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General

Information
GENERAL

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GI -2 GENERAL INFORMATION

GENERAL
IDENTIFICATION NUMBER
LOCATIONS E8ABBD32

Engine number (Diesel)

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Engine number (Gasoline)

Vehicle Identification number

Automatic Transmission number

Manual Transmission number

SUNGI7001L
GENERAL GI -3

IDENTIFICATION NUMBER DESCRIPTION PAINT CODE

VEHICLE IDENTIFICATION NUMBER CODE COLOR


J6 LIGHT AIMOND BEIGE
K5 VELVET INDIGO BLUE
K N A F G 5 2 1 2 6 7 000001
7S FINE SILVER
1 2 3 4 5 6 7 8 9 10 11 12 A5 AQUA BLUE
9V VIOLET IRIS
SUNGI7002L 1U URBAN GRAY

1. Geographic zone 1D CLEAR WHITE


- K : Korea 9H BLACK CHERRY

2. Manufacturer 3H VOLCANIC RED


- N : Kia motor company
ENGINE IDENTIFICATION NUMBER
3. Vehicle type

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- A : Passenger

4-5. Vehicle line D 4 E A 5 000001


- FG : UN
1 2 3 4 5 6
6-7. Body type
- 52 : 5 Door Station Wagon
KARG102A
8. Engine type
- 1 : Gosoline 2.0 1. Engine fuel
- 2 : Diesel 2.0 - G : Gasoline
- D : Diesel
9. Check digit
- 2 : Manual transmission 2. Engine range
- 3 : Automatic transmission - 4 : 4 cycle 4 cylinder
- 6 : 4 cycle 6 cylinder
10. Production year
- 6 : 2006, 7 : 2007, 8 : 2008 3~4 : Engine development order and capacity
- KA : Θ -engine, 1998cc (Gasoline)
11. Plant of production - EA : D-engine, 1991cc (Diesel)
- 7 : Hwasung Plant
5. Production year
12. Vehicle production sequence number - 6 : 2006, 7 : 2007, 8 : 2008
- 000001 ~ 999999
6. Engine production sequence number
- 000001 ~ 999999
GI -4 GENERAL INFORMATION

TRANSMISSION IDENTIFICATION NUMBER

MANUAL

S 4 A 000001

1 2 3 4

KARF103A

1. Model
- S : M6GF2
- L : M5GF1
2. Production year
- 6 : 2006, 7 : 2007, 8 : 2008
3. Gear ratio
- C : 4.063 (M6GF2)

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- L : 4.533 (M5GF1)
4. Transaxle production sequence number
- 000001 ~ 999999

AUTOMATIC

T 5 N MD 000001

1 2 3 4 5 6

SUNGI6009D

1. Model
- T : F4A51

2. Production year
- 6 : 2006, 7 : 2007, 8 : 2008

3. Gear ratio
- I : 3.274

4. Detailed chassification
- BD : Diesel - 2.0

5. Spare

6. Transaxle production sequence number


- 000001 ~ 999999
GENERAL GI -5

WARNING / CAUTION LABEL LOCATIONS

COOLANT CAUTION

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RADIATOR CAP CAUTION

FAN CAUTION AIRDUCT WARNING

BATTERY CAUTION

ATTENTION

SRS VEHICLE
THIS CAR IS EQUIPPED WITH A SUPPLEMENTAL
RESTRAINT SYSTEM. TO PROVIDE CONTINED RELIABLITY,
CERTAIN ELEMENTS OF THE SUPPLEMENTAL RESTRAINT
SYSTEM SHALL BE SERVICED OR REPLACED BY AUTHORIZED
DEALER TEN YEARS AFTER VEHICLE LABEL. FOR FURTHER INFORMATION.
SEE OWNER'S MANUAL.

SIDE AIR BAG


THIS CAR IS EQUIPPED WITH A SIDE AIRBAG SYSTEM.
TO PROVIDE CONTINUED RELIABILITY, CERTAIN ELEMENTS
OF THE SIDE AIRBAG SYSTEM SHALL BE SERVICED OR
VEHICLE MANUFACTURE DATE SHOWN ON CERTIFICATION LABEL.
FOR FURTHER INFORMATION
SEE OWNER'S MANUAL.

