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2004 RIO ECM Upgrade (ENG020)

Publication date: 2005-01-01
Reference number: ENG020

2004 RIO ECM UPGRADE

2004 RIO ECM UPGRADE

TECHNICAL SERVICE BULLETIN

Reference Number(s): Engine 020, Date of Issue:  January 2005
KIA: Rio
Volume: 3
GROUP: Engine

SUBJECT

2004 RIO ECM UPGRADE 

This bulletin provides information relating to a Rio ECM upgrade. Some 2004MY Rio vehicles built between 10/1/03 and 6/30/04 may experience a Malfunction Indicator Lamp (MIL) condition with Diagnostic Trouble Code (DTC) P0101.

Use the procedure in this bulletin to reprogram the (ECM) software for 2004MY Rio vehicles with the DTC P0101 concern.

ROM ID INFORMATION TABLE

ROM ID INFORMATION

Model Affected ECM P/N ECM ROM ID
Previous New
2004 RIO 39110 2X621 B4D6CNAA B4D6CNAE
B4D6CNAB
B4D6CNAC
39110 2X622 B4D6CNAD

Use the 32MB blue reprogramming card that was sent to your dealer in October 2004. Download the latest Hi-Scan Pro reprogramming software for the 32MB (blue label) reprogramming card from the Kia Service Information System (KSIS). The Downloads page is accessed by first logging onto KSIS, then by clicking on the Downloads link located in the left-hand navigation frame. Dealers can also order a CD (optional) by calling 866 KIA-TOOLS and ordering P/N 111220BC.

BEFORE STARTING THE PROCEDURE

Check the production date on the FMVSS door label to make sure that the vehicle is within the correct production range.

NOTE:
  • A fully charged battery is necessary before reprogramming can take place. DO NOT connect a battery charger to the vehicle during reprogramming. Make sure the blower motor is OFF during programming.
  • All reprogramming must be done with the ignition key in the ON position.
  • Be careful not to disconnect any cables connected to the vehicle or Hi-Scan Pro during the reprogramming procedure.
  • DO NOT start the engine during reprogramming.
  • DO NOT turn the ignition key OFF or interrupt the power supply during reprogramming.
  • When the reprogramming is completed, turn the ignition key OFF and wait 20 seconds before starting the engine.
  • ONLY use approved reprogramming software designated 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.

AUTOMATIC REPROGRAMMING PROCEDURE

  1. Attach the OBD II Data Link Connector (DLC) cable to the Hi-Scan Pro main body and tighten the two screws securely.

    Remove the current system software card from the Hi-Scan Pro and insert the 32MB blue label reprogramming card into the Hi-Scan Pro top slot.

    Fig 1: Attaching OBD II Data Link Connector (DLC) Cable To Hi-Scan Pro
    G03379213
  2. Connect the Hi-Scan Pro to the OBD II connector located under the dash on the driver's side as shown.
    Fig 2: Connecting Hi-Scan Pro To OBD II Connector
    G03379214
  3. Turn the ignition key to the ON position.
  4. Turn the Hi-Scan Pro ON and press "ENTER."
    NOTE: Do NOT interrupt the reprogramming at any time. The ECM may be rendered inoperative if the software does not download completely.
  5. Select option "22.RIO 1.6D 04MY MAF SENSOR IMPROVE." and press "ENTER."
    Fig 3: Selecting Option "22.RIO 1.6D 04MY MAF SENSOR IMPROVE."
    G03379215
  6. Select option "01.RIO 1.6D 04MY MAF SENSOR [AUTO]" and press "ENTER."
    Fig 4: Selecting Option "01.RIO 1.6D 04MY MAF SENSOR [AUTO]"
    G03379216
  7. Enter "0525" as the password for automatic update mode and press "ENTER."
    Fig 5: Entering Password 0525
    G03379217
  8. The Hi-Scan Pro will establish communication.
    Fig 6: Hi-Scan Pro Establishing Communication
    G03379218
  9. The Hi-Scan Pro will reprogram the ECM automatically.

