fuel pump KIA SOUL 2009 Owners Manual

15
Introduction
A020202AUN
Biodiesel
Commercially supplied biodiesel blends of no more than 5% biodiesel, commonly
known as "B5 biodiesel" may be used in
your vehicle if it meets EN 14214 or
equivalent specifications. (EN stands for
"European Norm"). The use of biofuels
made from rapeseed methyl ester
(RME), fatty acid methyl ester (FAME),
vegetable oil methyl ester (VME) etc. ormixing diesel with biodiesel will cause
increased wear or damage to the engine
and fuel system. Repair or replacement
of worn or damaged components due to
the use of non approved fuels will not be
covered by the manufactures warranty.A030000AUN
No special break-in period is needed. By
following a few simple precautions for the
first 1,000 km (600 miles) you may add to
the performance, economy and life of
your vehicle.
Do not race the engine.
While driving, keep your engine speed
(rpm, or revolutions per minute)
between 2,000 rpm and 4,000 rpm.
Do not maintain a single speed for long periods of time, either fast or slow.
Varying engine speed is needed to
properly break-in the engine.
Avoid hard stops, except in emergen- cies, to allow the brakes to seat prop-
erly.
Don't let the engine idle longer than 3 minutes at one time.
Don't tow a trailer during the first 2,000 km (1,200 miles) of operation.
VEHICLE BREAK-IN PROCESS
CAUTION
Never use any fuel, whether
diesel or B5 biodiesel that fails tomeet the latest petroleum indus-
try specification.
Never use any fuel additives or treatments that are not recom-mended or approved by the vehi- cle manufacturer.
CAUTION
Do not let any gasoline or water
enter the tank. This would make itnecessary to drain it out and tobleed the lines to avoid jamming
the injection pump and damagingthe engine.
In winter, in order to cut down incidents due to freezing, paraffinoil may be added to the fuel if the
temperature drops to below - 10°C(50°F). Never use more than20% paraffin oil.

75
Maintenance
G020200AUN Owner maintenance precautions
Improper or incomplete service may
result in problems. This section gives
instructions only for the maintenance
items that are easy to perform.
As explained earlier in this section, sev-
eral procedures can be done only by an
authorized KIA dealer with special tools.
✽✽NOTICE
Improper owner maintenance during the warranty period may affect warran-
ty coverage. For details, read the sepa-
rate Warranty & Maintenance book
provided with the vehicle. If you're
unsure about any servicing or mainte-
nance procedure, have it done by an
authorized KIA dealer.
WARNING - Maintenance
work
Performing maintenance work on a vehicle can be dangerous. You
can be seriously injured while
performing some maintenance
procedures. If you lack sufficient
knowledge and experience or the
proper tools and equipment to do
the work, have it done by an
authorized KIA dealer.
Working under the hood with the engine running is dangerous. It
becomes even more dangerous
when you wear jewelry or loose
clothing. These can become
entangled in moving parts and
result in injury. Therefore, if you
must run the engine while work-
ing under the hood, make certain
that you remove all jewelry (espe-
cially rings, bracelets, watches,
and necklaces) and all neckties,
scarves, and similar loose cloth-
ing before getting near theengine or cooling fans.WARNING - Diesel Engine
Never work on injection system with engine running or within 30
seconds after shutting off engine.
High-pressure pump, rail, injectorsand high-pressure pipes are sub-
ject to high pressure even after the
engine stopped. The fuel jet pro-
duced by fuel leaks may cause seri-
ous injury, if it touches the body.
People using pacemakers should
not move than 30cm closer to theECU or wiring harness within the
engine room while engine is run-
ning, since the high currents in the
electronic engine control system
produce considerable magneticfields.