SUNGI7004L
GI -6 GENERAL INFORMATION

AIR BAG WARNING / CAUTION LABEL

CAUTION
AIR BAG : Handing is limited to trained personnel.
To be used only in prescribed vehicles. If not propely
installed, device may become a dangerous projectile.
See serivce manual instruction

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DRIVE AIR BAG (DAB) CAUTION

Caution
Don't open, remove or transfer to another
vehicle. Risk of malfunction and bodily
injury!
This unit is to be installed and/or dismantled
by trained personnel only. This item contains
an explosive device.

EAKE002A
GENERAL GI -7

AIR BAG WARING / CAUTION LABEL (CONT’D)

C
D

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P

R
N
D

SUNGI6005D
GI -8 GENERAL INFORMATION

WARNING / CAUTION LABEL (CONT’D)

A : WARNING
SEE OWNER’S MANUAL.
This car is equipped a side airbag for each front seat.
• Do not use any accessory seat covers.
• Use of other seat covers could reduce the
effect of the system.
• Do not install any accessories on the side
or near the side airbag.
• Do not use excessive force on the side of the seat.
• For further information, see the owner’s manual.

B : CAUTION
AIRBAG ESPE UNIT

Detach connector before unmounting. Assemble


strictly according to manual instructions.

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C : PASSENGER MODULE CAUTION

CAUTION
Don’t open, remove or transfer to another vehicle.
Risk of malfunction and bodily injury!
This unit is to be installed and/or dismantled by trained
personnel only. This item contains an explosive device.

D : SUPPLEMENTAL RESTRAINT SYSTEM


(AIRBAG) INFORMATION
• The airbag is a Supplement Restraint
System (SRS).
You must always wear the seat belts.
• The airbag system condition is normal when
the "SRS" lamp in the cluster illuminates for
approximately 6 seconds after the ignition key
is turned on and then goes off.
• If any of the following condition occur, the
system must be serviced.
• "SRS" lamp does not light up when
the key is turned on.
• "SRS" lamp stays lit or flashes continuously.
• The airbag has inflated.

• The airbag system must be inspected by an


authorized dealer ten years after the vehicle
manufacture date shown on the certification label,
located on left front door opening area.

WARNING
Failure to the above instructions may result in injury
to you or other occupants in the vehicle
• See the "SRS" section in Owner’s Manual for
more information about airbags.
GENERAL GI -9

BATTERY CAUTION LABEL DESCRIBTION

Wear eye protection


when charging or working
near a battery.
Always provide ventilation
when working in an
enclosed space.
When lifting a plastic-cased
battery, exce sive pressure may
cause acid to leak resulting in
personal injury. Lift with a battery
carrier or with your hands on
opposite corners.
Keep batteries out of the
Never attempt to change the
reach of children
battery when the battery
because batteries
cables are connected.
Keep lighted cigarettes contain highly corrosive
The electrical ignition system
and all other flames or SULFURIC ACID. Do not
works with high voltage.
sparks away from the allow battery acid to
Never touch these components
battery. contact your skin, eyes,
with the engine running

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clothing or paint finish.
or the ignition switched on.

If any electrolyte gets into your eyes,


flush your eyes with clean water for Always read the following Hydrogen, which is a
at least 15 minutes and get immediate instructions carefully highly combustible gas,
medical attention. If possible, continue when handing a battery. is always present in battery
to apply water with a sponge or cloth cells and may explode if
until medical attention is received. ignited.
If electrolyte gets on your skin, throughly
wash the contacted area.
If you feel a pain or a burning sensation,
get medical attention immediately.

