1.
Inspection of parts
Each part, when removed, should be carefulley on spected for malfunction, deformation, damage, and other problems.
1 - 3. World Manufacturer Identification
U5Y : Kia motors slovakia passenger car.
4 - 5. Car line / Series
FF : ED
6 - 7. Body type
23 : 3 Door hatchback
24 : 5 Door hatchback
52 : 5 Door wagon
8. Engine type
1 : γ-1.4
2 : γ-1.6
3 : β-2.0
4 : U-1.6
5 : D-2.0
9. Transmission type
2 : Manual transmission (4x2)
3 : Automatic transmission (4x2)
10. Production year
6 : 2006, 7 : 2007, 8 : 2008
11. Plant of prodeuction
L : Zilinia
12. Vehicle production sequence number
000001 ~ 999999
CODE | COLOR |
WD | CASSA WHITE |
9S | MACHINE SILVER |
5K | PISTON |
1K | BLACK PEARL |
HR | SO RED |
R6 | INFRA RED |
GF | CLYDE |
3A | KOMPASS BLUE |
B6 | OIL BLUE |
A8 | ABYSS BLUE |
3C | CLYDE |
A6 | DAKAR YELLOW |
O4 | MARS RED |
7A | DARK SAND TRACK |
E2 | HIKE GREEN |
E5 | HIKE GREEN 2 |
4E | MACHINE SILVER |
7E | INFRA RED 2 |
9E | MEDIUM SAND TRK |
8Q | PEWTER |
1. Engine fuel
G : Gasoline
D : Diesel
2. Engine range
4 : 4 cycle 4 cylinder
6 : 4 cycle 6 cylinder
3 - 4. Engine development order and capacity
FA : γ engine, 1396cc (Gasoline)
FB : U engine, 1582cc (Diesel)
FC : γ engine, 1592cc (Gasoline)
GC : β engine, 1975cc (Gasoline)
EA : D engine, 1991cc (Diesel)
5. Production year
4 : 2004, 5 : 2005, 6 : 2006
6. Engine production sequence number
000001 ~ 999999
Model
- R : M5CF1
- P : M5CF2
- S : M5CF3, M6GF2
Production year
- 6 : 2006, 7 : 2007, 8 : 2008
Gear ratio
- 1873 = 4.056
- 1767 = 3.941
- C = 4.063
- L = 4.533
Transaxle production sequence number
- 000001 ~ 999999
Model
- A : A4CF1
- B : A4CF2
Production year
- 6 : 2006, 7 : 2007, 8 : 2008
Gear ratio
- A = 4.375
- B = 3.532
Detailed chassification
- AD : γ - 1.6
- CD : β - 2.0
- JD : U - 1.6
Spare
Transaxle production sequence number
- 000001 ~ 999999
A. 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. |
B. 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 |
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 AIR BAG ESPE UNIT Detach connector before unmounting. Assemble strictly according to manual instructions. |
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 (AIR BAG) INFORMATION ● The air bag 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.
● The air bag 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. |
A. Keep lighted cigarettes and all other flames or sparks away from the battery. |
B. 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, excesive pressure on acid to leak resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. ● Never attempt to change the battery when the battery cables are connected. ● The electrical ignition system works with high voltage. Never touch these components with the engine running or the ignition switched on. |
C. Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow battery acid to contact your skin, eyes, clothing or paint finish. |
D. If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate medical attention. If possible, continue to apply water with a sponge or cloth until medical attention is received. If electrolyte gets on your skin, throughly wash the contacted area. If you feel a pain or a burning sensation, get medical attention immediately. |
E. Always read the following instructions carefully when handing a battery. |
F. Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited. |
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. |
After reconnecting or recharging a discharged battery, the ESP OFF indicator may illuminate.
In this case, turn the handle half way to the left and right whilst the ignition switch is in the ON position.
Then, restart the engine after the ignition is OFF.
The ESP OFF indicator may turn OFF.
