Campaign SA032 - ECM Update For Various Issues
GROUP EngineNUMBER 063
MODEL 09MY Rio/Rio5 (JB)
DATE February 2010
SUBJECT
SERVICE ACTION: ECM UPGRADE FOR MULTIPLE DTC'S LISTED P0300, P0128, P0140, P0442, P0451, P0467 (SA032)
This bulletin provides the procedure to upgrade the Engine Control Module (ECM) of some 2009 RIO/RIO5 (JB) 1.6L vehicles produced Jul. 17, 2008 to Jul. 11, 2009 (MAP sensor vehicles only) which may experience a rough idle during initial cold start-up period and/or illuminate the MIL with DTC's below. The ECM update addresses engine roughness/misfire that may occur in the first minute of idle after cold start with coolant temperature ranging from 30-70°F and other indicated upgrades referenced below. If the engine misfire continues beyond this period refer to service manual diagnostic procedures involving engine mechanical and engine control hardware issues. For confirmation that the latest reflash has been done to a vehicle you are working on, verify ROM ID using the tables in this TSB.
^ P0300: Random/multiple Cylinder Misfire Detected and/or rough idle state
^ P0128: Thermostat Monitoring
^ P0140: O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2, stored in memory)
^ P0442: Evaporative Emission System - Leak detected
P0451: Evaporative Emission System Pressure Sensor/Switch Range Performance
^ P0461 or P0422: Fuel Level Sensor "A" Circuit Range/Performance
NOTICE
Do NOT replace the engine control parts related to misfire such as ignition coil, spark plug and oxygen sensor unless it can be proven the part is defective.
NOTICE
A Service Action is a repair program without customer notification that is preformed during the warranty period. Any dealer request to preform this repair outside the warranty period will require DPSM approval.
Repair status for a VIN is provided on WebDCS (Service>Warranty Coverage>Warranty Coverage Inquiry>Campaign Information). Not Completed recall/Service Action reports are available on WEBDCS (Consumer Affairs>Not Completed Recall Recall VIN>Select Report).
The issue number is SA032.
To correct this condition, the ECM should be reprogrammed using the GDS download as described in this bulletin.
NOTICE
^ A fully charged battery is necessary before ECU upgrade can take place. DO NOT connect a battery charger to the vehicle during ECU upgrade. Make sure the blower motor is "OFF" during ECU upgrade.
^ All ECU upgrades must be done with the ignition key in the "ON" position.
^ Be careful not to disconnect any cables connected to the vehicle or GDS during the ECU update procedure.
^ DO NOT start the engine during ECU upgrade.
^ DO NOT turn the ignition key "OFF" or interrupt the power supply during ECU upgrade.
^ When the ECU upgrade is completed, turn the ignition key "OFF" and wait 20 seconds before starting the engine.
^ ONLY use approved ECU upgrade software designed for the correct model, year and engine size. failure to do so may create other driveability issues due to the use of the incorrect ECM/PCM calibration.
ROM TABLE
To verify the vehicle is affected, be sure to check the Calibration Identification of the vehicle's ECM's PCM ID and reference the information Table as necessary.
1. Connect the power supply cable to the GDS tool.
NOTICE
If attempting to preform the ECU upgrade with the power supply cable disconnected from the GDS tool, be sure to check that the GDS tool is fully charged before ECU upgrade. If the GDS tool is not fully charged, failure to preform the ECU upgrade may occur. Therefore, it is strongly recommended that the power supply connector be connected to the GDS tool.
2. Connect the USB cable between the VCI and the GDS tool.
NOTICE
When preforming the ECU upgrade using the GDS tool, wireless communication between the VCI and the GDS tool is not available. Therefore, be sure to connect the USB cable between the VCI and the GDS tool.
3. Connect the Main 16-pin DLC cable (GHDM - 241000) to the VCI.
4. Connect the Main 16-pin DLC cable (GHDM - 241000) to the OBD-II connector, located under the driver's side of the instrument panel.
5. With the ignition key ON, turn ON the VCI and GDS tool. Access the GDS vehicle identification number (VIN) screen and configure the vehicle using the VIN AUTO DETECT Function.
NOTICE
Global Diagnostic System (GDS) users should access the "NOTICE" function from the GDS Main Screen for instructions reguarding ECU upgrade events.
6. Once back at the GDS Main Screen, select ECU upgrade from the bottom right-hand corner. Next select Auto Mode, Engine. Perform the ECU upgrade in accordance with normal GDS tool ECU upgrade procedures.
NOTICE
Do NOT attempt to preform a Manual Mode PCM upgrade unless Auto Mode fails. Always follow the instructions given on the GDS tool in either Auto or Manual mode. See tables for Manual Mode passwords. In addition, a PCM reset is required if Auto mode fails; refer to the table below for procedures.
MANUAL MODE ECU UPGRADE PASSWORDS*
7. When the GDS tool reports that the ECU upgrade has been successfully completed, click OK, turn OFF the ignition key, and wait at least 10 seconds before attempting to start the engine.
8. Check for Diagnostic Trouble Codes using the GDS and erase any DTCs stored.
AFFECTED PRODUCTION RANGE:
2009 Rio/Rio5 with 1.6L engine produced from Jul. 17, 2008 to Jul. 11, 2009.
WARRANTY CLAIM INFORMATION
NOTICE
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference SA032 when accessing the WebDCS system.