EAKE007E
GI -10 GENERAL INFORMATION

HANDLING AND STORAGE THE BATTERY

Battery Itself • Batteries should be stored in cool, dry (27 degrees Celsius) places
and out of direct sunlight.
• MF batteries are tightly sealed to prevent acid leakage.
However, tilting the battery to an angle of 45 degrees can cause acid to
leak through the vents on the sides. Therefore, batteries should always
be stored in their upright positions. Prevent placing any aqueous or solid
(i.e. conductors) bodies on top of the battery.
• It is extremely dangerous to use tools, such as hammers, on the battery
terminals when connecting cables to the mounted battery.
Battery on Vehicle • When storing the vehicle for long periods of time, make sure to remove the
memory fuse at junction box to prevent natural discharging.
• Also, run the engine for battery charging within 1 month if the memory fuse
wasn’t removed from the start of vehicle storing.
If the memory fuse was removed, run the engine for battery charging
within 3 months from the start of vehicle storing.

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GENERAL GI -11

LIFT AND SUPPORT POINTS the luggage area can assist with the weight dis-
tribution.
WARNING • Use the same support points to support the vehi-
cle on safety stands.
When heavy rear components such as suspen-
sion, fuel tank, spare tire, tailgate and trunk lid
1. Place the lift blocks under the support points as shown
are to be removed, place additional weight in the
in the illustration.
luggage area before hoisting. When substatial
weight is removed from the rear of the vehicle, the 2. Raise the hoist a few inches (centimeters) and rock
center of gravity may change and can cause the the vehicle to be sure it is firmly supported.
vehicle to tip forward on the hoist.
3. Raise the hoist to full height to inspect the lift points
NOTE for secure support.
• Since each tire/wheel assembly weights approx-
imately 30lbs (14kg), placing the front wheels in

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LIFT BLOCK LIFT BLOCK

[FRONT] [REAR]

SUNGI7006L
GI -12 GENERAL INFORMATION

TOWING FRONT :

If the vehicle needs to be towed, call a professional towing


service. Never tow vehicle with just a rope or chain. It is
very dangerous.

EMERGENCY TOWING

There are three popular methods of towing a vehicle :

Flat - bed Equipment- The operator loads the vehicle on


the back of truck. This is best way of transporting the ve-
hicle.

Wheel Lift Equipment- The tow truck uses two pivoting


arms that go under the tires (front or rear) and lift them off
the ground. The other two wheels remain on the ground.
SUNGI6007D
Sling type Equipment- The tow truck uses metal cables
with hooks on the ends. These hooks go around parts of REAR :
the frame or suspension, and the cables lift that end of

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the vehicle off the ground. The vehicle’s suspension and
body can be seriously damaged if this method of towing is
attempted.

If the vehicle cannot be transported by flat-bed, if should


be towed with the front wheels off the ground. If due to
damage, the vehicle must be toward with the front wheels
on the ground, do the following :
Manual Transmission
• Release the parking brake.
• Shift the transmission to neutral

Automatic Transmission
• Release the parking brake.
• Start the engine. SUNGI6008D

• Shift to [D] position, then [N] position.


• Turn off the engine.

CAUTION
• Improper towing preparation will damage the
transmission. Follow the above procedure
exactly. If you cannot shift the transmission
or start the engine(automatic transmission),
your vehicle must be transported on a flatbed.
• It is the best to tow vehicle no farther than
19miles (30km), and keep the speed below
30mph (50km/h).
• Trying to lift or tow your vehicle by the
bumpers will cause serious damage. The
bumpers are not designed to support the
vehicle’s weight.
GENERAL GI -13

TIGHTENING TORQUE TABLE OF STANDARD


PARTS

Bolt niminal diameter Torque Nm (kg.cm, lb.ft)


Pich (mm)
(mm) Head Mark 4 Head Mark 7

EAKE004E KASD100Y EAKE004F EAKE004G

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)


M6 1.0 5 ~ 6 (50 ~ 50, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)

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M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~ 18.0 )
M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)
M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)
120 ~ 140 (1,200 ~ 1,400,
M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61)
85 ~ 100)
110 ~ 130 (1,100 ~ 1,300, 180 ~ 210 (1,800 ~ 2,100,
M16 1.5
80 ~ 94) 130 ~ 150)
160 ~ 180 (1,600 ~ 1,800, 260 ~ 300 (2,600 ~ 3,000,
M18 1.5
116 ~ 130) 190 ~ 215)
220 ~ 250 (2,200 ~ 2,500, 360 ~ 420 (3,600 ~ 4,200,
M20 1.5
160 ~ 180) 260 ~ 300)
290 ~ 330 (2,900 ~ 3,300, 480 ~ 550 (4,800 ~ 5,500,
M22 1.5
210 ~ 240) 350 ~ 400)
360 ~ 420 (3,600 ~ 4,200, 610 ~ 700 (6,100 ~ 7,000,
M24 1.5
260 ~ 300) 440 ~ 505)

