Kia Optima Hybrid: Engine Control System / Engine Control Module (ECM) Repair procedures

Removal
1.
Shut off the High Voltage circuit.
(Refer to “High Voltage Shut-off Procedures”)
2.
Turn the ignition switch OFF and disconnect the auxiliary 12V negative (-) battery terminal.
3.
Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Intake And Exhaust System")
4.
Disconnect the ECM connector (A) and remove the engine room relay box (B).

5.
Disconnect the battery positive (+) terminal (A).

6.
Remove the reservoir mounting bolt (A) and coolant outlet pipe mounting bolt (B).

7.
Make a gap for removing the ECM bracket mounting bolt (C) by moving the battery cable (A) and the reservoir (B) as shown in the illustration below and then remove the bolt (C).

8.
Remove the ECM (C) by loosening the nut (A) and the bolt (B).

Installation
   
When replacing the ECM, the vehicle equipped with the smart key must be performed the procedure as below.
[In the case of installing used ECM]
1)
Perform "Neutral mode" procedure with GDS.
(Refer to Body Electrical System - "Smart key system")
2)
Turn the ignition ON and OFF position after completing "ECM neutral mode".
Then the ECM key register process is completed automatically.
[In the case of installing new ECM]
Turn the ignition ON and OFF position after completing "ECM neutral mode".
Then the ECM key register process is completed automatically.
   
ECM is combined with TCM. Therfore perform the necessary procedures after replacing or reinstalling a ECM.
(Refer to Automatic Transaxle Control System - "Adjustment")
1.
Install in the reverse order of removal.

ECM mouning bolt:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
ECM bracket mounting bolt/nut:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

ECM Problem Inspection Procedure
1.
TEST ECM GROUND CIRCUIT: Measure resistance between ECM and chassis ground using the backside of ECM harness connector as ECM side check point. If the problem is found, repair it.

Specification: Below 1?

2.
TEST ECM CONNECTOR: Disconnect the ECM connector and visually check the ground terminals on ECM side and harness side for bent pins or poor contact pressure. If the problem is found, repair it.
3.
If problem is not found in Step 1 and 2, the ECM could be faulty. If so, make sure there were no DTC''s before swapping the ECM with a new one, and then check the vehicle again. If DTC''s were found, examine this first before swapping ECM.
4.
RE-TEST THE ORIGINAL ECM: Install the original ECM (may be broken) into a known-good vehicle and check the vehicle. If the problem occurs again, replace the original ECM with a new one. If problem does not occur, this is intermittent problem (Refer to “Intermittent Problem Inspection Procedure” in Basic Inspection Procedure).
Engine Control Module (ECM) Schematic Diagrams

ECM Terminal And Input/Output signal ECM Terminal Function Connector [C100-K] PinNo.DescriptionConnected to1Power groundChassis Ground2Battery power (B+)Ignition Switch3Power groundChassis Ground4Battery ...

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