PUMP REMOVAL - CHEVY SUZUKI
The pump is located in the bumper support license plate area coming in from the engine side. Nothing else needs be removed to access the pump as there is some misinformation out there. Remove the two rubber hoses from steel line. The plug has a tab to squeeze and it doesn't separate easy. Use a Ratchet with an extension and 12 MM socket to remove the two bolts to the bracket that the pump is mounted to. Remove the bracket and pump. To release the tab from the mounting bracket, use a flat tiny screw driver or something pointy to push on the button from behind in middle of tab and slide off. Please don't break it. Spray some penetrating oil on It if doesn't come then send the Complete unit.
Then use Phillips screw driver to separate the pump from the bracket.
KIA SORENTO PUMP REMOVAL
This is located on the driver side fender well - under the hood and behind the headlight. It is fairly easy to get to. Remove the One rubber hose. The plug has a squeeze tab to unplug and it will offer resistance. Then remove the bolts to the mounting bracket. Finally use a pointed tool to push thru the hose on the steel bracket to unlock the locking tab while sliding the plug from the bracket. Please don't break. Use penetrating oil or send the bracket with the pump.
Use Phillips screw driver to separate the pump from the bracket.
Kia Test further down this page
CHEVY - SUZUKI
Can I By Pass the Vehicle Electrical and ECM and install a switch to operate the pump.
Yes, I do sell an ECM/PCM Bypass with installation instructions. Use contact page.
TEST ACTUATOR AIR PUMP Four Wheel Drive ActuatorPumpRepair.com. Chevy Tracker, Suzuki Vitara, XL7
NEVER SPRAY WD40, CARBURATOR CLEANER, OIL INSIDE THE AIR TUBES, YOU MAY AS WELL SPRAY IT INTO YOUR COMPUTER AS THE CHAMBER IS SHARED AND YOU RUIN THE ELECTRONICS AND SILICONE COMPONETS.
YOU CAN USE THE CONTACT FORM FOR TECHNICAL ASSISTANCE.
KIA SORENTO, KIA BORREGO, KIA BONGO 3, KIA MOHAVE
NEVER SPRAY WD40, CARBURATOR CLEANER, OIL INSIDE THE AIR TUBES, YOU MAY AS WELL SPRAY IT INTO YOUR COMPUTER AS THE CHAMBER IS SHARED AND YOU RUIN THE ELECTRONICS AND SILICONE COMPONETS.
Some Symptoms
Pump doesn't come on at all.
Pump won't turn off or turns on and off noticed by blinking 4wd indicator light.
4wd indicator light doesn't come on.
4wd Indicator light doesn't shut off
4wd works only in low range or vise versa (see test diff and switch)
4 wd engages but won't release or slow to release
pump runs sometimes or for 10 seconds and shuts off.
Have 4wd light but no 4 wd
Kia Air Pump Test (ALL)
The pump is a pressure pump, not a vacuum pump. If your 4WD indicator light is blinking it is usually the pump and not the differential actuator.
The AIR PUMP is under the hood in the wheel well behind the driver's headlight area.
One Air hose comes off the pump which goes to the diff. Find the hose to the diff and pull off from metal tube. Vehicle in park, Turn key to power and put in 4wd. Having located the hose to the diff (pressure side of pump), using flat needle nose pliers or fingers; Pinch and hold the hose closed and see if the pump shuts off within 1 second and stays off. If it keeps running or intermittently turns on and off then its bad. It should stay off for at least three minutes. Fail rates can excel rapidly under 60 seconds. If it is coming on every 30 seconds or less it is going to fail and not good for the actuator or diff. If pump shuts off and stays off then you may have a Differential Actuator problem (see testing Diff actuator).
A good Air Pump should put out between 5.4 - 8.2 PSI on a pressure tester and then hold it for three minutes.
When testing pump, squeeze and release a couple times, the pump comes on immediately and shuts off within 1 second. With hose squeezed, shut off key, make sure pressure releases back through the intake tube (not thru diff tube). These pumps are well made however they do experience catastrophic failures over time for a variety of reasons. A minimal skill level is recommended when testing as we don't want to make matters worse. Careful with the plug mounted on the bracket not to break it, I don't generally have replacements but can make some repairs if still in tact. Send pump with bracket if you have concerns.
Electrical Test
If pump doesn't come on at all then it is likely bad. Look at the Red wIre and Black wire on the pump and to which side is which on the vehicle side of the wiring harness. Unplug the wiring harness, Put a test light to what would be the red wire (Positive) and black wire (ground) on the vehicle side of the plug. Turn key on and put vehicle in 4wd (keep test under 10 seconds) if the plug has power then the pump is bad, no power then maybe bad Transfer Switch.
