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ECM Upgrade With TP Sensor Replacement - Mil On With DTC P2135/P0638 (ENG044R)

Publication date: 2009-11-01
Reference number: ENG044R
Supersedes refnos: ENG044

ECM UPGRADE WITH TP SENSOR REPLACEMENT - MIL ON WITH DTC P2135/P0638

ECM UPGRADE WITH TP SENSOR REPLACEMENT - MIL ON WITH DTC P2135/P0638

TECHNICAL SERVICE BULLETIN

Reference Number(s): 044 Rev, Date of Issue:  November 01, 2009
KIA: 2006-09 Sedona; 2007-09 Sorento, Amanti; 2006.5 Optima; 2007 Rondo
GROUP: Engine
Superceded Bulletin(s): 044

SERVICE INFORMATION

This bulletin provides information related to the ECM software and TP sensor upgrade on some Sedona (VQ), Sorento (BL) and Amanti (GH) with Delphi EMS, Optima (MG) and Rondo (UN) with 2.7L engines which may experience a Malfunction Indicator Lamp (MIL) illuminated with the Electronic Throttle Control (ETC) system-related DTC P2135 or P0638 or P2A00 or P2A03. Throttle body removal is not required to perform TP sensor replacement. The vehicle must have been produced prior to 4/1/2009.

These vehicles may set P1295 and/or P2106 as these are Forced Limited Power and Power Management DTC's. The main symptom of this condition is that the engine idles at a very low rate.

The ECM upgrade can improve DTC P0116 for vehicles equipped with block heater, catalyst damage related P0429, P0430 and P0300~306 (Due to poor fuel quality), oxygen sensor related DTC on Rondo (UN) equipped with 2.7L engine.

To correct this condition, the ECM should be reprogrammed using the GDS download as described in this bulletin, and the TP Sensor replaced.

Fig 1: Global Diagnostic System (GDS) With Old And Improved TPS
G06373286
NOTE: Global Diagnostic System (GDS) users should access the "Notice" function from the GDS Main Screen for instructions regarding ECU upgrade events.
UPGRADE EVENT

UPGRADE EVENT
68. BL 3.8 P2135 AND P0638 DTC LOGIC - K LINE 73. MG 2.7 P2135 AND P0638 DTC LOGIC - CAN
69. BL 3.8 P2135 AND P0638 DTC LOGIC - CAN 75. VQ 3.8 P2135 AND P0638 DTC LOGIC - K-LINE
70. BL 3.3 P2135 AND P0638 DTC LOGIC - CAN 76. VQ 3.8 P2135 AND P0638 DTC LOGIC - CAN
71. UN 2.7 P2135 AND P0638 DTC LOGIC - CAN 77. GH 3.8 P2135 AND P0638 DTC LOGIC - K-LINE
72. MG 2.7 P2135 AND P0638 DTC LOGIC - K-LINE 78. GH 3.8 P2135 AND P0638 DTC LOGIC - CAN

Some ECM configurations will require VIN writing and/or key teaching will be necessary. 

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

PARTS INFORMATION

PARTS INFORMATION

Part Name Part Number Part Kit
Throttle Position Sensor (TPS) Optima/Rondo with 2.7L 35107 3E000FFF or 35107 3E100FFF
  1. TP Sensor
  2. O-ring
  3. Screws(1)
G06373287
 or
G06373288
Sedona, Sorento and Amanti with 3.3L or 3.8L 35107 3C000FFF or 35107 3C100FFF
(1) Only supplied w/3C100FFF
  1. Open hood and remove the engine cover if necessary.
  2. Disconnect the TP sensor electrical connector.
    Fig 2: TP Sensor Electrical Connector
    G06373289
  3. Remove the three (3) torx mounting screws (T-20).
    Fig 3: Torx Mounting Screws
    G06373290
  4. Remove the TP sensor from the ETC actuator.
NOTE: The O-ring sometimes will stick to the housing during removal. Be sure to remove if this occurs.
Fig 4: ETC Actuator
G06373291

Installation Procedure: 

  1. Lubricate the O-ring on the TP sensor and align the mating hole on the throttle shaft while aligning the electrical terminals.
    Fig 5: Mating Holes and Electrical Terminals
    G06373292
  2. Install the new TP sensor to the ETC actuator and tighten the Torx T-20 screws hand tight only. Use Loctite® Threadlocker Green 290 on screws during assembly.
    NOTE: On p/n 35107 3C100FFF or 35107 3E100FFF, the 4th hole is not used.
    Fig 6: Tightening Torx T-20 Screws
    G06373293
  3. Install the electrical connector to the TP sensor.
  4. Install engine cover if removed.
  5. Proceed to the reflash instructions.
  6. Road test when complete to ensure proper installation of the TP sensor and base setting of transaxle adaptive reset since reflash of PCM was performed. This only applies to vehicles with PCM, vehicles with ECM and TCM do not require transaxle adaptive learning.