3. Reduce the torque values to the indicated per-


NOTE
centage of the standard value under the following
1. The torques shown in the table are standard val- conditions.
ues under the following conditions : • If spring washers are used : 85%
• Nuts and bolts are made of galvanized steel • If threads and bearing sufaces are stained
bar. with oil : 85%
• Galvanized plain steel washers are inserted.
• All nuts, bolts and plain washers are dry.

2. The torques shown in the table are not applicable


:
• When spring washers, toothed washers and
the like are inserted.
• If plastic parts are fastened.
• If self-tapping screws or self-locking nuts are
used.
• If threads and surfaces are coated with oil.
GI -14 GENERAL INFORMATION

LUBRICANTS

RECOMMENDED LUBRICANTS

Parts OIL & GREASE STANDARD


Gasoline 2.0 (G4KA) API SJ or ABOVE
Engine Oil
Diesel 2.0 (D4EA) API CF-4 or ABOVE
Manual (M5GF1/M6GF2) SAE 75W/85 (API GL - 4)
Transaxle
Auto (F4A51) DIAMOND ATF SP-III, SK ATF SP-III
Power Steering PSF - 3
Breake Steering DOT 3 or equivalent
Coolant Ethlyene glycol base for aluminium radiator
Transaxle linkage, parking breake cable mechanism,
hood, door latch, seat adjuster, tailgate latch, Multipurpose grease NIGL grade #2
door hinges, tailgate hinge

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WARNING Using any other type of parts and fluid can cause
serious damaged if the vehicle.RECOMMENDED
Always use Genuine Kia parts and recomme- LUBRICANTS
dended fluid.

LUBRICANTS CAPACITIES

Description 2.0 (G4KA) 2.0 (D4EA)


Oil pan 3.7 (3.9, 3.26) 5.4 (5.6, 4.7)
Engine oil Oil filter 0.3 (0.32, 0.26) 0.5 (0.58, 0.47)
Total 4.0 (4.23, 3.52) 5.9 (6.23, 5.19)
Cooling system 6.6 (7.18, 5.98) 5.0 (5.7, 4.9)
M5GF1 1.9 (2.0, 1.67) 1.9 (2.0, 1.67)
Manual transaxle
M6GF2 1.9 (2.0, 1.67) 1.9 (2.0, 1.67)
Automatic transaxle F4A51 7.8 (8.89, 7.64) 7.8 (8.89, 7.64)
Power steering 0.8 (0.92, 0.78) 0.8 (0.92, 0.78)

Capacities : [liter (U.S.qts, lmp.qts)]


GENERAL GI -15

SELECTION OF ENGINE OIL

RECOMMENDED API CLASSIFICATION : SJ OR SL


ABOVE - 2.0 (GASOLINE)

RECOMMENDED SAE VISCOSITY GRADES :

Temperature range
anticipated before Recommended SAE viscosity number
next oil change

5W 10W

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-20 -30
-30
-30

-18 0

EARF012A
GI -16 GENERAL INFORMATION

RECOMMENDED API CLASSIFICATION : CH-4 ABOVE - 2.0 (DIESEL)

Temperature range
anticipated before
Recommended SAE viscosity number
next oil change

˚C ˚F
40 104 15W
10W

-30
20 68 -40

10 50

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0 32

-10 14
5W 0W
-15 5 -30
-30
-20 -4
-25 -13
*1

*2

*1 Restricted by driving condition and environment.


*2 Not recommended for sustained high speed vehicle operation

SNFEM6100D

NOTE
For best performance and maximum protection of all
types of operation, select only those lubricants which
:
1. Satisfy the requirements of the API classification.
2. Have the proper SAE grade number for expected
ambient temperature range.