YOU CAN USE THE CONTACT FORM FOR TECHNICAL ASSISTANCE.
KIA 2 PRONG 2006 Air Pump (Additional Info)
Kia changed from a 3 prong to a 2 prong somewhere about 2006. The pump is still the same with three prongs, however the vehicle side of the plug eliminated a prong and is now only power and ground.
So, what that means is the 4 WD indicator light messaging has moved. Otherwise said, the pump is capable of sending a message to the 4 wheel drive indicator light, however Kia has eliminated that function and opted for a message sent from a location inside the differential carrier, arguably a more true reading.
Should you have 4WD but no light then you have an idea where to look for the problem
TEST ACTUATOR and 4WD Differential Engage - Never use unrestricted air pressure to test the actuator.
First, If you conclude your air pump is working properly disconnected from the Differential, then you find the air pump will not shut off when connected to the differential then it is likely the Actuator. You may also hear or see air coming out the oil seal.
USING AIR PRESSURE TO TEST - A pump puts out 5.4 to 8.2 PSI. A differential Actuator Can take well over 15 PSI during a test however I am going to suggest no more than 10 PSI and gradually, rather than abruptly.
Hook an air hose with proper regulator to the differential air tube. Gradually bring the air up to 6 lbs. The Actuator is the equivalent of a balloon (Bladder) and should hold and maintain the 6 lbs. If is doesn't hold then you have a bad actuator.
IF is holds well, then proceed to the following steps to check if the Four Wheel drive is engaging at the wheels.
Failed actuator (torn rubber) Inside Diff is removed, side bearing removed to replace actuator. Bad pumps that keep coming on (blinking light) stress the actuator and can exceed specs, also age. It is a great system that lasts a long time. However, maybe think twice before risking good money on junk yard Air Pump or used differential when you can replace with new parts or refurbished for reasonable money and it will be great for a long time.
Front Kia Sorento Diff w/ Bad Actuator courtesy of Kia Forum
IS 4wd ENGAGING AT THE WHEELS
Jack the front of vehicle off the ground and put on jack stands. Turn both wheels at once and they should turn freely. Turn key to On Position put into 4 WD. Using the vehicle Actuator Air Pump or using a bicycle pump with gauge - Pump 6 - 8 lbs into the differential and see if the Actuator holds the air. (The human mouth can't produce 6 - 8 lbs). It must maintain 6 - 8 lbs. Turn One wheel and see if the other wheel turns in reverse. If yes the actuator is engaging the 4 WD. Take out of 4 WD ( Discontinue air pressure) and turn wheels, only one wheel should turn (test with actuator air pump to be sure air pump is releasing the air, if it doesn't release then you have a big problem with the pump).
Key on Put back into 4WD (Reengage the air pressure to the actuator if not using Actuator Air Pump). Turn both wheels forward at the same time and it should lock into four wheel drive to where you can't turn the wheels. This is limited slip diff and not posi traction so just turning one wheel will cause the other side to turn opposite. If the wheels are able to turn both forward to where the front drive shaft is turning then the diff is working but you aren't engaging in the transaxle.
Some Symptoms
Pump doesn't come on at all.
Pump won't turn off or turns on and off noticed by blinking 4wd indicator light.
4wd indicator light doesn't come on.
4wd Indicator light doesn't shut off
4wd works only in low range or vise versa (see test diff and switch)
4 wd engages but won't release or slow to release
pump runs sometimes or for 10 seconds and shuts off.
Have 4wd light but no 4 wd
FRONT DRIVESHAFT WON'T TURN WHEN DISENGAGED
Bad Actuator, Came apart into 2 Pieces (also replace bearings)
Timing Chain, Bearing issue or other part within Transfer Case
CAN I TEST MY OWN PUMP? Chevy, Suzuki
The pump is a pressure pump, not a vacuum pump. If your 4WD indicator light is blinking it is usually the pump, less common is the differential actuator.
The pump is located on the back side of the Ft bumper behind the license plate area;
There are two hoses, The larger nipple is the intake and the smaller nipple closest to the engine goes to the Differential.
TEST PUMP (also see additional pump test below)
Vehicle in park, Turn key to power and put in 4wd. Listen from driver seat or have a 2nd person at the pump. Keeping the test under 10 seconds, Does pump come on and shut off after 3 seconds and display 4WD light at dash? If so, does the pump then come back on briefly and the light at the dash blink every 1 – 60 seconds. If it blinks then likely bad pump or early failure. If the pump doesn't come at all then it is likely bad. Less often is a switch on the differential. Also try in Lo Range to test the Lo Range switch.