ECM ROM TABLE INFORMATION

ECM ROM TABLE INFORMATION

BL 3.8L with K-line - Upgrade event #68
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2007 Without 39106 - 3C360 BL6N38*S2**653D* BL6N38*S2**683AC
BL6N38*S2**653E*
ECM ROM TABLE INFORMATION

BL 3.8L with CAN - Upgrade event #69
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2007 Without 39106 - 3C361 BL6N38*S2**7D0C* BL6N38*S2**8JHBC
(VIN writing procedure required)
BL7N38*S2**7F4C* BL6N38*S2**8JHCC
BL7N38*S2**7F4E*
(VIN writing procedure required)
2008 39106 - 3C362 BL7N38*S2**7J1A* BL7N38*S2**8JHDC
BL7N38*S2**7J2E*
BL7N38*S2**7J2F* BL7N38*S2**8JHEC
BL7N38*S2**7J2H* BL7N38*S2**8JHFC
2009 39106 - 3C363 BL8N38*S2**8J0A* BL8N38*S2**8JHAC
BL8N38*S2**8JHAB
ECM ROM TABLE INFORMATION

BL 3.3L with CAN - Upgrade event #70
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2008 MY Without 39106 - 3C261 BL7N33*S2**7J1A* BL7N33*S2**7M0DD
BL7N33*S2**7J2D*
BL7N33*S2**7J2E* BL7N33*S2**7M0EE
2009 MY 39106 - 3C262 BL8N33*S2**8J0A* BL8N33*S2**8JHBB
ECM ROM TABLE INFORMATION

UN 2.7L with CAN - Upgrade event #71
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2007 Without 39109-3E631 UN7N27*S2AS7C1BB UN8N27*S2AS7M0EA
UN7N27*S2AS7D0BB
UN7N27*S2AS7D0CB
UN7N27*S2AS7F0BB
UN6N27*S2AS7F4AA
UN6N27*S2AS7F4CD
(VIN writing procedure required)
39109-3E650 UN6N27*S2AS7G3XZ UN8N27*S2AS7M0FA
2008 39109-3E632 UN7N27*S2AS7G3CA UN8N27*S2AS7M0GA
UN7N27*S2AS7J0AA
UN7N27*S2AS7J1AA
39106-3E633 UN7N27*S2AS7K6BA
2009 39106-3E634 UN8N27*S2AS8JFAA UN8N27*S2AS8JHBA
UN8N27*S2AS8JHAA
ECM ROM TABLE INFORMATION

MG 2.7L with K-line - Upgrade event #72
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2006 Without 39109 - 3E210 MG6N27*S2AS5E1DB MG6N27*S2AS683EA
MG6N27*S2AS5E1GB
MG6N27*S2AS5E1HB
MG6N27*S2AS5E1IC
MG6N27*S2AS5E1ID
MG6N27*S2AS5E3AA
MG6N27*S2AS5E4AA
2007 39109 - 3E211 MG6N27*S2AS653AB
MG6N27*S2AS653CC
MG6N27*S2AS671BB
MG6N27*S2AS672AA
ECM ROM TABLE INFORMATION

MG 2.7L with CAN - Upgrade event #73
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2008 Without 39109 - 3E212 MG7N27*S2AS7G3BA MG7N27*S2AS7M0EA
MG7N27*S2AS7J0AA
MG7N27*S2AS7J1AA
39109 - 3E213 MG7N27*S2AS7K6AA MG7N27*S2AS7M0EA
MG7N27*S2AS7M0AA
2009 39109 - 3E210 MG8N27*S2AS8JGEA MG8N27*S2AS8JIBA
MG8N27*S2AS8JHAA
39109 - 3E211 MG8N27*S2AS8JIAA
ECM ROM TABLE INFORMATION

