General Information

General Information

Vehicle Identification Number Location

Vehicle Protection

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

Tool Preparation and Measuring Equipment

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

   Each part must be carefully inspected for malfunction, deformation, damage and other problems when removed.

   

2. 2

   Part Arrangement

   All disassembled parts must be neatly arranged for efficient reassembly.

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

   

3. 3

   Cleaning Parts for Reuse

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

   

Parts

When replacing parts, use genuine KIA 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 after removal.

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 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 battery cable from the negative (-) battery terminal.

2. 2

   Never pull on the wires when disconnecting connectors.

3. 3

   Locking connectors will click when 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

   Basically, all measurements in this manual are made with a tracking measuring tape.

2. 2

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

3. 3

   Both projected and actual dimensions are used in this manual for measuring dimensions.

Projected Dimensions

1. 1

   These are dimensions measured by projecting measuring points from the vehicle surface, and are reference dimensions used for body repair.

2. 2

   If the length of the tracer probes can be adjusted, measure it by extending one of the two probes until there is no difference in height between the two surfaces.

   

Actual Dimension Measurement

1. 1

   These dimensions indicate the actual linear distance between points and are used as reference dimensions when measuring.

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.

Inspection of Cables and Wires

1. 1

   Check the terminal for tightness.

2. 2

   Check terminals and wires for corrosion from battery electrolyte, etc.

3. 3

   Check terminals and wires for open circuits.

4. 4

   Check wire insulation and coating for damage, cracks, and wear.

5. 5

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

6. 6

   Check the grounded parts to make sure there is continuity between their mounting bolt(s) and the vehicle body.

7. 7

   Check for correct connections.

8. 8

   Make sure the wiring is secured so that it does not contact sharp body edges, corners, etc., or hot parts (exhaust manifold, etc.).

9. 9

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

10. 10

    Make sure the wiring has enough slack to vibrate between stationary and moving parts, such as the body and the engine.

    

Check fuses

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

Electrical System Maintenance

1. 1

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

   

2. 2

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

   

3. 3

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

   

4. 4

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

   

5. 5

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

   

6. 6

   Electronic parts used in the computer, relays, etc. are easily damaged by heat. If service operations are required that may cause the temperature to exceed 80 °C, remove the electronic components beforehand.

   

7. 7

   Loose connectors cause problems. Make sure connectors are always securely connected.

   

8. 8

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

   

9. 9

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

   

10. 10

    Connect connectors with locks by inserting them until they click.

    

11. 11

    When using a circuit tester to check continuity or voltage at a connector terminal, insert the test probe from the wire 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.

    

12. 12

    To prevent overloading the wiring, take the current load of additional equipment into account and select the appropriate wire 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

Catalytic Converter Precautions

1. 1

   Use only unleaded gasoline.

2. 2

   Do not run the engine when the vehicle has been at rest 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. Engine compression tests must be performed as quickly as possible. Remove the fuel pump relay before performing the compression test.

4. 4

   Do not dispose of a used catalytic converter together with parts contaminated with gasoline or oil.