General Information

Vehicle Protection

Always cover the fenders, seats and floor before starting work.

Tool and Measuring Equipment Preparation

Make sure all required tools and measuring equipment are available before starting the work.

Special Service Tools

Use special service tools when required.

Part Removal

First identify the cause of the problem, then determine whether removal or disassembly is required before starting work.

Disassembly

If the disassembly procedure is complex and requires removing many parts, all parts must be disassembled in a way that does not affect their function or appearance.

1. 1
   Part Inspection

   Carefully inspect each part for signs of malfunction, deformation, damage and other problems when removed.

   

2. 2
   Part Arrangement

   Arrange all disassembled parts carefully so they can be reassembled efficiently.

   Be sure to separate and correctly identify parts to be replaced from those to be reused.

   

3. 3
   Cleaning Parts for Reuse

   All parts that will be reused must be thoroughly cleaned using the appropriate method.

   

Parts

When replacing parts, use genuine KIA MOTORS parts.

Replacement

Specified values, such as torque and specified adjustments, must be strictly observed when assembling all parts.

The following parts must always be replaced with new ones when removed.

1. 1
   Oil Seals
2. 2
   Gaskets
3. 3
   O-rings
4. 4
   Lock Washers
5. 5
   Cotter Pins
6. 6
   Plastic Nuts

   

   Depending on their location.
7. 7
   Apply sealant to the gaskets.
8. 8
   Apply oil to the moving parts.
9. 9
   Apply the specified oil or grease to the specified locations (oil seals, etc.) before assembly.

   

Adjustment

Use gauges and testers to correctly set parts to specified values.

Electrical System

1. 1
   Be sure to disconnect the cable from the negative (-) battery terminal.
2. 2
   Never pull on the wires when disconnecting connectors.
3. 3
   Locking connectors will click when the connector is securely connected.
4. 4
   Handle sensors and relays carefully. Be careful not to drop them onto other parts.

   

Rubber Parts and Hoses

Always avoid contact of gasoline with rubber parts or hoses.

Body Dimension Measurement

1. 1
   All measurements in this manual are taken with a tracking gauge.
2. 2
   When using a measuring tape, make sure it is not stretched, twisted or bent.
3. 3
   When measuring dimensions, both projected and actual dimensions are used in this manual, as specified.

Projected Dimensions

1. 1
   These are the dimensions measured when the measuring points are projected from the vehicle surface, and are the reference dimensions used for body repair.
2. 2
   If the tracking gauge probes are adjustable, measure by extending one of the two probes until the height of the two surfaces is equal.

   

Actual Dimension Measurement

1. 1
   These dimensions indicate the actual linear distance between measuring points and are used as reference dimensions when a gauge is used for measurement.
2. 2
   First adjust both probes to the same length (A=A') before measuring.

   

Measuring point

Measurements should be taken at the center of the hole.

Cable and Wire Inspection

1. 1
   Check the terminal for tightness.
2. 2
   Check the terminals and wires for corrosion from battery electrolyte, etc.
3. 3
   Check the terminals and wires for open circuits.
4. 4
   Check the insulation and covering of the wires for damage, cracks and deterioration.
5. 5
   Check the current-carrying parts of the terminals for contact with other metal parts (vehicle body and other parts).
6. 6
   Check the grounded parts to verify there is full continuity between their mounting bolt(s) and the vehicle body.
7. 7
   Check for correct connections.
8. 8
   Make sure the wiring harness is clamped so it does not contact sharp body edges or similar, or hot parts (exhaust manifold, etc.).
9. 9
   Make sure the wiring harness is firmly clamped to provide sufficient clearance from the fan pulley, fan belt and other rotating or moving parts.
10. 10
    Make sure the wiring harness has some slack so it can move between stationary and moving parts, such as the body and the engine.

    

Check fuses

Test points are provided for blade-type fuses, allowing the fuse to be checked without removing it from the fuse block. The fuse is good if the test lamp lights when one lead is connected to a test point (one at a time) and the other lead is grounded. (Turn the ignition key to activate the fuse circuit.)

Electrical System Service

1. 1
   Before servicing the electrical system, be sure to turn the ignition off and disconnect the ground cable from the battery.

   

2. 2
   Secure wiring harnesses with clamps so they do not sag. However, for any harness that passes near the engine or other vibrating parts of the vehicle, provide enough slack so that engine vibration does not cause the harness to contact any surrounding parts, then secure the harness with clamps.

   

3. 3
   If any section of the wiring harness interferes with an edge or corner of a part, wrap that section with tape or similar material to protect it from damage.

   

4. 4
   When installing any parts, be careful not to pinch or damage the wiring harness.

   

5. 5
   Never drop relays, sensors or electrical parts, or subject them to strong impact.

   

6. 6
   Electronic parts used in computers, relays, etc. are easily damaged by heat. If service operations are required where the temperature may exceed 80 °C, remove the electronic parts beforehand.

   

7. 7
   Loose connectors cause problems. Make sure that connectors are always securely fastened.

   

8. 8
   When disconnecting a connector, hold only the connector, not the wires.

   

9. 9
   Disconnect the connector that is locked by pressing in the direction of the arrows shown in the illustration.

   

10. 10
    Connect connectors that have locks by inserting them until they click.

    

11. 11
    When using a circuit tester to check circuit continuity or voltage at connector terminals, insert the test probe from the wiring harness side. If the connector is a waterproof connector, insert the probe through the hole in the rubber cap until it contacts the terminal, taking care not to damage the wire insulation.

    

12. 12
    To prevent wiring overload, take into account the electrical load of additional equipment and select a wire of appropriate size.

    Nominal size	SAE Gauge No.	Allowable Current
    		In Engine Compartment	Other Areas
    0.3 mm²	AWG 22	-	5A
    0.5 mm²	AWG 20	7A	13A
    0.85 mm²	AWG 18	9A	17A
    1.25 mm²	AWG 16	12A	22A
    2.0 mm²	AWG 14	16A	30A
    3.0 mm²	AWG 12	21A	40A
    5.0 mm²	AWG 10	31A	54A

Catalytic Converter Precautions

1. 1
   Use only unleaded gasoline.
2. 2
   Do not run the engine while the vehicle is parked for a long time. Avoid running the engine at high idle speed for more than 10 minutes and at idle for more than 20 minutes.
3. 3
   Do not perform an engine compression test for a long time. The engine compression test must be performed as quickly as possible. Before performing the compression test, remove the fuel pump relay.
4. 4
   Do not dispose of a used catalytic converter together with parts contaminated with gasoline or oil.