Kia Stonic Quiz
General Information

General Maintenance Information

In this manual: General Information
General Information — 8Maintenance — 31Engine Mechanical — 49Engine Electrical — 15Emission control system — 11Engine Control System/Fuel System — 45Clutch System — 12Manual Transaxle System — 11DCT (Dual Clutch Transmission) System — 16Drive Shafts and Axles — 9Suspension — 16Steering — 10restraint system — 15Braking system — 22Body (Interior and Exterior) — 89Rear Seat — 16Electrical System — 25Electrochromic Interior Rear View Mirror — 64Heating, Ventilation, and Air Conditioning — 31
45steps
~270min
5/5difficulty
Done 0 of 45

General Information

VEHICLE IDENTIFICATION NUMBER LOCATION

VEHICLE PROTECTION

Before starting work, always cover the fenders, seats, and floor surfaces with protective covers.

TOOL PREPARATION AND MEASURING INSTRUMENTS

Before starting work, make sure all required tools and measuring instruments are available.

SPECIAL TOOLS

Use special tools where required.

REMOVING COMPONENTS

Before starting work, first identify the cause of the malfunction, then decide whether it should be repaired or whether disassembly is required.

DISASSEMBLY

During complex disassembly involving many parts, disassemble components in a way that does not impair their function or appearance.

  1. COMPONENT INSPECTION

    After disassembly, carefully inspect each individual part for proper function, deformation, damage, or other faults.

  2. Removed Components

    Keep all removed parts in the exact order for reassembly.

    Parts that are to be reused must be kept separately from parts that are to be replaced.

  3. CLEANING REUSABLE PARTS

    All parts to be reused must be carefully and thoroughly inspected for serviceability. Clean as required.

DISASSEMBLY

When replacing individual parts, always use genuine KIA parts.

REMOVAL AND INSTALLATION

Standard values, such as torque or special settings, must be strictly observed when reassembling all parts.

The following parts must always be replaced with new ones after disassembly.

  1. oil seals

  2. O-rings

  3. O-rings

  4. lock plates

  5. cotter pins

  6. plastic nuts

    Depending on location.

  7. Apply sealant to gaskets.

8th)

Apply oil to moving parts.

  1. Before assembly, apply the specified type of oil or grease to the designated locations (oil seals, etc.).

INSPECTION

Use gauges and testers to check that all parts conform to the standards set.

ELECTRICAL

  1. Disconnect the battery cable from the negative (-) battery terminal.

  2. When disconnecting connectors, never pull on the wires.

  3. Self-locking connectors click when the connector is fully engaged.

  4. Handle sensors and relays with care. Do not drop these parts or subject them to impact.

RUBBER PARTS AND HOSES

Always avoid getting gasoline or oil on rubber parts or hoses.

BODY DIMENSION MEASUREMENT

  1. In general, all measurements described in this manual are made using a frame gauge.

  2. When using a measuring tape, make sure it is not stretched, twisted or kinked.

  3. This manual uses both nominal and actual dimensions for specifications. Use the dimensions as indicated.

TARGET DIMENSIONS

  1. These dimensions are obtained when the measuring points are on the vehicle body surface as designed; they are reference dimensions for body distortion.

  2. If the frame gauge probes are adjustable in length, perform the measurement by moving one of the two probes around the specified value. Increase the height difference between the two surfaces.

MEASUREMENT WITH ACTUAL DIMENSIONS

  1. These dimensions give the actual linear distance between two measuring points; they serve as reference dimensions when using a frame gauge.

  2. Before measuring, set both probes to the same length (A = A').

MEASURING POINT

Measurement must be taken at the center of the hole.

CABLE AND WIRE HARNESS INSPECTION

  1. Check clamps for tightness.

  2. Check terminals and cables for corrosion caused by battery electrolyte, etc.

  3. Check terminals and wires for open circuits.

  4. Inspect cable insulation and sheathing for damage, cracks and wear.

  5. Check the conductive parts of terminals for contact with other metal parts (body parts or other components).

  6. Check that grounded parts have unrestricted electrical continuity with the vehicle frame, including the mounting screws.

  7. Check wiring routing.

8th.

Make sure wiring is secured so that contact with sharp body edges or similar, or with hot parts (exhaust manifold, pipe, etc.), is eliminated.

  1. Make sure wiring is securely fastened to provide sufficient clearance from the fan pulley, fan belt and other rotating or moving parts.

  2. Check wire slack so that wiring is not stretched between moving parts, such as the vehicle frame and the engine, which can move back and forth.

CHECKING FUSES

Blade fuses are equipped with test tabs so they can be checked without removal from the fuse box. If a test lamp is connected to one test tab and the other is grounded, and the lamp lights, the fuse is good. (Turn the ignition on to energize the fuse circuit.)

ELECTRICAL SERVICE PRECAUTIONS

  1. Before performing electrical service, turn the ignition off and disconnect the battery ground cable.

  2. Secure wire harnesses with cable ties so that they do not sag. However, leave some freedom of movement for all harnesses running to the engine or other vibrating parts, but only enough so that the harness is not damaged by engine vibration or does not contact surrounding parts. Then secure the harness with a clamp.

  3. When a harness section runs along an edge or corner of a part, wrap tape or similar protective material around the harness to prevent damage.

  4. When installing parts, take care not to pinch wire harnesses or damage them.

  5. Never drop relays, sensors or electrical parts, and do not subject them to strong vibration.

  6. Electronic components used in the ECM, relays, etc. can be easily damaged by heat. When repair work is required that may raise the temperature above 80 °C (176 °F), remove the electronic components first.

  7. Loose connectors cause problems. Make sure connectors are properly connected.

8th.

When disconnecting a connector, make sure you pull on the connector body and not on the wires.

  1. To disconnect connectors with locks, pull the connector in the direction of the arrow shown in the illustration.

  2. To connect connectors with locks, insert the connector until you hear a click.

  3. When checking current flow or voltage at connector receptacles with a voltage tester, insert the test probe from the wire harness side. If it is a waterproof connector, insert the test probe through the hole in the rubber cap until it contacts the terminal. Make sure the cable insulation is not damaged.

  4. To avoid overloading wires, consider the current load of optional equipment when determining the appropriate wire size.

    Nominal size
    Size    		 SAE Gauge No. Maximum allowable current
    In engine compartment Other Areas
    0.3 mm² AWG 22 - 5A
    0.5 mm² AWG 20 7 A 13A
    0.85 mm² AWG 18 9 A 17 A
    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 31 A 54 A

CATALYST PRECAUTIONS

  1. Use only unleaded gasoline.

  2. Do not run the engine if the vehicle will not be used for a long period of time. Do not run the engine at idle for more than 10 minutes or idle for 20 minutes.

  3. Do not perform engine compression measurements for a long period of time. Compression pressure measurements must be performed as quickly as possible. Remove the fuel pump relay before checking compression.

  4. Do not mix used catalytic converters with gasoline or parts contaminated with oil.

Test yourself

A quick Kia Stonic quiz: every answer comes with an explanation and a link to the manual page.