If the ESP OFF indicator does not turn OFF, have the system checked refering to DTC. (Refer to the BR group.)
When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of the vehicle, the center of gravity may change and can cause the vehicle to tip forward on the hoist.
Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage area can assist with the weight distribution.
Use the same support points to support the vehicle on safety stands.
Place the lift blocks under the support points as shown in the illustration.
Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.
Raise the hoist to full height to inspect the lift points for secure support.
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.
There are three popular methods of towing a vehicle :
- The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.
- 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.
- The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension, and the cables lift that end of 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.
Shift to [D] position, then [N] position.
Turn off the engine.
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.
RECOMMENDED API CLASSIFICATION : SJ OR SL ABOVE - 2.0 (GASOLINE)
For best performance and maximum protection of all types of operation, select only those lubricants which :
Satisfy the requirements of the API classification.
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 container should not be used.
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas before starting work.
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 vehicle.
Be sure that all necessary tools and measuring equipment are available starting work.
Use special tools when they are required.
First find the cause of the problem and then determine whether removal or disassembly before starting the job.
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not aggect their performance or external appearance.
Inspection of parts
Each part, when removed, should be carefulley on spected for malfunction, deformation, damage, and other problems.
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.
Cleaning parts for reuse
All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.
When replacing parts, use KIA genuine parts.
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.
Oil seals
Gaskets
O-rings
Lock washers
Cotter pins (split pins)
Plastic nuts
Depending on their location.
Selalant should be applied to gaskets.
Oil should be applied to the moving components of parts.
Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.
Use gauges and testers to adjust correclty the parts to standard values correctly.
Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
Never pull on the wires when disconnecting connectors.
Locking connectors will click when the connector is secure.
Handle sensors and relays carefully. Be careful not to drop them against other parts.
Always prevent gasoline or from touching rubber parts or tubing.
Basically, all measurements in this manual are taken with a tracking gauge.
When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
For measuring dimensions, both projected dimensioners and actual - measurement dimensions are used in this manual.
These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the reference dimensions used for used for body alterations.
If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the different value in height of the two surface.
These dimensions indicate the actual linear distance between mesaurement points, and are used as the reference dimensions when a tracking gauge is used for measurement.
First adjust both probes to the same length (A=A') before measurement.
Check the probes and gauge itself to make sure there is no free play.
Measurements should be taken at the center fo the hole.
Check the terminal for tightness.
Check terminals and wires for corrosion from battery electrolyte, etc.
Check terminals and wires for open corcuits.
Check wire insulation and coating for damage, cracks and degrading.
Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
Check grounded parts to verify that there is complete continuity between thier attaching bolt(s) and the vehicle's body.
Check for incorrect wiring.
Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot parts (exhaust manifold, etc.)
Check that the wiring is clamped firmy to provide enough clearance from the fan pulley, fan belt and other rotating or moving parts.
Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle body and the engine.
A blade type fuse test taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse is good if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is grounded. (Turn the ignition switch so that the fuse circuit becomes operative)
Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.
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.
Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to come into contact with any of the surronding parts and then secure the harness by using a clamp.
If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or something similar in order to protect if from damage.
When installing any parts, be careful not to pinch or damage any of the wiring harness.
Never throw relays, sensors or electrical parts, or expose them to strong shock.
The electronlic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.
Loose connectors cause problems. Make sure that the connectors are always securely fastened.
When disconnecting a connector, be sure to grip only the connector, not the wires.
Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.
Connect connectors which have catches by inserting the connectors until they make a clicking sound.
When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until contacts the terminal, being careful not to damage the insulation of the wires.
To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the appropartate wire size.
Noeminal size | SAE gauge No. | Permissible current | |
In engine compartment | Other areas | ||
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 |
5.0mm² | AWG 10 | 31A | 54A |
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 precations and explain them to your customer.
Use only unleaded gasoline.
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.
Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as possible. Remove the fuel pump relay before performing a compression test.
Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.
