive fluid pressure from a diagonally split brake line configuration The brakes for both front and rear use floating calipers with vented discs The brake calipers in the front are dual piston while the rear calipers are single piston The ventilated discs outer diameter at the front measure 11 8 inches and the rear discs measure 12 4 inches Standard brake bleeding procedure is appropriate consult the Sorento Service Manual General Information The 2003 Sorento is optionally equipped with the Sa Bosch 5 3 Anti Lock Brake System ABS This i Ea badi System is a four sensor four channel diagonally split brake ABS line ABS system with EBD Control The Hydro Electric Control Unit uses a 180 watt motor sole noids for Inlet Outlet Control and an ECU attached to the body Since the Bosch ABS system uses four AF 2 rf SLA wheel speed sensors the waveforms for all four sen A sors must be identical ch
88. valve through the use of a duty cycled signal As vehicle speed increases the percentage of duty cycle is lowered reducing current flow through the solenoid and increasing steering effort The solenoid valve is fully energized 1 amp of current 71 duty cycle and closes the gallery from pump supply to the reaction chamber Because of the relief orifice in the cut off valve the pressure in the reaction chamber is always on return pressure level Therefore the steering wheel torque is deter mined only by the torsion bar plus the centering spring characteristic system s hydraulic pressure which is converted into mechanical force through the rack and pinion steer ing gear to turn the wheels The power steering pump is a vane type pump that draws fluid from the power steering reservoir when the engine is running Fluid type PSF III Positive Centring Cut Off Valve iE Spring L Res es zy E from ECU Ta inf WAAL in W E S y a Solenoid Valve N P cl Opened in in Coupling Parking High Speed System FR SI PACE 5 3 mS CHB 8 Z V HIN 868 6mV AVE 7 5 U MAX 11 2 V FREQ 125 88 Hz DUTY 71 4 pe BE zoon curs ual RECD MENU Signal at solenoid pin 2 0 MPH H revised version 3 SECTION 7 STEERING AND S hi solenoid a ieee and therefore pp 5 mS HH 0 2 V when activating the valve the reaction pre
89. ve been made to improve the transmission s perfor mance Automatic Transmission e An input turbine engine speed sensor has been added to conform to new OBD II regulations The torque converter housing has been redesigned to accommodate the input speed sensor e The TCM is located under the steering column e Inside the transmission the direct clutch disc surfaces now have a new wavy pattern to reduce engagement shock e The disc facing material on the other clutches has been changed to enhance shift quality engine BWR 30 40LEi AISIN AW 4 speed transmission line pressure control Weight bs 3 planetary gear sets simple type P R N D 2 L SNOW 2WD only ATF capacity quarts a B Fluid Service Intervals Normal e Inspect 7 500 miles or 7 5 months Fluid Service Intervals Severe e Inspect 7 500 miles or 7 5 months e Replace 30 000 miles or 30 months Non serviceable screen internal screen Note Fluid must be checked at operating temperature revised version 3 Item Output speed sensor Neutral switch A T inlet tube A T outlet tube Air breather hose Oil temperature sensor Input speed sensor Outer lever T M wire MO GO 4 G Ln BWN a revised version 3 Function Detects output shaft revolution Detects N range A T or Neutral range M T From cooler to A T From A T to cooler For air ventilation inside transmissi

Section 5 • Transmission

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Section 5 &bull; Transmission

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Section 5 • Transmission