    (See the "ROM ID INFORMATION TABLE  " above for previous and new ECM ROM ID's)

    Fig 7: Reprogramming In Progress Display
    G03379219
  10. When the "REPROGRAMMING COMPLETED" message is displayed, turn the ignition key to the OFF position, wait 20 seconds and then start the engine to check for proper operation.
    Fig 8: Reprogramming Completed Display
    G03379220
  11. Check for diagnostic trouble codes (DTCs) using the Hi-Scan Pro with system software card. Erase any diagnostic trouble codes. For automatic transaxle equipped vehicles, both the engine and transaxle section DTCs must be checked.
NOTE: The current ECM ROM ID will be replaced by the new ECM ROM ID. If the Hi-Scan Pro does not download the program properly, use the MANUAL UPDATE PROCEDURE.
Refer to ECM REPROGRAMMING TROUBLESHOOTING  section if download does not work properly.

MANUAL UPDATE PROCEDURE

If the REPROGRAMMING Selection menu item "01 - RIO 1.6D 04MY MAF SENSOR. [AUTO]" fails to download properly, then option "02. RIO 1.6D 04MY MAF SENSOR. [ERROR]" must be used.

Confirm all connections are established as shown in the "AUTOMATIC REPROGRAMMING PROCEDURE" before continuing.

  1. Turn the ignition key to the ON position.
  2. Turn the Hi-Scan Pro ON and press "ENTER."
    NOTE: Do NOT interrupt the reprogramming at any time. The ECM may be rendered inoperative if the software does not download completely.
  3. Select option "22.RIO 1.6D 04MY MAF SENSOR IMPROVE." and press "ENTER."
    Fig 9: Selecting Option "22.RIO 1.6D 04MY MAF SENSOR IMPROVE."
    G03379221
  4. Select option "02.RIO 1.6D 04MY MAF SENSOR [ERROR]" and press "ENTER."
    Fig 10: Selecting Option "02.RIO 1.6D 04MY MAF SENSOR [ERROR]"
    G03379222
  5. Select from 01. or 02. RE-PROGRAMMING menu item by looking at the vehicle ECM label (use mirror to see ECM label in vehicle). Compare the vehicle ECM part number to the part numbers in menu 01. or 02. Select the correct item number and then press "ENTER."
    Fig 11: Selecting Item Number
    G03379223
  6. Enter the correct password by using the chart below and press "ENTER."
    PASSWORD CHART

    Menu Item Password
    01. RIO 1.6 04MY (CAL/FED) 2621
    02. RIO 1.6 04MY (CAL/FED) 2622
    NOTE: Be sure to input the correct password. If an incorrect password is selected, the correct ECM software will NOT be downloaded.
    Fig 12: Entering Password From Chart
    G03379224
  7. The Hi-Scan Pro will establish communication.
    Fig 13: Hi-Scan Pro Establishing Communication
    G03379225
  8. The Hi-Scan Pro will reprogram the ECM.
  9. Verify that the correct ECM software has been downloaded. The new ECM ROM ID displayed must be B4D6CNAE.
    Fig 14: Reprogramming In Progress Display
    G03379226
  10. When the "REPROGRAMMING COMPLETED" message is displayed, turn the ignition key to the OFF position, wait 20 seconds and then start the engine to check for proper operation.
    Fig 15: Reprogramming Completed Display
    G03379227
  11. Check for diagnostic trouble codes (DTCs) using the Hi-Scan Pro with system software card. Erase any diagnostic trouble codes. For automatic transaxle equipped vehicles, both the engine and transaxle section DTCs must be checked.

ECM REPROGRAMMING TROUBLESHOOTING

AFFECTED PRODUCTION RANGE

2004MY Rio vehicles with production dates from 10/1/03 through 6/30/04.

WARRANTY CLAIM INFORMATION

WARRANTY CLAIM INFORMATION

Claim Type Causal P/N Qty. Cond. Code Cause Code Repair Description Labor OP Code Time Related Parts Qty.
W 39110 2X621
39110 2X622		 0 N03 C40 ECM Reprogramming 39110F16 0.3 N/A 0
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