VQ 3.8L with K-line - Upgrade event #75
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2006 With 39110-3C410 VQ5N38*M2AS5D1BA VQ5N38*M2AS683CB
VQ5N38*M2AS5D2AA
VQ5N38*M2AS5E1BB
VQ5N38*M2AS5E2AA
VQ5N38*M2AS5E3AA
VQ5N38*M2AS660AB
VQ5N38*M2AS660BB
VQ5N38*M2AS671CB
VQ5N38*M2AS671DB
VQ5N38*M2AS683BB
Without 39110-3C460 VQ5N38*S2AS5D1BA VQ5N38*S2AS683CB
VQ5N38*S2AS5D2AA
VQ5N38*S2AS5E1BB
VQ5N38*S2AS5E2AA
VQ5N38*S2AS5E3AA
VQ5N38*S2AS660AB
VQ5N38*S2AS660BB
VQ5N38*S2AS671CB
VQ5N38*S2AS671DB
VQ5N38*S2AS683BB
2007 With 39110-3C415 VQ6N38*M2AS653DB VQ6N38*M2AS683CB
VQ6N38*M2AS660AB
VQ5N38*M2AS660BB
VQ6N38*M2AS671BA
VQ6N38*M2AS671DA
VQ6N38*M2AS671EA
VQ6N38*M2AS671FA
VQ6N38*M2AS683BB
Without 39110-3C465 VQ6N38*S2AS653DB VQ6N38*S2AS683CB
VQ6N38*S2AS660AB
VQ5N38*S2AS660BB
VQ6N38*S2AS671BA
VQ6N38*S2AS671DA
VQ6N38*S2AS671EA
VQ6N38*S2AS671FA
VQ6N38*S2AS683BB
ECM ROM TABLE INFORMATION

VQ 3.8L with CAN - Upgrade event #76
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2008 With 39110-3C416 VQ7N38*M2AS7G3BA VQ7N38*M2AS7M0CA
VQ7N38*M2AS7J0AA
VQ7N38*M2AS7J1AA
VQ7N38*M2AS7M0AA
Without 39110-3C466 VQ7N38*S2AS7G3BA VQ7N38*S2AS7M0CA
VQ7N38*S2AS7J0AA
VQ7N38*S2AS7J1AA
VQ7N38*S2AS7M0AA
With 39110-3C417 VQ7N38*M2AS7G3BP VQ7N38*M2AS7M0CP
VQ7N38*M2AS7J0AP
VQ7N38*M2AS7J1AP
VQ7N38*M2AS7J2AP
VQ7N38*M2AS7J2BP
VQ7N38*M2AS7M0AP
Without 39110-3C467 VQ7N38*S2AS7G3BP VQ7N38*S2AS7M0CP
VQ7N38*S2AS7J0AP
VQ7N38*S2AS7J1AP
VQ7N38*S2AS7J2AP
VQ7N38*S2AS7J2BP
VQ7N38*S2AS7M0AP
With 39110-3C418 VQ7N38*M2AS7K6BP VQ7N38*M2AS7M0CP
VQ7N38*M2AS7K6CP
VQ7N38*M2AS7M0AP
Without 39110-3C468 VQ7N38*S2AS7K6BP VQ7N38*S2AS7M0CP
VQ7N38*S2AS7K6CP
VQ7N38*S2AS7M0AP
2009 With 39110-3C419 VQ8N38*M2AS8JACA VQ8N38*M2AS8JHCA
VQ8N38*M2AS8JFAB
VQ8N38*M2AS8JHAA
Without 39110-3C469 VQ8N38*S2AS8JACA VQ8N38*S2AS8JHCA
VQ8N38*S2AS8JFAB
VQ8N38*S2AS8JHAA
ECM ROM TABLE INFORMATION

GH 3.8L with K-line: Upgrade event #77
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2007 With 39110-3C810 GH6N38*M2AS653BB GH6N38*M2AS683CA
GH6N38*M2AS660DC
GH6N38*M2AS660DD
GH6N38*M2AS671AA
GH6N38*M2AS671BA
GH6N38*M2AS683BA
ECM ROM TABLE INFORMATION

