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6 DOHC > General Information

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IDENTIFICATION NUMBER LOCATIONS

IDENTIFICATION NUMBER DESCRIPTION
VEHICLE IDENTIFICATION NUMBER
1 - 3 : Make / Vehicle type
- KNE, KNA = Kia Passenger Car
4 - 5 : Vehicle Line / Series
- DE = RIO
6 - 7: Body type
- 12 = 4 Door Sedan
- 16 = 5 Door Hatchback
8 : Engine type
- 3 = 1.6 Gasoline (G4ED)
9 : Transaxle type
- Check digit
10 : Model year
- 5 = 2005, 6 = 2006
11 : Plant location
- 6 = Sohari plant
12 : Sequential number
- 000001 ~ 999999
PAINT CODE
CODE COLOR

UD CLEAR WHITE

6C CLEAR SILVER

J1 POLAR SILVER

J4 CASHMERE BEIGE

2D SOFT GREEN

T5 SAPPHIRE

06 SUNSET ORANGE

08 TROPICAL RED

7V OLIVE GRAY

9B MIDNIGHT BLACK

ENGINE IDENTIFICATION NUMBER

1. Engine fuel
- G = Gasoline
2. Engine range
- 4 = 4 cycle 4 cylinder
3. Engine development order
- E = ALPHA Engine
4. Engine capacity
- D = 1,599cc
5. Production year
- 5 : 2005, 6 : 2006
6. Engine production sequence number
- 000001 ~ 999999

TRANSMISSION IDENTIFICATION NUMBER MANUAL

MANUAL

1. Model
- R = M5CF1
- P = M5CF2
2. Production year
- 5 : 2005, 6 : 2006
3. Gear ratio(Tooth number)
<Differential drive gear tooth number / Output shaft gear tooth number>
- 1873 = 73/18 = 4.056
4. Transaxle production sequence number
- 000001 ~ 999999

AUTOMATIC

1. Modle
- T = A4AF3
2. Production year
- 5 : 2005, 6 : 2006
3. Gear ratio
- N = 4.041
4. Detailed chassification
- UD = 1.4 DOHC
- WD = 1.6 CVVT
5. Spare
6. Transaxle production sequence number
- 000001 ~ 999999
WARNING / CAUTION LABEL LOCATIONS

AIR BAG WARNING / CAUTION LABEL

AIR BAG WARNING / CAUTION LABEL (CONT’D)
AIR BAG 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 seal.
• For further information, see the owner's manual.

B : CAUTION
AIRBAG 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 to be installed igniter.

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 flashes approximately 6
times 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.

BATTERY CAUTION LABEL DESCRIBTION

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 substantial
 weight is removed from the rear of the vehicle, the center of gravity may change and cam 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 propular methods of towing a vehicle :
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 not 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 nominal diameter Torque Nm (kg.cm, lb.ft)

Pitch (mm)
(mm) Head Mark 4 Head Mark 7
 3 ~ 4 (30 ~ 40, 2.2 ~ 5 ~ 6 (50 ~ 60, 3.6 ~
M5 0.8
2.9) 4.3)
5 ~ 6 (50 ~ 60, 3.6 ~ 9 ~ 11 (90 ~ 110, 6.5 ~
M6 1.0
4.3) 8.0)
12 ~ 15 (120 ~ 150, 9 ~ 20 ~ 25 (200 ~ 250,
M8 1.25
11) 14.5 ~ 18.0 )
25 ~ 30 (250 ~ 300, 18 30 ~ 50 (300 ~ 500, 22
M10 1.25
~ 22) ~ 36)
35 ~ 45 (350 ~ 450, 25 60 ~ 80 (600 ~ 800, 43
M12 1.25
~ 33) ~ 58)
75 ~ 85 (750 ~ 850, 54 120 ~ 140 (1,200 ~
M14 1.5
~ 61) 1,400, 85 ~ 100)
110 ~ 130 (1,100 ~ 180 ~ 210 (1,800 ~
M16 1.5
1,300, 80 ~ 94) 2,100, 130 ~ 150)
160 ~ 180 (1,600 ~ 260 ~ 300 (2,600 ~
M18 1.5
1,800, 116 ~ 130) 3,000, 190 ~ 215)
220 ~ 250 (2,200 ~ 360 ~ 420 (3,600 ~
M20 1.5
2,500, 160 ~ 180) 4,200, 260 ~ 300)
290 ~ 330 (2,900 ~ 480 ~ 550 (4,800 ~
M22 1.5
3,300, 210 ~ 240) 5,500, 350 ~ 400)
360 ~ 420 (3,600 ~ 610 ~ 700 (6,100 ~
M24 1.5
4,200, 260 ~ 300) 7,000, 440 ~ 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. If you reduce the torques in the table to the percentage indicated below, under the following
conditions, if will be the standard value.
• If spring washers are used : 85%
• If threads and bearing sufaces are stained with oil : 85%

LUBRICANTS
RECOMMENDED LUBRICANTS
Parts OIL & GREASE STANDARD

API SL(SJ) or ABOVE,

Engine Oil
ILSAC GF-3 and ABOVE

Manual transaxle GENUINE PART MTF 75W/85 (API GL - 4)

Automatic transaxle DIAMOND ATF SP-III, SK ATF SP-III

Brake DOT 3, DOT 4 or equivalent

Coolant Ethlyene glycol base for aluminium radiator

Coolant Ethlyene glycol base for aluminium radiator

Transaxle linkage, parking

breake cable mechanism, hood,
Multipurpose grease NIGL grade #2
door latch, seat adjuster, tailgate
latch, door hinges, tailgate hinge

Power Steering PSF - III

Always use Genuine Kia parts and recommended fluid.

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

LUBRICANTS CAPACITIES
Description Capacities

Engine oil Oil pan 3.0 (3.17, 2.64)

Oil filter 0.3 (0.32, 0.26)

Total 3.3 (3.49, 2.90)

Cooling system 5.5~5.8 (5.81~6.13, 4.84~5.10)

Manual transaxle 2.0 (2.11, 1.76)

Automatic transaxle 6.1 (6.45, 5.37)

Power steering 0.75~0.8 (0.79~0.85, 0.66~0.70)

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

SELECTION OF ENGINE OIL

RECOMMENDED ILSAC classification : GF-3 OR ABOVE
RECOMMENDED API classification : SL(SJ) OR ABOVE

RECOMMENDED SAE VISCOSITY GRADES :

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 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 affect their performance or external appearance.
1. Inspection of parts
Each part, when removed, should be carefully inspected 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 replaced 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 MOTORS 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. Sealant 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 correctly 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.
RUBBER PARTS AND TUBES
Always prevent gasoline or from touching rubber parts or tubing.

MEASURING BODY DIMENSIONS

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 dimensions 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 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 measurement 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 circuits.
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 their 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 firmly 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. Therefore, if necessary, read
the diagnostic 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
surrounding 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 electronic 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 appropriate wire size.
Permissible current
Noeminal size SAE gauge No. In engine
Other areas
compartment

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

PRECAUTIONS FOR CATALYTIC CONVERTER

If a large amount of unburned gasoline flow into the converter, it may overheat and create a fire
hazard. To prevent this observe the following precautions 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. Avoid start-jump tests. Do start-jumps only when absolutely necessary. Perform this test as rapidly
as possible and, while testing, never race the engine.
4. Do not measure engine compression for and extended time. Engine compression tests must be
made as rapidly as possible.
5. Avoid coasting with the ignition turned and during prolonged braking.
6. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.

BODY - DIMENSION