General Information

General Information

General Information
 2009 > G 1.6 DOHC >

Identification Number Locations

Identification Number Description

Vehicle Identification Number
1 - 3. World Manufacturer Identifier
- KNA
4 - 5. Car line / Series
- JG : AM
6 - 7. Body type
- 55 : 4DR, Sports Utility
8. Engine type
- 1 : Gasoline 1.6 (Gamma)
- 2 : Gasoline 2.0 (Beta)
- 3 : Diesel 1.6 (U)
9. Transmission type
- 2 : Manual transmission
- 3 : Automatic transmission
10. Check digit or others
11. Plant of prodeuction
- 5 : Hwasung plant
- 6 : Soha plant
12. Vehicle production sequence number
- 000001 ~ 999999
Paint Code

Code Color
1D Clear White
3D Silver
IM Titanium Silver
H5 Java Brown
9H Cherry Black
A1 Vanilla Shake
1E Tomato Red
I2 Moonlight Blue
Y1 Cocktail Orange
I7 Green tea Latte
1H Blue Stone

Engine Identification Number

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
- FB : U engine, 1582 cc
- FC : Gamma engine, 1592 cc
- GC : Beta-II engine, 1975cc
5. Production year
- 7 : 2007, 8 : 2008, 9 : 2009
6. Engine production sequence number
- 000001 ~ 999999

Transmission Identification Number

Manual

1. Model
A. T : M5CF1-1
B. W : M5CF3-1
2. Production year
A. 7 : 2007, 8 : 2008, 9 : 2009
3. Plant of production
4. Speed (5 or 6)
5. Reserve
6. Gear ratio
A. C : 3.941
B. F : 4.267
7. Transaxle production sequence number
- 000001 ~ 999999

Automatic

1. Model
A. A : A4CF1
B. D : A4CF2
2. Production year
- 7 : 2007, 8 : 2008, 9 : 2009
3. Gear ratio
A. 6 : 4.619
B. 8 : 3.849
4. Detailed classification
 A. AU : !-1.6
B. DW : U-1.6
5. Spare
6. Transaxle production sequence number
- 000001 ~ 999999

Warning / Caution Label Locations

1. Coolant level caution 4. Battery caution

2. Fan caution 5. Air cleaner caution
3. Radiator cap caution

Battery Caution Label Describtion

WARNING / CAUTION LABEL (CONT'D)
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.
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.

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.)

Lift And Support Points

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.

1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.
Towing
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 :
- 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.

Tightening Torque Table Of Standard Parts

Bolt niminal Torque Nm (kg.cm, lb.ft)
Pich (mm)
diameter (mm) Head Mark 4 Head Mark 7

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)
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)
M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85
~ 100)
 M16 1.5 110 ~ 130 (1,100 ~ 1,300, 80 180 ~ 210 (1,800 ~ 2,100, 130
~ 94) ~ 150)
M18 1.5 160 ~ 180 (1,600 ~ 1,800, 116 260 ~ 300 (2,600 ~ 3,000, 190
~ 130) ~ 215)
M20 1.5 220 ~ 250 (2,200 ~ 2,500, 160 360 ~ 420 (3,600 ~ 4,200, 260
~ 180) ~ 300)
M22 1.5 290 ~ 330 (2,900 ~ 3,300, 210 480 ~ 550 (4,800 ~ 5,500, 350
~ 240) ~ 400)
M24 1.5 360 ~ 420 (3,600 ~ 4,200, 260 610 ~ 700 (6,100 ~ 7,000, 440
~ 300) ~ 505)

1. The torques shown in the table are standard values under the following conditions.
• Nuts and bolts are made of galvanized steel bar.
• 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.
3. Reduce the torque values to the indicated percentage of the standard value under the following conditions.
• If spring washers are used : 85%
• If threads and bearing sufaces are stained with oil : 85%

Lubricants
Recommended Lubricants
Parts Oil & Grease Standard
Engine Oil Gasoline 1.6 (G4FC) Above API SJ or SL, Above ILSAC GF3
(For Middle East area :
Above API SL or SM, 5W-40)
Gasoline 2.0 (G4GC) Recommendation (except Middle East) : 5W-20/GF4
Classification : API SL, SM or above , ILSAC GF3, GF4 or above
SAE viscosity grade : Recommended SAE viscosity number
Diesel 1.6 (D4FB) ACEA : without CPF-B4, with CPF-C3
API : Above CH - 4
Transaxle Manual (M5CF1) SAE 75W/85
Manual (M5CF3) API GL-4
TGO-7(MS517-14)
Auto (A4CF1) GENUINE DIAMOND ATF SP-III or SK ATF SP -III
Auto (A4CF2) GENUINE DIAMOND ATF SP-III or SK ATF SP -III

Always use Genuine Kia parts and recommedended fluid.

