Repair Procedures: Adjustment

[Rod Adjustment Procedure Flowchart] 

Fig 1: Rod Adjustment Procedure Flowchart

Courtesy of KIA MOTORS AMERICA, INC.

1. Check that the waste gate turbo charger is cool enough to work.
   NOTE: Information  Use an electric fan to cool down fast. The cooling part (A) and the wind direction (B) are as follows.
Fig 2: Cooling Down Waste Gate Turbo Charger
Courtesy of KIA MOTORS AMERICA, INC.
2. Turn the ignition switch to OFF position.
3. Connect the diagnostic tool to DLC connector (16 pin) under the driver side instrument panel.
4. Turn the ignition switch ON position.
   CAUTION:

   Do not start the engine.

5. Select VIN or Vehicle on the initial screen.
6. Enter "Engine Control" menu after selecting vehicle information (Vehicle model, Model year, Engine type) or entering the VIN number.
7. Access to GDS Engine > Current Data
8. Without starting the engine, cycle the ignition ON for 5 seconds then ignition OFF for 5 seconds then check the "Adaption value for the low mechanical stop of EWGA" on the GDS. Repeat this step until the amount of the adaption value change compared to previous cycle is below 0.05V.
   NOTE: Do not start the engine. This is a crucial step to read the correct adaption value.
Fig 3: Waste Gate Position Waveform
Courtesy of KIA MOTORS AMERICA, INC.
9. Check that " Adaption value for the lower mechanical stop of EWGA" is within the specified voltage value.
   ADAPTION VALVE SPECIFICATIONS
   
   

   Coolant temperature (°C)	Specified voltage value (V)
   41 ~ 60	3.8 ~ 4.0
   26 ~ 40	3.85 ~4.05
   Below 25	3.9 ~ 4.1

10. If the voltage value measured is not within the specified voltage value, adjust the EWGA rod length. But, if no, no further procedure is required.
    1. Loosen the rod end lock nut (A) and remove the C-ring (B).
    2. Adjust the rod end part (C) by rotating it clockwise (D) or counterclockwise (E) to satisfy the specification.

       For example, if the coolant temperature is below 25 °C adjusted as follows.

       WASTE GATE ADJUSTMENT TABLE
       
       

       Turning angle	Changing level of the adaption value (V)
       0.5 turn (180°)	0.15 ~ 0.20
       1 turn (360°)	0.30 ~ 0.40

       Information 

       MECHANICAL ADJUSTMENTS
       
       

       Turning angle	Changing level of the adaption value (V)
       0.5 turn (180°)	0.15 ~ 0.20
       1 turn (360°)	0.30 ~ 0.40

    Fig 4: Rotating Rod End Part
    Courtesy of KIA MOTORS AMERICA, INC.
11. Install the rod end (B) to the turbo charger lever (A) temporarily. Don't tighten the rod end lock nut (C) and C-ring (D).
Fig 5: Rod End Components
Courtesy of KIA MOTORS AMERICA, INC.
12. Check " Adaption value for the lower mechanical stop of EWGA" after selecting "Current Data" menu. Turn the ignition switch ON/OFF repeatedly until the changing value of " Adaption value for the lower mechanical stop of EWGA" is within 0.05V.
    NOTE: Turn the ignition switch ON/OFF. But hold 5 seconds at each IG ON or OFF state.
Fig 6: Waste Gate Position Waveform
Courtesy of KIA MOTORS AMERICA, INC.
13. If the voltage value measured is not within the specified voltage value, repeat 9~11 procedures until the voltage value is within the specified voltage value
14. Check that " Adaption value for the lower mechanical stop of EWGA" is within the specified voltage value.
15. If it is within the specified voltage value, install the rod end to the turbo charger lever.
    1. Install the rod end (B) to the turbo charger lever (A).
    2. Tighten the rod end lock nut (C).
    3. Install the C-ring (E).
       NOTE: * Be careful not to remove the washer (D).
    Fig 7: Washer, Rod End, Lever & C-Ring
    Courtesy of KIA MOTORS AMERICA, INC.
    Fig 8: Rod End Lock Nut
    Courtesy of KIA MOTORS AMERICA, INC.