General Information

General Information

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

Always insert the hood support rod into the hole near the edge of the hood whenever you inspect the engine compartment, to prevent the hood from falling and causing possible injury. Make sure the hood support rod is released before closing the hood. Always check that the hood is securely latched before driving the vehicle.

Preparation of Tools and Measuring Equipment. Before starting work, make sure that all necessary tools and measuring equipment are available. Special Service Tools. Use special service tools as required.

Removal of Parts. First determine the cause of the problem, then decide whether parts need to be removed or disassembled 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
   Inspection of Parts. Each removed part must be carefully inspected for suspected faults, deformation, damage and other problems.

   

2. 2
   Arrangement of Parts. All disassembled parts must be neatly arranged for efficient reassembly. Be sure to separate and properly identify parts to be replaced from parts that can be reused.

   

3. 3
   Cleaning of Reusable Parts. All reusable parts must be thoroughly cleaned using an appropriate method.

   

   

4. 4
   Oil Seals
5. 5
   Gaskets
6. 6
   O-rings
7. 7
   Lock Washers
8. 8
   Cotter Pins
9. 9
   Plastic Nuts

   

   Depending on their location.
10. 10
    Apply sealant to gaskets.
11. 11
    Apply oil to the moving parts.
12. 12
    Before assembly, apply specified oil or grease to the designated locations (oil seals, etc.).

    

13. 13
    Be sure to disconnect the battery cable from the negative (-) battery terminal.
14. 14
    Never pull on the wires when disconnecting connectors.
15. 15
    Locking connectors will click when securely connected.
16. 16
    Handle sensors and relays carefully. Be careful not to drop them onto other parts.

    

    

17. 17
    In general, all measurements in this manual are made with a caliper.
18. 18
    When using a measuring tape, make sure it does not stretch, twist, or bend.
19. 19
    Both projected and actual dimensions are used for measurements in this manual.
20. 20
    These are dimensions measured when the measurement points are projected from the vehicle surface and are reference dimensions used for body repair.
21. 21
    If the length of the tracking gauge probes is adjustable, measure by extending one of the two probes to the height difference between the two surfaces.

    

22. 22
    These dimensions indicate the actual linear distance between measurement points and are used as reference dimensions when the tracking gauge is used for measurement.
23. 23
    First set both probes to the same length (A=A') before measuring.

    Inspect the sensors and measure them to make sure there are no loose parts.

    

    

24. 24
    Check the terminal for tightness.
25. 25
    Check terminals and wires for corrosion from battery electrolyte, etc.
26. 26
    Check terminals and wires for open circuits.
27. 27
    Check wire insulation and coating for damage, cracks, and wear.
28. 28
    Check the conductive parts of the terminals for contact with other metal parts (vehicle body and other components).
29. 29
    Check the grounded parts to make sure there is full continuity between their mounting bolt(s) and the vehicle body.
30. 30
    Check for correct connections.
31. 31
    Make sure the wiring is secured so that it does not contact sharp body edges or similar parts, or hot parts (exhaust manifold, etc.).
32. 32
    Make sure wiring is secured with sufficient clearance from the fan pulley, fan belt, and other rotating or moving parts.
33. 33
    Make sure the wiring has enough slack so that it can absorb vibration between stationary and moving parts, such as the vehicle body and engine.

    

    

34. 34
    Before servicing the electrical system, be sure to turn the ignition off and disconnect the battery ground cable.

    When diagnosing the MFI or ELC system, if the battery cable is disconnected, any stored diagnostic trouble codes in the computer will be erased. Therefore, if necessary, record the diagnostic data before disconnecting the battery cable.

    

35. 35
    Secure wire harnesses with clamps so that they are not loose. However, for any harness that passes near the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow engine vibration to pull the harness, contact any surrounding parts, and then secure the harness with a clamp.

    

36. 36
    If any section of the wire harness interferes with the edge or corner of a part, wrap the section with tape or similar material to protect it from damage.

    

37. 37
    When installing any parts, take care not to pinch or damage the wiring harness.

    

38. 38
    Never drop relays, sensors, or electrical parts, or subject them to strong impact.

    

39. 39
    Electronic parts used in the computer, relays, etc. are susceptible to heat. If there is a need for service operations that may cause the temperature to exceed 80 °C, remove the electronic parts before performing the operation.

    

40. 40
    Loose connectors cause problems. Make sure that connectors are always securely fastened.

    

41. 41
    When disconnecting a connector, hold only the connector, not the wires.

    

42. 42
    Disconnect the connector with locks by pressing in the direction of the arrows as shown in the illustration.

    

43. 43
    Connect connectors that have locks by inserting them until they click.

    

44. 44
    When using a circuit tester to check continuity or voltage at a connector, insert the test probe from the wire harness side. If the connector is a waterproof connector, insert the test probe through the hole in the rubber seal until it contacts the terminal, taking care not to damage the wire insulation.

    

45. 45
    To avoid overloading the wires, determine the appropriate wire size taking into account the current load of the additional equipment.

    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

Parts. When replacing parts, use genuine KIA MOTORS parts. Replacement. Specified values, such as torque values and specified adjustments, must be strictly observed when reassembling all parts. After removal, the following parts must always be replaced with new ones. Adjustment. Use gauges and testers to correctly adjust parts to the specified values. Electrical System. Rubber Parts and Hoses. Always keep rubber mats and hoses away from gasoline. Body Dimensions. Dimensions. Measurement of Actual Dimensions. Measurement Point. Measurements should be taken at the center of the hole. Inspection of Cables and Wires. Check Fuses. Blade-type fuse test taps are provided so that the fuse can be checked without removing it from the fuse block. The fuse is good if the test lamp lights when one lead is connected to the test taps (one at a time) and the other lead is grounded. (Turn the ignition switch ON and operate the circuit so that the fuse circuit is energized.) Electrical System Service.