Kia Soul 2009–2010 Repair Manual (P/N KT2009052001)

• Complete 16-section factory workshop coverage for the 2009 Kia Soul (AM) with the G 1.6 DOHC engine, with separate 2009 D 1.6 TCI-U2 diesel powertrain supplements and selected 2010 G 2.0 DOHC engine sections.
• Covers compression testing, valve-clearance inspection and tappet selection, timing-chain service, CVVT checks, cylinder-head and block work, cooling and lubrication systems, and engine/transaxle removal for the G 1.6 DOHC.
• Diesel material adds turbo/intercooler work, common-rail injector and high-pressure-pump service, fuel-system bleeding, preheating diagnosis, VGT and EGR controls, variable-swirl components, and catalyzed particulate-filter fault tracing.
• Drivetrain and chassis sections address manual and automatic transaxles, clutch hydraulics, driveshafts and hubs, electric power steering, suspension and alignment, TPMS, brakes, ABS/EBD, and ESP testing and calibration.
• Electrical and body repair coverage includes ECM and BCM scan-tool functions, immobilizer key teaching, transmitter registration, SRS components, rear parking assist, back-view camera circuits, sunroof reset, HVAC diagnosis, and body service.
• 2,130-page PDF set in 32 files — 1,277 pages of gasoline workshop material, 461 pages of diesel supplements, a 314-page Canadian owner’s manual, 64 pages of 2010 G 2.0 DOHC extracts, and 14 pages of Bluetooth publication material.

Gasoline and Diesel Powertrain Coverage

The 16-section gasoline workshop set is organized around the 2009 G 1.6 DOHC configuration. Its engine-mechanical material goes well beyond routine maintenance: compression and valve-clearance checks, mechanical lash adjuster inspection, tappet selection, timing-chain removal and installation, CVVT and oil-control-valve checks, cylinder-head disassembly, crankshaft and piston inspection, and engine/transaxle removal are documented. Cooling, lubrication, intake, exhaust, fuel delivery, ignition, charging, starting, and emissions systems have their own repair procedures and specification data.

The diesel supplement is not a second complete body-and-chassis manual. It adds the powertrain information for the 2009 D 1.6 TCI-U2 engine, including turbocharger and intercooler components, diesel starting and preheating, common-rail fuel delivery, injector and high-pressure-pump work, fuel-system bleeding, and electronic diagnosis of the VGT, EGR, variable-swirl, rail-pressure, exhaust-temperature, and CPF systems. M5CF3-series manual-transaxle and A4CF2 automatic-transaxle sections are supplied alongside the G 1.6 DOHC M5CF1-1 and A4CF1 material.

The 2010 G 2.0 DOHC content is a focused engine extract, not a full 2010 workshop manual. It covers identification and specifications, compression and MLA valve-clearance work, timing-belt tension and replacement, engine/transaxle removal, mounting and timing-component layouts, and engine-noise troubleshooting. Automatic-transaxle coverage includes operational tests, hydraulic-pressure diagnosis, sensors, solenoids, shift controls, and removal/installation; internal valve-body overhaul is referred to a separate publication.

Chassis, Electrical, Body, and HVAC Sections

The gasoline manual carries the repair scope through the rest of the vehicle. Brake coverage runs from the booster, master cylinder, lines, calipers, drums, and parking brake to ABS hydraulics, wheel-speed sensors, EBD, ESP, steering-angle calibration, scan-tool bleeding, and DTC diagnosis. Suspension chapters cover struts and subframes, the rear torsion beam, wheel alignment, wheel and tire service, and TPMS initialization. Separate sections address electric power steering, clutch hydraulics, CV joints, hubs, airbags, impact sensors, and seat-belt pretensioners.

Body-electrical material documents BCM current-data and actuator tests, immobilizer key teaching and neutralization, remote-transmitter registration, locks, mirrors, windows, wipers, lighting and DRL circuits, rear parking assist, audio/AUX components, the instrument cluster, sunroof initialization, and the back-view camera. HVAC repair content covers refrigerant diagnosis, compressor and clutch service, condenser and evaporator components, pressure and temperature sensing, heater and blower units, mode and temperature actuators, the PTC heater, and controller testing.

Factory Data, Tools, and Visual References

Component-specific torque tables, tightening sequences, clearances, wear limits, fluid capacities, approved lubricants and sealants, electrical test values, connector data, waveforms, and troubleshooting charts appear with the related repair sections. Listed service tools include the 09215-3C000 oil-pan remover, 09221-4A000 torque-angle adapter, 09200-38001 engine-support fixture, and 09351-4A300 diesel injector remover.

Useful visual references include the G 1.6 timing-chain exploded view, cylinder-head/CVVT assembly, ABS/ESP hydraulic circuit, ECM sensor circuits and waveforms, rear parking-assist connector pinout, and diesel common-rail and CPF layouts. The separate 2010 owner’s manual and Kia Bluetooth FAQ are included as operating and feature references rather than workshop repair sections.

The engine chapters call out the dedicated oil-pan separator because prying at the joint can gouge the sealing faces and leave a persistent leak path. The ABS bleeding material limits scan-tool pump operation; ignoring the required pause can overheat and damage the HECU motor. Airbag, refrigerant, brake-hydraulic, and engine/transaxle removal work requires proper isolation, recovery equipment, and rated lifting and support equipment.