GH 3.8L with CAN: Upgrade event #78
MODEL YEAR IMMOBILIZER ECM P/N ROM ID
PREVIOUS NEW
2008 With 39110-3C811 GH7N38*M2AS7G2BA GH7N38*M2AS7M0CA
GH7N38*M2AS7G3AA
GH7N38*M2AS7G3BA
GH7N38*M2AS7J0AA
GH7N38*M2AS7J1AA
GH7N38*M2AS7M0AA
With 39110-3C812 GH7N38*M2AS7G3BP GH7N38*M2AS7M0CP
GH7N38*M2AS7J0BP
GH7N38*M2AS7J1AP
GH7N38*M2AS7K6BP
GH7N38*M2AS7M0AP
2009 With 39110-3C814 GH8N38*M2AS8JACA GH8N38*M2AS8JHEA
GH8N38*M2AS8JFAA
GH8N38*M2AS8JHBA
  1. Connect the power supply cable to the GDS tool.
    NOTE: If attempting to perform the ECU upgrade with the power supply cable disconnected from the GDS tool, be sure to check that the GDS tool is fully charged before ECU upgrade. If the GDS tool is not fully charged, failure to perform the ECU upgrade may occur. Therefore, it is strongly recommended that the power supply connector be connected to the GDS tool.
  2. Connect the USB cable between the VCI and the GDS tool.
    NOTE: When performing the ECU upgrade using the GDS tool, wireless communication between the VCI and GDS tool is not available. Therefore, be sure to connect the USB cable between the VCI and the GDS tool.
  3. Connect the Main 16-pin DLC cable (GHDM - 241000) to the VCI.
  4. Connect the Main 16-pin DLC cable (GHDM - 241000) to the OBD-II connector, located under the driver's side of the instrument panel.
    Fig 7: 16-pin DLC Cable (GHDM - 241000)
    G06373294
  5. With the ignition key ON, turn ON the VCI and GDS tool. Access the GDS vehicle identification number (VIN) screen and configure the vehicle using the VIN AUTO DETECT Function.
    NOTE: Global Diagnostic System (GDS) users should access the "Notice" function from the GDS Main Screen for instructions regarding ECU upgrade events.
  6. Once back at the GDS Main Screen, select ECU upgrade from the bottom right-hand corner. Next select Auto Mode  , Engine. Perform the ECU upgrade in accordance with normal GDS tool ECU upgrade procedures.
    NOTE: DO NOT attempt to perform a Manual Mode ECU upgrade unless Auto Mode fails. Always follow the instructions given on the GDS tool in either Auto or Manual mode. See table for Manual Mode passwords. In addition, a ECU reset is required if Auto Mode fails; refer to the table below for procedure.

    MANUAL MODE ECU UPGRADE PASSWORDS:

    MANUAL MODE ECU UPGRADE PASSWORDS

    68. BL 3.8 P2135 AND P0638 DTC LOGIC - K LINE
    MENU PASSWORD
    BL 3.8 07MY NON IMMO: 39106-3C360 3360
    MANUAL MODE ECU UPGRADE PASSWORDS

    69. BL 3.8 P2135 AND P0638 DTC LOGIC - CAN
    MENU PASSWORD
    BL 3.8 07MY NON IMMO:
    39106-3C361[~7D0C*]    		 3361
    BL 3.8 07MY NON IMMO:
    39106-3C361[~7F4C*,~7F4E*]    		 3362
    BL 3.8 08MY NON IMMO:
    39106-3C362[~7J1A*,~7J2E*]    		 3362
    BL 3.8 08MY NON IMMO:
    39106-3C362[~7J2F*]    		 3363
    BL 3.8 08MY NON IMMO:
    39106-3C362[~7J2H*]    		 3364
    BL 3.8 09MY NON IMMO: 39106-3C363 3365
    MANUAL MODE ECU UPGRADE PASSWORDS

    70. BL 3.3 P2135 AND P0638 DTC LOGIC - CAN
    MENU PASSWORD
    BL 3.3 07MY NON IMMO:
    39106-3C260[~7D0F*]    		 3260
    BL 3.3 07MY NON IMMO:
    39106-3C260[~7F4A*,~7F4C*]    		 3261
    BL 3.3 08MY NON IMMO:
    39106-3C261[~7J1A*,~7J2D*]    		 3262
    BL 3.3 08MY NON IMMO:
    39106-3C261[~7J2E*]    		 3263
    BL 3.3 09MY NON IMMO: 39106-3C262 3263
    MANUAL MODE ECU UPGRADE PASSWORDS

    71. UN 2.7 P2135 AND P0638 DTC LOGIC - CAN
    MENU PASSWORD
    UN 2.7 NON IMMO: 39109 - 3E631 3631
    UN 2.7 NON IMMO: 39109 - 3E650 3650
    UN 2.7 NON IMMO: 39109 - 3E632/33 3633
    UN 2.7 NON IMMO: 39109 - 3E634 3634
    MANUAL MODE ECU UPGRADE PASSWORDS

    72. MG 2.7 P2135 AND P0638 DTC LOGIC - K-LINE
    MENU PASSWORD
    MG 2.7 NON IMMO: 39109-3E210/11 3211
    MANUAL MODE ECU UPGRADE PASSWORDS

    73. MG 2.7 P2135 AND P0638 DTC LOGIC - CAN
    MENU PASSWORD
    MG 2.7 NON IMMO: 39109-3E212/13 3213
    MG 2.7 NON IMMO: 39129-3E210/11 3211
    MANUAL MODE ECU UPGRADE PASSWORDS