Maintenance
10
7
NORMAL MAINTENANCE SCHEDULE - GASOLINE ENGINE (CONT.)
Number of months or driving distance, whichever comes first
Months 12 24 36 48 60 72 84 96
Miles×1,000 10 20 30 40 50 60 70 80
Km×1,000 15 30 45 60 75 90 105 120
Valve clearance * 5
Vapor hose and fuel filler cap II
Vacuum hose and crankcase ventilation hoses I I I I
Vacuum hose (for EGR & throttle body) III IIIII
(if equipped)
Fuel filter *6For Europe II
Except Europe IRI R
Fuel lines, hoses and connections II
Fuel tank air filter (if equipped)
For Europe II
Except EuropeIRIR
Cooling system
Inspect “Coolant level and leak” every day
Inspect “Water pump” when replacing the drive belt or timing belt
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.* 4
: For your convenience, it can be replaced prior to it's interval when you do maintenance of other items.
* 5
: Inspect for excessive valve noise and/or engine vibration and adjust if necessary. An authorized KIA dealer should perform the operation.
* 6
: The fuel filter is considered to be maintenance free but periodic inspection is recommended for this maintenance schedule depends on fuel
quality. If there are some important matters like fuel flow restriction, surging, loss of power, hard starting problem etc, replace the fuel filter
immediately regardless of maintenance schedule and consult an authorized KIA dealer for details.
MAINTENANCE
INTERVALS
MAINTENANCE ITEM
Inspect every 96,000 km (60,000 miles) or 48 months * 4

Maintenance
16
7
NORMAL MAINTENANCE SCHEDULE - DIESEL ENGINE (CONT.)
Number of months or driving distance, whichever comes first
Months 12 24 36 48 60 72 84 96 Miles×1,000
12.5 25 37.5 50 62.5 75 87.5 100
Km×1,000 20 40 60 80 100 120 140 160
Vapor hose and fuel filler cap I I I I I I I I
PCV and crankcase ventilation hoses I I I I I I I I
Vacuum hose (for VGT & throttle body) III IIIII
(if equipped)
Vacuum pump and vacuum hose I I I I I I I I
Vacuum pump oil hose I I I I I I I I
Fuel filter cartridge For Europe *
3
IIRIIRIIExcept Europe*4IIRIIRII
Fuel lines, hoses and connections I I I I I I I I
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.* 3
: This maintenance schedule depends on fuel quality. It is applicable only when using a qualified fuel <"EN590 or equivalent">.
If the diesel fuel specifications don't meet the EN590, it must be replaced more frequently.
If there are some important safety matters like fuel flow restriction, surging, loss of power, hard starting problem etc., repl ace
the fuel filter immediately regardless of maintenance schedule and consult an authorized KIA dealer for details.
* 4
: This maintenance schedule depends on fuel quality. It is applicable only when using a qualified fuel <"EN590 or equivalent">.
If the diesel fuel specifications don't meet the EN590, it must be replaced more frequently. KIA recommends "every 7,500km
inspection, every 15,000km replacement".
If there are some important safety matters like fuel flow restriction, surging, loss of power, hard starting problem etc., repl ace
the fuel filter immediately regardless of maintenance schedule and consult an authorized KIA dealer for details.
MAINTENANCE
INTERVALS
MAINTENANCE ITEM

721
Maintenance
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS
G050100AUN Engine oil and filter The engine oil and filter should be
changed at the intervals specified in the
maintenance schedule. If the car is being
driven in severe conditions, more fre-quent oil and filter changes are required.
G050200AUN Drive belts
Inspect all drive belts for evidence of
cuts, cracks, excessive wear or oil satu-
ration and replace if necessary. Drive
belts should be checked periodically forproper tension and adjusted as neces-
sary. G050300AUN
Fuel filter (cartridge) A clogged filter can limit the speed at
which the vehicle may be driven, damage
the emission system and cause multiple
issues such as hard starting. If an exces-
sive amount of foreign matter accumu-
lates in the fuel tank, the filter may
require replacement more frequently.
After installing a new filter, run the engine
for several minutes, and check for leaks
at the connections. Fuel filters should be
installed by an authorized KIA dealer.
G050400AUN
Fuel lines, fuel hoses and con- nections
Check the fuel lines, fuel hoses and con-
nections for leakage and damage. Have
an authorized KIA dealer replace any
damaged or leaking parts immediately.
WARNING -
Diesel only
Never work on injection system with engine running or within 30
seconds after shutting off engine.
High pressure pump, rail, injectorsand high pressure pipes are sub-
ject to high pressure even after the
engine stopped. The fuel jet pro-
duced by fuel leaks may cause seri-
ous injury, if it touch the body.
People using pacemakers should
not move than 30cm closer to theECU or wiring harness within the
engine room while engine is run-
ning, since the high currents in the
Common Rail system produce con-
siderable magnetic fields.

