General Information

General Information

Vehicle Identification Number Location

Vehicle Protection. Always cover the fenders, seats and floor before starting work.Preparation of Tools and Measuring Equipment Make sure all necessary tools and measuring equipment are available before starting work. Special Service Tools Use special service tools when required.

Parts Removal Always first identify the cause of the problem, then determine whether removal or disassembly is required before starting work.

Disassembly. If the disassembly procedure is complicated and many parts must be removed, all parts must be disassembled so that their function or appearance is not affected.

1. 1
   Inspection of Parts: Every part removed must be carefully inspected for malfunction, 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 those to be reused.

   

3. 3
   Cleaning of Parts for Reuse: All parts to be reused 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 dimensions, measured by projecting the measurement points from the vehicle surface, are reference dimensions used for body modification.
21. 21
    If the length of the oxygen sensor probes is adjustable, measure its extension of one of the two probes until there is no difference in height between the two surfaces.

    

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

    

    

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
    Check that the wiring is clamped so as to prevent contact with sharp edges of the body, etc., or hot parts (exhaust manifold, etc.).
32. 32
    Check that the wiring is securely fastened to provide sufficient clearance from the fan pulley, fan belt, and other rotating or moving parts.
33. 33
    Check that the wiring has slight slack so that it can move between fixed 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.

    

35. 35
    Secure wiring harnesses with clamps so that they do not sag. However, for any harness that passes near the engine or other vibrating parts of the vehicle, allow slight slack within a range that prevents engine vibration from causing the harness to contact any surrounding parts, then secure the harness with a clip.

    

36. 36
    If any section of the wiring harness contacts the edge of a part or a corner, wrap that 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 easily damaged by heat. If service operations that may cause the temperature to exceed 80 °C are necessary, remove the electronic components beforehand.

    

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 indicated by the arrows in the illustration.

    

43. 43
    To connect locking connectors, insert the connectors until they click.

    

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

    

45. 45
    To avoid overloading the wiring, take the current load into account when adding optional equipment and select a wire of the appropriate size.

    Rating 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 parts. Replacement. Standard 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 standard values. Electrical System. Rubber Parts and Hoses. Always avoid exposing rubber parts or hoses to gasoline. Body Dimensions. Dimensions. Actual Dimension Measurement. Measurement Point. Measurements should be taken at the center of the hole. Inspection of Cables and Wires. Fuses. Blade fuse test points are provided for testing the fuse without removing it from the fuse block. The fuse is good if the test lamp lights when one lead is connected to the test points (one at a time) and the other lead is grounded. (Turn the ignition key so that the fuse circuit is energized.) Electrical System Service. Precautions for the Catalytic Converter.

1. 1
   Use only unleaded gasoline.
2. 2
   Do not run the engine when the vehicle has been stationary for a long time. Avoid running the engine at high idle speed for more than 10 minutes or at idle for more than 20 minutes.
3. 3
   Do not perform engine compression measurement for a long time. Engine compression tests must be carried out as quickly as possible. Remove the fuel pump relay before checking compression.
4. 4
   Do not dispose of a used catalytic converter together with parts contaminated with gasoline or oil.