Using any other type of parts and fluid can cause serious damaged if the vehicle.

Lubricants Capacities
 Description Gasoline 1.6 (G4FC) Gasoline 2.0 (G4GC) Diesel 1.6 (D4FB)
3.7 L (3.91 US qt, 4.1L (4.33US qts, 5.7 L (6.02 US qt,
Oil quantity (Total)
3.26 lmp qt) 3.60lmp qts) 5.02 lmp qt)
3.0 L (3.17 US qt, 3.7L (3.91US qts, 4.8 L (5.07 US qt,
Engine oil Oil quantity (Oil pan)
2.64 lmp qt) 3.26lmp qts) 4.22 lmp qt)
Oil quantity (Drain and 3.3 L (3.49 US qt, 4.0L (4.23US qts, 5.3 L (5.60 US qt,
refill including oil filter) 2.90 lmp qt) 3.25lmp qts) 4.66 lmp qt)
6.5L (6.86US qt., 7.2 L (7.6 US qt, 6.3 7.2 L (7.60 US qt,
Cooling system
5.71lmp qt.) lmp qt) 6.33 lmp qt)
Manual (M5CF1)
2.0"(2.1US qt, 1.76lmp qt)
Manual (M5CF3)
Automatic transaxle(A4CF1) 6.8 (7.2, 5.98)
Automatic transaxle(A4CF2) 6.6 (6.9, 5.81)

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

Selection Of Engine Oil

Gasoline (G4FC)
Recommended ILSAC classification : Above GF3
Recommended API classification : Above SJ or SL

Recommended Sae Viscosity Grades :

 For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirement of the API classification.
2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.

Selection Of Engine Oil

Gasoline (G4GC)
Recommendation (except Middle East) : 5W-20/GF4 (If not available, refer to the recommended API or ILSAC
classification and SAE viscosity number.)
API classification : SL, SM or above
ILSAC classification : GF3, GF4 or above

SAE viscosity grade : Refer to the recommended SAE viscosity number.

 For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirement of the API classification.
2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.

Selection Of Engine Oil

Diesel (D4FB)
Recommended API classification : CH-4 OR ABOVE
Recommended ACEA classification : B4 (without CPF) or C3 (with CPF)

Recommended Sae Viscosity Grades :

 For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirement of the API classification.
2. Have proper SAE grade number for expected ambient temperature range.
3. Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.

General Service Information

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.

Preparation Of Tools And Mesuring Equipment

Be sure that all necessary tools and measuring equipment are available starting work.

Special Tools
Use special tools when they are required.
Removal Of Parts
First find the cause of the problem and then determine whether removal or disassembly before starting the job.

Disassembly
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.
1. Inspection of parts
Each part, when removed, should be carefulley on spected for malfunction, deformation, damage, and other
problems.

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.
3. Cleaning parts for reuse
All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.

Parts
When replacing parts, use KIA genuine parts.

Replacement
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.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts

Depending on their location.

7. Selalant should be applied to gaskets.
8. Oil should be applied to the moving components of parts.
9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.

Adjustment
Use gauges and testers to adjust correclty the parts to standard values correctly.

Electrical System
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wires when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully. Be careful not to drop them against other parts.

Ruber Parts And Tubes

Always prevent gasoline or from touching rubber parts or tubing.

Measuring Body Dimensiongs

1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensioners and actual - measurement dimensions are used in this
manual.

Dimensions Projected
1. 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.
2. 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.

Measuring Actual Dimensions

1. 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.
2. 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.
Measurement Point
Measurements should be taken at the center fo the hole.

Checking Cables And Wires

1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open corcuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact 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 vehicle's
body.
7. Check for incorrect wiring.
8. 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.)
9. Check that the wiring is clamped firmy to provide enough clearance from the fan pulley, fan belt and other rotating
or moving parts.
10. 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.
Check Fuses
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)

Serivicing The Electrical System

1. 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.

2. 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
 vibrations to cause the harness to come into contact with any of the surronding parts and then secure the harness
by using a clamp.

3. 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.

4. When installing any parts, be careful not to pinch or damage any of the wiring harness.

5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
6. 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.

7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.

8. When disconnecting a connector, be sure to grip only the connector, not the wires.
9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.

10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.

11. 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.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and
determine the appropartate wire size.

Noeminal Permissible current

SAE gauge No.
size In engine compartment Other areas
0.3mm# AWG 22 - 5A
0.5mm# AWG 20 7A 13A
0.85mm# AWG 18 9A 17A
1.25mm# AWG 16 12A 22A
2.0mm# AWG 14 16A 30A
3.0mm# AWG 12 21A 40A
5.0mm# AWG 10 31A 54A

Precautions For Catalytic Converter

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.

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.
3. 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.
4. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.