application for certification - part 2

Application For Certification - Part 2

• Model Year : 2008 • Durability Group : 8KMXGPGNNMW5 (C/O from 2007MY) • Evap. Family : 8KMXR0120PDM (C/O from 2007MY) • Test Group : 8KMXV02.4MW5 (C/O from 2007MY) • Model Name : OPTIMA • Summary Sheet No : 338T2-03 • Durability Group Description : Four Stroke, Otto Cycle, Gasoline Fueled, Ported FI • Test Group Description : 2.4 Liter/ I4, LDV • Applicable Standards : FED: Tier2 Bin5,

CAL: LEV-II ULEV • Vehicles Covered : Carline 1(50 St) • Vehicles Run :

Vehicle ID Config Test Type/No

FTP-1066087 HFET-1066088 50F-1066089 US06-1066090

SC03-1066091 Cold CO-1066092 3D Evap-1066093 2D Evap-1066094 MG06EM-24D-1 ‘00’

ORVR-1066095

MG06EM-24D-2 ‘00’ FTP-1066096 HWY-1066097

• For Questions, Contact : David Barker 734-337-2343

E-mail : [email protected]

EPA Response Requested By : December 28, 2007

TABLE OF CONTENTS

SECTION TITLE

01.00 Part numbers

02.00 Calibration Information

03.00 Detailed description of vehicles covered by certificate and test parameters

04.00 Final US sales

05.00 Service manual, Service bulletins

06.00 California ARB Information

8KMXV02.4MW5 – Kia Optima 2.4L – Part 2 Issued : 12-03-2007 Revised :

01-1

01.00 Part numbers

Test Group Name : 8KMXV02.4MW5

Part Name Part Number

MANIFOLD MODULE-INLET 28300-25100

┣ MANIFOLD ASSY-INLET 28310-25081

┗ MANIFOLD-STUD 28331-25010

THERMOSTAT ASSY 25500-25001

VALVE-P.C.V 26740-32804

BODY ASSY-THROTTLE 35100-25200

COIL ASSY-IGNITION 27301-3C000

CONVERTER ASSY-CATALYTIC 28950-25560

ENGINE CONTROL MODULE

39101-25142, 39101-25152, 39101-25182, 39101-25192, 39111-25132, 39111-25142, 39111-25172, 39111-25182

INJECTOR ASSY-FUEL 35310-25200

MANIFOLD CATALYTIC ASSY-EXHAUST 28510-25450

PIPE ASSY-DELIVERY 35340-25250

PLUG ASSY-SPARK 27410-25000

SENSOR ASSY-AIR FLOW 28164-25000

SENSOR ASSY-CAMSHAFT POSITION 39350-25000

SENSOR ASSY-CRANK ANGLE 39180-25200

SENSOR-KNOCK 39250-25200

SENSOR ASSY-OXYGEN, FRONT 39210-25300

SENSOR ASSY-OXYGEN, REAR 39210-25110

SENSOR ASSY-WATER TEMP. 39220-38030


01-2

Part Name Part Number

VALVE-PURGE CONTROL 28910-25100

COMPLETE-CANISTER 31410-2G100

┣ CANISTER ASSY 31420-2G100

┗ CANISTER CLOSE VALVE 31430-29200

CAP ASSY-FUEL FILLER 31010-2C800

FILLER NECK ASSY-FUEL 31030-2G100

FUEL PUMP & SENDER ASSY 31110-2G100

┣ PUMP ASSY-FUEL 31111-1G500

┣ FUEL TANK PRESSURE SENSOR 31435-3K600

┗ VALVE ASSY-FUEL VENT 31155-2G100

TANK ASSY-FUEL 31150-2G110

┣ VALVE ASSY-FUEL CUT 31190-2G100

┗ VALVE ASSY-FUEL SHUT OFF 31160-2G100

SWITCH-A/T INHIBITOR 42700-39050, 42700-39055


02-1

02.00 Calibration Information

Emission Component Sensed Parameter Controlled Parameter Calibration

Fuel Pump & Flow Rate - Fuel Pressure/Flow Rate 3.5kgf/cm2, 80ℓ/h MIN.

Fuel Pressure Regulator & Regulated Fuel Pressure - Fuel Pressure 3.5±0.05kgf/cm2

EGR valve & EGR Exhaust gas flow rate (at specified vacuum levels)

- - -

EGR vacuum regulator & Regulated vacuum - - -

EGR orifice & orifice diameter - - -

Basic engine timing Eng. Coolant Temp. Sensor, RPM, LOAD, Intake Air Temp. Sensor Ignition BTDC 8˚ ± 5˚

Idle RPM Eng. Coolant Temp. Sensor, RPM, LOAD, Intake Air Temp. Sensor Electronic Throttle Control 650±100 rpm

Spark plug gap - - 1.0 ~ 1.1 mm

Oxygen sensor output Air/Fuel Ratio Air/Fuel Ratio 0 ~ 1000 mV

Thermostat opening temperature Wax Pellet Water 82˚C±1.5˚C


03-1

03.00 Detailed Description of Vehicles Covered by Certificate and Test Parameters

03.01 Updated Vehicle Parameters

Vehicle parameters are not changed from part 1 application.