    75. VQ 3.8 P2135 AND P0638 DTC LOGIC - K-LINE
    MENU PASSWORD
    VQ 3.8 IMMO: 39110-3C410 3410
    VQ 3.8 IMMO: 39110-3C415 3415
    VQ 3.8 NON IMMO: 39110-3C460 3460
    VQ 3.8 NON IMMO: 39110-3C465 3465
    MANUAL MODE ECU UPGRADE PASSWORDS

    75. VQ 3.8 P2135 AND P0638 DTC LOGIC - K-LINE
    MENU PASSWORD
    VQ 3.8 IMMO: 39110-3C410 3410
    VQ 3.8 IMMO: 39110-3C415 3415
    VQ 3.8 NON IMMO: 39110-3C460 3460
    VQ 3.8 NON IMMO: 39110-3C465 3465
    MANUAL MODE ECU UPGRADE PASSWORDS

    76. VQ 3.8 P2135 AND P0638 DTC LOGIC - CAN
    MENU PASSWORD
    VQ 3.8 IMMO: 39110-3C416 3416
    VQ 3.8 IMMO: 39110-3C417 3417
    VQ 3.8 IMMO: 39110-3C418 3418
    VQ 3.8 IMMO: 39110-3C419 3419
    VQ 3.8 NON IMMO: 39110-3C466 3466
    VQ 3.8 NON IMMO: 39110-3C467 3467
    VQ 3.8 NON IMMO: 39110-3C468 3468
    VQ 3.8 NON IMMO: 39110-3C469 3469
    MANUAL MODE ECU UPGRADE PASSWORDS

    77. GH 3.8 P2135 AND P0638 DTC LOGIC - K-LINE
    MENU PASSWORD
    GH 3.8 IMMO: 39110-3C810 3810
    MANUAL MODE ECU UPGRADE PASSWORDS

    78. GH 3.8 P2135 AND P0638 DTC LOGIC - CAN
    MENU PASSWORD
    GH 3.8 IMMO: 39110-3C811 3811
    GH 3.8 IMMO: 39110-3C812 3812
    GH 3.8 IMMO: 39110-3C814 3814
  7. When the GDS tool reports that the ECU upgrade has been successfully completed, click OK, turn OFF the ignition key, and wait at least 10 seconds before attempting to start the engine.
  8. Check for Diagnostic Trouble Codes (DTCs) using the GDS and erase any DTCs stored in the Engine and Transaxle Control Modules.
  9. Road test when complete to ensure proper installation of the TP sensor and base setting of transaxle adaptive reset since reflash of PCM was performed. This only applies to vehicles with PCM, vehicles with ECM and TCM do not require transaxle adaptive learning.

AFFECTED PRODUCTION RANGE

(Vehicles produced prior to 4/1/2009)

2006~2009 Sedona (VQ) with 3.8L engine equipped with PCM

2007~2009 Sorento (BL) with 3.3L and 3.8L engines equipped with ECM&TCM

2007~2009 Amanti (GH) with 3.8L engine equipped with PCM

2006.5 Optima (MG) with 2.7L engine equipped with PCM

2007 Rondo (UN) with 2.7L engine equipped with PCM

WARRANTY CLAIM INFORMATION

WARRANTY CLAIM INFORMATION

Claim Type Model Causal P/N Comm. Interface Labor OP Code Repair Description Time Related Parts Qty. N Code C Code
W BL 3.3/3.8 39106 3C361 CAN 35107F00 TPS REPLACEMENT&ECM UPGRADE 0.4 35107 3C000FFF or 35107 3C100FFF 1 N69 C40
GH 3.8 39110 3C811 CAN 35107F01 TPS REPLACEMENT&ECM UPGRADE 0.6 35107 3C000FFF or 35107 3C100FFF
UN 2.7 39109 3E631 35107 3E000FFF or 35107 3E100FFF
MG 2.7 39109 3E212 CAN 35107F02 TPS REPLACEMENT&ECM UPGRADE 0.7 35107 3E000FFF or 35107 3E100FFF
VQ 3.8 39110 3C416 35107 3C000FFF or 35107 3C100FFF
BL 3.8 39106 3C360 K-LINE 0.8 35107 3C000FFF or 35107 3C100FFF
GH 3.8 39110 3C810 K-LINE 35107F03 35107 3C000FFF or 35107 3C100FFF
MG 2.7 39109 3E210 K-LINE 35107F04 TPS REPLACEMENT&ECM UPGRADE 0.9 35107 3E000FFF or 35107 3E100FFF
VQ 3.8 39110 3C410 35107 3C000FFF or 35107 3C100FFF
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