Lubricants which do not have both an SAE grade


number and an API service classification on the con-
tainer should not be used.
GENERAL GI -17

GENERAL SERVICE INFORMATION REMOVAL OF PARTS

PROTECTION OF THE VEHICLE First find the cause of the problem and then determine
Always be sure to cover fenders, seats, and floor areas whether removal or disassembly before starting the job.
before starting work.

CAUTION
The support rod must be inserted 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 that the support rod has been released
prior to closing the hood. Always check to be sure
the hood is firmly latched before driving the vehi-
cle.

PREPARATION OF TOOLS AND MESURING


EQUIPMENT

Be sure that all necessary tools and measuring equipment

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EAKE005B

are available starting work.


DISASSEMBLY
SPECIAL TOOLS
If the disassembly procedure is complex, requiring many
Use special tools when they are required. parts to be disassembled, all parts should be disassem-
bled in a way that will not aggect their performance or ex-
ternal appearance.
1. Inspection of parts
Each part, when removed, should be carefulley on
spected for malfunction, deformation, damage, and
other problems.

EAKE005A

EAKE005C
GI -18 GENERAL INFORMATION

2. Arrangement of parts
All disassembled parts should be carefully arranged
for effective reassembly.
Be sure to separate and correctly identify the parts to
be repllaced from those that will be used again.

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EAKE005D

3. Cleaning parts for reuse LAIF006A


All parts to be used again should be carefully and
thoroughly cleaned by an appropriate method. REPLACEMENT

Standard values, such as torques and certain adjust-


ments, must be strictly observed in the reassembly of all
parts.
If removed, the following parts should always be replaced
with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts

EAKE005E

PARTS

When replacing parts, use KIA genuine parts.

EAKE005G

Depending on their location.


7. Selalant should be applied to gaskets.
8. Oil should be applied to the moving components of
parts.
GENERAL GI -19

9. Specified oil or grease should be applied to the pre- RUBER PARTS AND TUBES
scribed locations (oil seals, etc) before assembly.
Always prevent gasoline or from touching rubber parts or
tubing.

EAKE005H

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ADJUSTMENT EAKE005J

Use gauges and testers to adjust correclty the parts to MEASURING BODY DIMENSIONGS
standard values correctly.
1. Basically, all measurements in this manual are taken
ELECTRICAL SYSTEM with a tracking gauge.
1. Be sure to disconnect the battery cable from the neg- 2. When a measuring tape is used, check to be sure
ative (-) terminal of the battery. there is no elongation, twisting or bending.
2. Never pull on the wires when disconnecting connec- 3. For measuring dimensions, both projected dimen-
tors. sioners and actual - measurement dimensions are
used in this manual.
3. Locking connectors will click when the connector is
secure. DIMENSIONS PROJECTED
4. Handle sensors and relays carefully. Be careful not to 1. These are the dimensions measured when the mea-
drop them against other parts. surement points are projected from the vehicle’s sur-
face, and are the reference dimensions used for used
for body alterations.

2. If the length of the tracking gauge probes is ad-


justable, measure it by lengthening one of two probes
as long as the different value in height of the two
surface.

Height
EAKE005I

Projected dimension

EAKE005K
GI -20 GENERAL INFORMATION

MEASURING ACTUAL DIMENSIONS CHECKING CABLES AND WIRES

1. These dimensions indicate the actual linear distance 1. Check the terminal for tightness.
between mesaurement points, and are used as the
reference dimensions when a tracking gauge is used 2. Check terminals and wires for corrosion from battery
for measurement. electrolyte, etc.

2. First adjust both probes to the same length (A=A’) 3. Check terminals and wires for open corcuits.
before measurement.
4. Check wire insulation and coating for damage, cracks
NOTE and degrading.
Check the probes and gauge itself to make sure there
5. Check the conductive parts of terminals for contact
is no free play.
with other metallic parts (vehicle body and other
parts).

6. Check grounded parts to verify that there is complete


continuity between thier attaching bolt(s) and the ve-
hicle’s body.