03.02 Updated Test Parameters : None

Test parameters are not changed from part 1 application.

03.03 Basic Information about the Engine Code.

Engine horsepower at speed (HP, SAE-Net) 162/5800

Engine torque at speed (lb-ft, SAE-Net) 164/4250

Idle speed 650±100 RPM

Basic timing BTDC 8˚ ± 5˚

Catalyst Code (ID) WCC: 25450 UCC: 25560


03-2

03.04 General Technical Description

03.04.01 Fuel and Emission Control System

1. General Description

The Sequential Multiport Fuel Injection System (SFI) is an electronic fuel metering system that has a fuel injector near each cylinder inlet port. The amount of fuel metered by the injectors is determined by an electronic signal supplied by the Engine Control Unit (ECU).

The basic SFI system has a fuel injector near each port to supply the required fuel. Air flow to the intake manifold is controlled by the throttle valve. A device to provide information regarding throttle valve position is included at the throttle body unit. An air by-pass valve electronically operated to control idle speed is introduced.

The fuel injection strategy is based on air quantity and engine speed calculation where the appropriate volume (pulse width) of fuel is calculated to yield a desired A/F ratio for each particular operating condition.

Injection timing is controlled by the ECU in response to the signals from the Crank Shaft Position Sensor and Cam shaft position sensor.

The Mass Airflow Sensor (MAF) measures air flow rate by measuring the mass-flow of air entering the engine

Closed loop control is used to adjust the calculated pulse width to yield a near stoichiometric A/F ratio when required.

In addition, some modification pulses are delivered as required.

2. Fuel Injection Control

1) Closed Loop A/F Control

The major components of this A/F feedback control system are the ECU and two oxygen sensors.

The front and rear oxygen sensors are mounted in the exhaust gas stream pipe before and after the front TWC respectively. The front oxygen sensor shall be to manage the pumped reference current and pump current control of the ECU. The pump current is a measure of lambda. The output signal from this sensor varies with oxygen concentration of the exhaust gas stream and is provided to the ECU for use in controlling closed loop compensation of fuel delivery.

2) Starting Enrichment

To ensure the starting performance, the fuel delivery time is determined by the ECU which takes account of information on coolant temperature and others instead of electric pulses from the mass air flow sensor because the air flow rate is unstable under the starting conditions.

The starting enrichment control is over terminated the ignition switch is released from the "START" position and the engine speed exceeds the specified one.

3) After Starting Enrichment

For a very short time period just after engine starting, another enrichment is provided to obtain stable combustion. To get proper enrichment for that t ime period, the ECU processes information on the coolant temperature as a parameter to determine the enrichment characterist ic.


03-3

4) Warm-Up Enrichment

The warm-up enrichment is provided for proper vehicle operation by a signal from the ECU which processes information on coolant temperature, air flow and engine speed, until the coolant temperature rises at the pre-set value.

5) Acceleration Enrichment

The acceleration enrichment is provided for ensuring vehicle drivability during acceleration by a signal from the ECU which processes information on air flow, throttle movement, coolant temperature, and engine speed.

6) Fuel Cut Off

During deceleration, fuel injection is terminated in order to decrease HC emissions and to improve fuel economy.

7) Battery Voltage Compensation

The ECU compensates the fuel injection pulse width to compensate for the effect of low available battery voltage which leads to injection delay.

8) Enrichment correction

After engine start additional mixture enrichment is carried out in order to accelerate catalyst heating.

The duration of which is determined according to the threshold of mass air flow integral depending on engine coolant temperature.

9) Transient control

Transient control determines the required additional or reduced injected fuel during a change in load to compensate for wall hang up and dead time between load determination and injection.

10) Support of driving away

A/F Enrichment is carried out to improve the engine torque during driving away and to reduce drop of engine speed when shifting the Auto. T/M vehicle from neutral mode to drive mode.

This function is effective until engine speed increases a threshold or monitoring time elapsed.


