Kia Rio 2002 Workshop Service Manual

RIO(BC) > 2002 > G 1.5 DOHC > General Information General Information > General Information > General Information Fundamental procedures Symbols There are six primary symbols used to complement illustrations. These symbols indicate the areas to apply such materials during service. 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 NOTICES, CAUTIONS, AND WARNINGS As you read through the various procedures, you will encounter Notice, Cautions and Warnings. Each one is there for a specific purpose. Notice give you added information that will assist you in completing a particular procedure. Cautions prevent you from making an error that could damage the vehicle. Warnings remind you to be especially careful in specific areaswhere carelessness can cause personal injury The following items contain general procedures you should always follow when working on a vehicle: PROTECTION OF THE VEHICLE • Always cover fenders, seats, and floor areas before starting work. Operate the engine only in a well-ventilated area to avoid carbon monoxide poisoning. A WORD ABOUT SAFETY The following precautions must be followed when jacking up the vehicle: 1. Block the wheels. Page 1 of 15

2. Use only the specified jacking positions. 3. Support the vehicle with safety stands. The engine compartment must be clear of tools and people before starting the engine. PREPARATION OF TOOLS AND MEASURING EQUIPMENT • All necessary tools and measuring equipment should be available before starting any work. SPECLAL SERVICE TOOLS (SST'S) • Use special service tools when they are required. SST's can be found under "preparation" prior to any procedure requiring them. REMOVAL OF PARTS • Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement for repair. DISASSEMBLY • If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance. Additionally, these parts should be identified so that reassembly can be done easily and efficiently. Page 2 of 15 tomsn048@gmail.com

INSPECTION OF PARTS • When removed, each part should be carefully inspected for malfunction, deformation, damage, or other problems. ARRANGEMENT OF PARTS • All disassembled parts should be carefully arranged for assembly. Separate or identify the parts to be replaced form those that will be reused. CLEANING PARTS FOR REUSE • All parts to be reused should be carefully and thoroughly cleaned according to the appropriate method. REASSEMBLY Standard values, such as torques and certain adjustments, must be strictly observed in the assembly of all parts. When removed, the following parts should be replaced with new ones: 1. Oil seals 2. O-rings 3. Cotter pins 4. Gaskets 5. Lock washers 6. Nylon nuts DEPENDING ON LOCATION : 1. Sealant should be applied or new gaskets used. 2. Oil should be applied to the moving components of parts. Page 3 of 15

3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before assembly. ADJUSTMENT • Use appropriate gauges and/or testers when making adjustments. RUBBER PARTS AND TUBING • Prevent gasoline or oil from getting on rubber parts or tubing. ELECTRICAL TROUBLESHOOTING TOOLS 1. Test Light The test light, as shown in the figure, uses a 12V bulb. The two lead wires should be connected to probes. 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. Page 4 of 15 tomsn048@gmail.com

2. Jumper Wire The jumper wire is used for testing by shorting across switch terminals and ground connections. 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. 3. Voltmeter The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15V or more is used by connecting the positive (+) probe to the point where voltage is to be measured and the negative (-) probe to a body ground. 4. Ohmmeter The ohmmeter is used to measure the resistance between two points in a circuit to check for continuity, and in diagnosis of short circuits. Do not attempt to connect the ohmmeter to any circuit to which voltage is applied ; this may bum or otherwise damage the ohmmeter. ELECTRICAL PARTS • Battery Cable Before disconnecting connectors or replacing electrical parts, disconnect the negative battery terminal. CONNECTORS (Removal of connector) Page 5 of 15

1. Never pull on the wiring harness when disconnecting connectors. 2. Connectors can be removed by pressing or pulling the lock lever. CONNECTORS (Locking a connector) • Listen for a click when locking connectors. This sound indicates that they are securely locked. CONNECTORS (Inspection) 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wire harness side. 2. Check the terminals of waterproof connectors from the connector side because they cannot be accessed from the wire harness side. • Use a fine wire to prevent damage to the terminal. • Do not damage the terminal when inserting the tester lead. Terminals Page 6 of 15 tomsn048@gmail.com

1. Inspection Pull lightly on individual wires to ensure that they are secured in the terminal. 2. Replacement or terminals Use the appropriate tools to remove the terminal as shown. When installing the terminal, be sure to insert it until it locks securely. (1) Female Insert a thin piece of metal from the terminal side of the connector, and with the terminal locking tab pressed down, pull the terminal out from the connector. (2) Male Follow the same procedure as female-type terminal. 3. Sensors, switches, and relays Always handle sensors, switches, and relays carefully. Do not drop them or accidentally strike them against other parts. Page 7 of 15

4. Wiring color codes. Two-color wires are indicated by two color code symbols. The first code symbol indicates the base color of the wire, and the second the color of the stripe on the base color. Code Color Code Color BLK Blakc O Orange BR Brown P Pink G Green R Red GR Gray V Violet L Blue W White LB Light Blue Y Yellow LG Light Green JACK AND SAFETY STAND POSITIONS 1. Front end jack position : At the front subframe 2. Safety stand positions : On both sides of the side sills JACK AND SAFETY STAND POSITIONS 1. Jack position : At the center of the rear crossmember Page 8 of 15 tomsn048@gmail.com

2. Safety stand positions : On both sides of the body frame VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS 1. Front end (1) Side sills (both sides) 2. Rear end (1) Side sills (both sides) TOWING • Proper towing equipment is necessary to prevent damage to the vehicle. Always observe laws and regulations applicable to vehicles in tow. As a general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies. With either automatic or manual transmission : 1. Set the ignition switch in the ACC position. 2. Place the selector lever or shift lever in N (Neutral). Page 9 of 15

3. Release the parking brake. • Do not tow the vehicle backward with driving wheels on the ground. This may cause internal damage to the transmission. • Do not use the hook loops under the front and rear of the vehicle for towing purposes. These hook loops are designed ONLY for transport tie-down. If tie-down hook loops are used for towing, the front/rear bumper will be damaged. VIN LOCATIONS • Vehicle identification number arrangement ENGLISH/METRIC CONVERSION TABLE MULTIPLY BY TO GET inch (") foot (ft.) yard (yd.) mile LENGTH 25.4 0.3048 0.9144 1.609 millimeters (mm) meters (m) meters kilometers (km) inch² (in²) Foot² (ft²) yard² (yd³) AREA 645.2 6.45 0.0929 0.8361 millimeters² (mm²) centimeters² (cm²) meters² (m²) meters² (m²) inch³(in³) quart (qt.) gallon (gal.) yard³ (yd³) VOLUME 16387 16.387 0.0164 0.9464 3.7854 0.7646 mm³ cm³ liters (l) liters liters meters³(m³) Page 10 of 15 tomsn048@gmail.com

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Kia Rio 2002 Workshop Service Manual

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