Engine Controls - Rough Idle/Possible MIL
SOURCE: Kia Technician TimesTITLE: Rough Idle
APPLIES TO: Sportage
SERVICE TIP:
CONDITION
Some Sportages have exhibited a rough idle condition where the MIL may or may not illuminate.
CAUSE
This condition is frequently caused by a high resistance condition in the fuel injector wiring.
CORRECTIVE ACTION
To correct this concern it is necessary to cut open the harness, solder two crimp splice connections, and improve the connection at two connectors. The harness requiring these repairs is located on top of the intake manifold, under the surge tank.
NOTICE
In order to gain access to the splices in the harness, it is necessary to remove the surge tank from the intake manifold. Remove the surge tank and air pipe as a single unit to minimize gasket replacement.
1. Remove the battery, battery tray, and battery hold down bracket.
2. Remove the charcoal canister.
3. Remove surge tank/intake air pipe assembly
4. Locate the section of the harness between the branch for the oil pressure wire and the coolant temperature sensor.
5. Using your finger, locate the split that runs lengthwise in the plastic split wrap; on the harness, carefully slit open three inches of the tape covering the split wrap.
6. Locate splice S116 where GRN/YEL wires join.
7. Apply solder to the splice using a high wattage soldering gun.
NOTICE
Make sure the solder flows into the splice.
8. Apply electrical tape to the soldered splice then retape the harness.
9. Disconnect two connectors C123 and C124.
10. Cut wire tie securing harness to fuel rail.
11. Pull up wiring harness to gain access to connectors.
12. Find the section of the harness approximately four inches from C124.
13. Using your finger, locate the split that runs lengthwise in the plastic split wrap on the harness.
14. Carefully slit open three inches of the tape covering the plastic split wrap.
15. Locate splice S114 where five green wires join.
16. Apply solder to the splice using a high wattage soldering gun.
NOTICE
Make sure the solder flows into the splice.
17. Apply electrical tape to the soldered splice then retape the harness.
18. Using needle nose pliers, remove the gray plastic insert in both female connectors C123 and C124. This can be done through the right front fender.
19. Using a pick, bend each metal terminal spring tab in each of the connectors to increase the tension.
20. Reinstall the gray plastic inserts into the female connectors.
21. Apply Stabilant 22A to contacts in both connectors.
22. Check that the harness has at least two inches of slack when all of the electrical connectors are connected. If not, re-route the wiring harness around the fuel rail.
23. Reconnect electrical connectors.
24. Install new surge tank gasket.
25. Reinstall components in reverse order or removal.