733
Maintenance
FUEL FILTER (FOR DIESEL)
G150100ASA-ED
Draining water from the fuel filter
The fuel filter for diesel engine plays an
important role of separating water from
fuel and accumulating the water in itsbottom.
If water accumulates in the fuel filter, the
warning light comes on when the ignition
switch is in the ON position. If this warning light illuminates,
take your car to an authorized
KIA dealer and have drain the
water and checked the sys-tem. G150300ASA-AM
Extracting air from the fuel filter
If you drive until you have no fuel left or if
you replace the fuel filter, be sure to
extract air from the fuel system as it
makes it difficult to start the engine.
1. Pump up and down(1) approximately
50 times until the pump is hard.
2. Extract air from the fuel filter by remov- ing the bolt(2) with a cross-tip screw
driver and reinstall the bolt(2).
3. Pump up and down(1) approximately 15 times.
4. Extract air from the fuel filter by remov- ing the bolt(2) with a cross-tip screw
driver and reinstall the bolt(2).
5. Pump up and down(1) approximately 5 times.
✽✽ NOTICE

Maintenance
58
7
Engine compartment fuse panel
Description Fuse rating Protected component
BATT 2 50A I/P Junction Box (Relay - Tail Lamp, Fuse - TAIL LH 10A, TAIL RH 10A, S/ROOF 20A, AMP 25A,
DR LOCK 20A, STOP 15A, T/GATE 15A, F/FOG 15A, R/FOG 10A, Power Connector - ROOM 10A,
AUDIO 15A)
BATT 1 50A I/P Junction Box (Relay - Power Window, Fuse - P/WDW LH 25A, P/WDW RH 25A, FOLD'G 10A,HAZARD 15A)
C/FAN 30A C/Fan Relay (High), C/Fan Relay (Low)
MAIN 150A Generator, Fuse [ABS 2 40A, ABS 1 40A, RR HTD 40A, BLW 40A, MDPS 80A, A/CON 10A, DSL 150A (Diesel)]
ABS 2 40A ABS Control Module, ESP Control Module
ABS 1 40A ABS Control Module, ESP Control Module
RR HTD 40A I/P Junction Box (Rear Defogger Relay) BLW 40A Blower Relay
MDPS 80A EPS Control Module DSL 150A Diesel - DSL Fuse & Relay Box (GLOW 80A, PTC 1 50A, PTC 2 50A, PTC 3 50A)
IGN 2 40A Ignition Switch, Start Relay
ECU A 30A Main Relay, ECU B 10A
F/FILTER HTR 30A Diesel - Fuel Filter Heater Relay F/PUMP 20A Gasoline - Fuel Pump RelayIGN 1 40A Ignition Switch
H/LP HI 20A Head Lamp Relay (High)
H/LP LO 20A Head Lamp Relay (Low) HORN 10A Horn Relay
H/LP LO RH 10A Head Lamp RH H/LP LO LH 10A Head Lamp LH, Instrument Cluster (Low Beam IND.)

759
Maintenance
Description Fuse rating Protected componentECU B 10A Diesel - TCM Gasoline - ECM, PCM
ECU 3 10A Diesel - Fuel Pressure Regulating Valve
ECU 2 10A Diesel - Stop Lamp Switch
ECU 1 20A Diesel - ECM Gasoline - ECM, PCM
INJECTOR 15A Diesel - DSL Fuse & Relay Box (Glow Relay, PTC 1 Relay, PTC 2 Relay, PTC 3 Relay),
Camshaft Position Sensor, Electrical EGR Actuator, VGT Actuator, Immobilizer Module
Gasoline - Injector #1 ~ #4, Idle Speed Control Actuator, Immobilizer Module, Fuel Pump Relay
SENSOR 10A Diesel - A/Con Relay, C/Fan Relay (High/Low), Lambda Sensor, Air Heater Relay
Gasoline - A/Con Relay, C/Fan Relay (High/Low), Camshaft Position Sensor, Canister Purge Solenoid
Valve, Oil Control Valve, Oxygen Sensor Up/Down, Stop Lamp Switch
A/CON 10A A/Con Relay
Engine compartment fuse panel (Diesel engine only)
Description Fuse rating Protected component GLOW 80A Glow Relay, Air Heater Relay PTC 1 50A PTC 1 Relay
PTC 2 50A PTC 2 Relay
PTC 3 50A PTC 3 Relay