CHAPTER 1:

General Information

2004 > 1.6L DOHC >

FUNDAMENTAL PROCEDURES
SYMBOLS Symbol Meaning Type

Apply oil

New engine oil, gear oil, etc. as appropriate

Apply brake fluid

Only brake fluid

Apply automatic transmission fluid (ATF)

Only ATF

Apply grease

Appropriate grease

Apply sealant

Appropriate sealant

Apply petroleum jelly

Appropriate petroleum jelly

Whenever special oil or grease is required, it will be identified in figure.

NOTICE, CAUTIONS AND WARNINGS

The following items contain general procedures you should always follow when working on a vehicle:

PROTECTION OF VEHICLE

A WORD ABOUT SAFETY

1. Block the wheels. 2. Use only the specified jacking positions. 3. Support the vehicle with safety stands.

PREPARATION OF TOOLS AND MEASURING EQUIPMENT

SPECIAL SERVICE TOOLS (SST'S)

REMOVAL OF PARTS

DISASSEMBLY

INSPECTION OF PARTS

ARRANGEMENT OF PARTS

CLEANING PARTS FOR REUSE

REASSEMBLY
a. b. c. d. e. f. Oil seals O-rings Cotter pins Gaskets Lock washers Nylon nuts

DEPENDING ON LOCATION:
1. Sealant should be applied or new gaskets installed. 2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the appropriate locations (such as oil seals) before reassembly.

ADJUSTMENTS

RUBBER PARTS AND TUBING

ELECTRICAL TROUBLESHOOTING TOOLS (TEST LIGHT)

The test light is used for simple voltage checks and in checking for short circuits.

When checking the engine control module (ECM), never use a bulb exceeding 3.4W.

ELECTRICAL TROUBLESHOOTING TOOLS(JUMPER WIRE)

Do not connect a jumper wire from the power source line to a body ground. Such a connection may cause damage to harnesses or electronic components.

VOLTMETER

OHMMETER

Do not attempt to connect the ohmmeter to any circuit in which voltage is applied. Such a connection may damage the ohmmeter.

ELECTRICAL PARTS

<REMOVAL OF CONNECTOR> 1. Never pull on the wiring harness when disconnecting connectors.

2. Connectors can be removed by pressing or pulling lock lever.

Listen for a click when locking connectors. This sound indicates that they are securely locked.

1. When a tester is used to check for continuity or to measure voltage, insert tester probe from wire harness side.

2. Check terminals of waterproof connectors from connector side because they cannot be accessed from harness side.

a. Use a fine wire to prevent damage to the terminal. b. Do not damage the terminal when inserting the tester lead.

Pull lightly on individual wires to ensure that they are secured in the terminal.

REPLACEMENT OF TERMINALS
<FEMALE>

<MALE>

SENSORS, SWITCHES, AND RELAYS

Do not drop them or accidentally strike them against other parts.

WIRING COLOR CODES

Code BLK BRN GRN GRY BLU LT BLU LT GRN

Color Black Brown Green Gray Blue Light blue Light green

Code ORN PNK RED VIO WHT YEL LT GRY

Color Orange Pink Red Violet White Yellow Light gray

VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS <FRONT END>
a. Side sills (both sides)

<REAR END>
a. Side sills (both sides)

JACK AND SAFETY STAND POSITIONS Front end

Jack position: At the front subframe

Safery stand positions: On both sides of the side sills

Rear end
Jack position: At the center fo the rear crossmember

Safery stand positions: On both sides of the side sills

TOWING

VIN LOCATIONS

VIN SYSTEM (GENERAL) Vehicle Gasoline 1.8L MT Gasoline 1.8L AT 1 K K 2 N N 3 A A 4 F F 5 C C 6 5 5 7 2 2 8 3 3 9 1 3 10 2 2 11 5 5 12 X X 13 X X 14 X X 15 X X 16 X X 17 X X

1-3 4-5 6-7 8 9 10 11 12 - 17 VIN SYSTEM (MIDDLE EAST) Vehicle Gasoline 1.8L MT Gasoline 1.8L AT 1 K K 2 N N 3 A A 4 F F 5 C C 6 5 5 7 2 2 8 3 3

World Manufacturer's Identification KNA = Kia Motors corporation Vehicle Type FC = Kia CARENS Body Type 52 = 4 door wagon Engine Type 3 = Gasoline 1.8L Transmission Type 1 = 5 speed manual, 3 = 4 speed automatic Model Year 2 = 2002 Plant Location 5 = Hwasung Plant Sequential Number

10 2 2

11 5 5

12 X X

13 X X

14 X X

15 X X

16 X X

17 X X

1-3 4-5 6-7 8 9

World Manufacturer's Identification KNA = Kia Motors Corporation Vehicle Type FC = Kia CARENS Body Type 52 = 4 door Wagon Engine Type 3 = Gasoline 1.8L Check Digit

10 11 12 - 17 VIN SYSTEM (EUROPE) Vehicle 1.8L DOHC Gasoline MT 2.0L Diesel AT 0 1 2 3 4 5 6 7 8

Model Year 2 = 2002 Plant Location 5 = Hwasung Plant sequential Number

10

11

12

13

14

15

16

17

0 1-3 4-5 6-7

"-" symbol according to No.3.1.2 sentence 4 of 76/114/EEC World Manufacturer's Identification KNE = Kia Motors Corporation Vehicle Type FC = Kia CARENS Body Type 52 = 4 door Wargon Engine Type 3 = 1.8L DOHC Gasoline, 4 = 2.0L Deisel, 5 = 1.6L DOHC Gasoline Transmission type 1 = 5 speed manual, 3 = automatic Model Year or Dummy "0" 2 = 2002 Plant location 5 = Hwasung Plant Sequential Number

9 10 11 12 - 17

* We do not use the letters "I", "O", "Q" in Vehicle Identificatin Number

ENGINE NUMBER LOCATIONS

ENGLISH/METRIC CONVERSION TABLE

UNITS

ABBREVIATIONS

MAINTENANCE SCHEDULE

MAINTENANCE UNDER SEVERE USAGE CONDITIONS