03-4

03.04.02 Emission Control System

to Air

UCC

Canister Close Valve

Downstream O2 Sensor

Upstream O2 Sensor

WCC

Tank Pressure Sensor

Canister

Purge Canister Solenoid

Crankshaft Position Sensor

Knock Sensor

Ignition Coil

Fuel Pressure Regulator

Coolant Sensor

Injectors

CVVT (Continuous Variable Valve Timing)

Camshaft Position Sensor

Oil Temp. Sensor

Spark Plug

TMAF Sensor

ETCWith position

sensor


05-1

03.05.00 Ignition System

03.05.01 Ignition System General Description

Electronic Spark Timing (EST) system is provided to control ignition timing. This EST system consists of an ECU, battery, ignition switch, ignition coil, spark plugs.

Cam position sensor is installed on the cylinder head and crank shaft position sensor is installed in the flywheel housing and on the cylinder block respectively to determine ignition timing by detecting the crank position and No.1 TDC position..

The ECU monitors information from various engine sensors, computes the desired spark timing and signals the power transistor to change the timing accordingly. Appropriate ignition timing information based on torque management is previously incorporated in the ECU.

With this EST system, proper ignition timing is obtained at both low- and high-altitudes and during cold engine operation, resulting in good emission performance and drivability.

03.05.02 Spark Plugs

Test Group GAP

8KMXV02.4MW5 1.0 - 1.1 mm

03.06 Evaporative & ORVR Emission Control System

Please refer to the sec. 03.00 of Part 1 application submitted already.

04.00 Final US Sales

Final US sales will be include in the submission of the final update application. 05.00 Service Manual & Bulletins

05.01 Service Manual

Service manual will be submitted together with part 2 application.

05.02 Service Bulletin

Service Bulletin is submitted to EPA & CARB whenever occasion arises.


06-1

06.00 California ARB Information

06.01 Ratio for a test (NMOG/NMHC, HCHO/NMHC)

Please refer to the sec. 17.17 of Part 1application.

06.01.01 NMOG/NMHC Ratio

Kia uses the following NMOG/NMHC ratio for certification testing according to §86.1810-01(p) and for in-use

testing according to §86.1845-04(f)(1):

NMOG/NMHC = 1.04

06.01.02 HCHO/NMHC Ratio

Kia uses the following HCHO/NMHC ratio for in-use testing based on EPA’s approval dated June 15, 2006

according to §86.1845-04(f)(3):

HCHO/NMHC = 0.03 06..02 7 Year/70,000 Mile Emission Warranty

Emission related parts that are estimated to cost at the time of certification individually more than $510.00 (including parts and labor) to replace, are warranted for 7 years from the date of original retail delivery or date of first use, or 70,000 miles, whichever occurs first.

The followings are the Emission Parts covered under emission warranties

Part Name Retail part cost Labor cost *1

(hours) Total

MANIFOLD MODULE-INLET $322.98 $120.00 (1.0) $442.98

BODY ASSY-THROTTLE $366.52 $60.00 (0.5) $426.52

CONVERTER ASSY-CATALYTIC $761.88 $36.00 (0.3) $797.88

AT $759.5 $36.00 (0.3) $795.50 ENGINE CONTROL MODULE

MT $683.55 $36.00 (0.3) $719.55

MANIFOLD CATALYTIC ASSY-EXHAUST $912.87 $180.00 (1.5) $1092.87

TANK ASSY-FUEL $369.53 $144.00 (1.2) $513.53

Note *1 : The labor rate is $120 per hour.

06.03 Owner’s Manual/Warranty Handbook

Owner’s manual is submitted with this part 2 application and warranty handbook will be submitted soon.


06-4

06.04 Engineering Evaluation Demonstration Continuity in Emissions

Statement of Compliance for 20 to 86˚F Temperature Range as required by California Exhaust Emission Standards and Test Procedures for 2001 and Subsequent Model Passenger Cars, Light-Duty Trucks, and Medium-Duty Vehicles amended May 28, 2004.

Kia Motors Corporation hereby attests that a discontinuity in emission of non-methane organic gases, carbon monoxide, oxides of nitrogen and formaldehyde measured on the Federal Test Procedure (40CFR Part 86) does not occur in the temperature range of 20 to 86˚F.

Test Vehicle : Vehicle ID E. T. W. T/M Test Temp.

MG06EM-24D-1 3500 L5 20˚F, 50˚F, 77˚F

Test Results :

Temp. NMOG CO NOX HCHO

20˚F 0.3412 1.3633 0.0219 0.0057

50˚F 0.0595 0.3182 0.0105 0.0011

77˚F 0.0186 0.2606 0.0083 0.0003

Test Result Graph :

0

1

2

20 50 77

Temperature( )

NM

OG

,CO

(g/m

ile)

00.0050.010.0150.020.0250.030.0350.040.0450.05

NO

x,H

CH

O(g

/mile

)

CO

NMOG

NOX

HCHO


06-5

06.05 Vehicle Emission Control Information Label

Location : Label are affixed underside of hood which is readily visible position in the engine compartment.

application for certification - part 2

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