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Ac
tu
al
7. Check for incorrect wiring.
ly
-m
ea
su 8. Check that the wiring is so clamped to the prevent
re
d contact with sharp corners of the vehicle body, etc.
di
m
en or hot parts (exhaust manifold, etc.)
si
on
9. Check that the wiring is clamped firmy to provide
enough clearance from the fan pulley, fan belt and
other rotating or moving parts.
EAKE005L

10. Check that the wiring has a little space so that it can
MEASUREMENT POINT
vibrate between fixed and moving parts such as the
Measurements should be taken at the center fo the hole. vehicle body and the engine.

Hole center

EAKE005M EAKE005R
GENERAL GI -21

CHECK FUSES 2. Attach the wiring harnesses with clamps so that there
is no slack. However, for any harness which passes
A blade type fuse test taps provided to allow checking the the engine or other vibrating parts of the vehicle, al-
fuse itself without removing if from the fuse box. The fuse low some slack within a range that does not allow the
is good if the test lamp lights up when one lead is con- engine vibrations to cause the harness to come into
nected to the test taps (one at a time) and the other lead is contact with any of the surronding parts and then se-
grounded. (Turn the ignition switch so that the fuse circuit cure the harness by using a clamp.
becomes operative)

Fuse box

Test leads

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EAKE005R
EAKE005O

3. If any section of a wiring harness interferes with the


SERIVICING THE ELECTRICAL SYSTEM edge of a parts, or a corner, wrap the section of the
harness with tape or something similar in order to pro-
1. Prior to servicing the electrical system, be sure to
tect if from damage.
turn off the ignition switch and disconnect the battery
ground cable.

NOTE
In the course of MFI or ELC system diagnosis, when
the battery cable is removed, any diagnostic trouble
code retained by the computer will be cleared. There
fore, if necessary, record the diagnostic data before
removing the battery cable.

EAKE005S

EAKE005P
GI -22 GENERAL INFORMATION

4. When installing any parts, be careful not to pinch or 7. Loose connectors cause problems. Make sure that
damage any of the wiring harness. the connectors are always securely fastened.

EAKE005T EAKE006B

5. Never throw relays, sensors or electrical parts, or ex- 8. When disconnecting a connector, be sure to grip only

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pose them to strong shock. the connector, not the wires.

EAKE005U EAKE006C

6. The electronlic parts used in the computer, relays, etc. 9. Disconnect connector which have catches by press-
are readily damaged by heat. If there is a need for ing in the direction of the arrows shown the illustration.
service operations that may cause the temperature
to exceed 80 C (176 F), remove the electronic parts
before hand.

80˚C
(176˚F)

EAKE006D

EAKE006A
GENERAL GI -23

10. Connect connectors which have catches by inserting 12. To avoid overloading the wiring, take the electrical cur-
the connectors until they make a clicking sound. rent load of the optional equipment into consideration,
and determine the appropartate wire size.

Permissible current
Noeminal SAE gauge In engine
size No. Other
compart-
areas
ment
0.3mm² AWG 22 - 5A
0.5mm² AWG 20 7A 13A
0.85mm² AWG 18 9A 17A
1.25mm² AWG 16 12A 22A
2.0mm² AWG 14 16A 30A
3.0mm² AWG 12 21A 40A
EAKE006E
5.0mm² AWG 10 31A 54A
11. When using a circuit tester to check continuity or volt-

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age on connector terminals, insert the test probe into PRECAUTIONS FOR CATALYTIC CONVERTER
the harness side. If the connector is a sealed con-
nector, insert the test probe through the hole in the CAUTION
rubber cap until contacts the terminal, being careful
not to damage the insulation of the wires. If a large amount of unburned gasoline flows into
the converter, it may overheat and create a fire
hazard. To prevent this observe the following pre-
cations and explain them to your customer.

1. Use only unleaded gasoline.

2. Do not run the engine while the car is at rest for a


long time. Avoid running the engine at fast idle for
more than 10minutes and idle speed for more than
20 minutes.
Test probe
3. Do not measure engine compression for an extended
Connector time. Engine compression tests must be made as
rapidly as possible. Remove the fuel pump relay be-
Test probe fore performing a compression test.

EAKE006G 4. Do not dispose of used catalytic converter together


with parts contaminated with gasoline or oil.

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