If pump coming on and off or, If when testing the pump it comes on and stays running and then shuts off only after 10 seconds(PCM discontinues power - sometimes displays 4wd light in 2 WD.
ADDITIONAL PUMP TEST (If needed, also see other page - Test Diff and Switch). Locate the hose to the differential (diff) being the smaller hose and closest to the engine. Using fingers or needle nose pliers, fully block all air between the pump and differential. Turn key on and put into 4 WD Does the pump come on and shut off within 1 second and stay off? If it keeps running or intermittently turns on and off then it is generally bad. It should stay off and hold the air pressure. Fail rates can excel rapidly under 60 seconds. If it is coming on every 30 seconds or less it is going to fail and not good for the actuator, differential or PCM.. If pump shuts off and stays off then you may have a Diff Actuator problem (see testing Diff actuator).
WHEN TESTING PUMP - If pump passed the tests above – Separate the rubber hose from the metal line on diff side. With power to pump, squeeze and release the hose a couple times, the pump comes on immediately and shuts off within 1 second. With hose squeezed, shut off key, make sure pressure releases back through the intake tube (not thru diff tube). These pumps are well made however they do experience catastrophic failures over time for a variety of reasons. A minimal skill level is recommended when testing as we don't want to make matters worse. Careful with the plug mounted on the bracket not to break i. The plug has a locking tab, to release push into the hole on the back side of the plug mount and wiggle the plug off.
TESTING POWER COMING FROM VEHICLE
STARTING POINT - NO 4WD LIGHT ON WITH KEY ON IN 2 WD) TESTING VEHICLE SIDE OF PLUG - With it Unplugged from the pump. Put a test light to the RED WIRE (Positive) and black wire (ground) going to the vehicle. Put it where you can see it from driver seat or keep test under 10 seconds. Key On put into 4wd, it should light up the test light. If the plug has power then the pump is bad, no power then maybe bad Transfer Switch. (see Transfer switch).
VEHICLE ELECTRIC CONTOLS TO PUMP, Transfer Case Circuit Description. PCM - POWER CONTROL MODULE INTERACTION, HOW IT WORKS (Factory Manual)
There are two main components for the four wheel drive. The powertrain control module (PCM) and the front drive axle actuator pump. The pump is controlled by the PCM. The pump compresses air to engage the front axle. When the transfer case is in four wheel drive (4H or 4L), the four wheel drive switch closes providing a ground signal to the PCM. The PCM actuates the pump which pressurizes the actuator in the front axle. This pressure engages the axle hub which connects the front drive shaft to the axle shafts, allowing the transmission/transfer case to turn the front wheels. The PCM will not operate the pump for more than 10 seconds in order to protect it. The PCM will also provide a path to ground for the 4WD indicator in the instrument cluster. The indicator is provided battery voltage when the ignition switch is in the ON or START position through the IG fuse. With power and ground supplied, the indicator lights.
When the transfer case is in 4L (with auto trans), the four wheel drive low switch sends a ground signal to the PCM. The PCM will not engage the torque converter clutch while this signal is being received.
When the transfer case is returned to the two wheel drive mode, the release valve in the pump opens and releases the pressure in the actuator. Without pressure, the hub disengages. The PCM also releases the ground to the 4WD indicator which causes the indicator to turn off.
YOUR Vehicle could be in PRE PCM, POST PCM OR POSSIBLY IN BETWEEN (Not Factory Input)
THIS IS COMPLICATED AND DOESN'T ALWAYS FUNCTION THE SAME USUALLY DUE TO THE PUMP FUNCTIONING ON/OFF/ON/OFF IN A FAILED STATE AND CAN CONFUSE THE PCM
PRE PCM - PCM did not disconnect power to the pump as a safety precaution because it did not run for 10 seconds and therefore didn’t lock in that Post PCM position, hence you can test for power to the plug. You know this because with pump disconnected and key on in 2 WD there is no 4 WD light on.
POST PCM - PCM locked in after the 10 seconds and stayed locked, it sends continuous power to the Red, Pink and 4wd light indicator, 4 wd indicator stays on with key on in Two or 4 WD. If your pump when plugged in won't return the PCM function to normal then it is likely catastrophic failure of pump and requiring correctly functioning pump to return to normal state.
WEBSITE DOES NOT DISPLAY WELL ON PHONE, UPPER LEFT CORNER OF PHONE TO SELECT A DIFFERENT PAGE FOR PARTS, TESTING, CONTACT, ETC