brake KIA CERATO 2004 Service Manual

63
In case of an emergency
OVERHEATING
If your temperature gauge indicates
overheating, if you experience a loss
of power, or if you hear a loud knock-
ing or pinging noise, the engine has
probably overheated. Should any of
these symptoms occur, use the fol-
lowing procedure:
1. Turn on the hazard warning flash- er, then drive to the nearest safe
location and stop your vehicle; set
the automatic transaxle in P
(Park), or shift the manual
transaxle to N (Neutral) and apply
the parking brake.
2. Make sure the air conditioner is off.
3. If coolant or steam is boiling out of the radiator, stop the engine and
call an Authorized Kia Dealer for
assistance. If coolant is not boiling out, allowthe engine to idle and open the
hood to permit the engine to cool
gradually.
If the temperature does not go
down with the engine idling, stop
the engine and allow sufficient
time for it to cool.
4. The coolant level should then be checked. If the level in the reser-
voir is low, look for leaks at the
radiator hoses and connections,
heater hoses and connections,
radiator, and water pump. If youfind a major leak or another prob-
lem that may have caused the
engine to overheat, do not operatethe engine until it has been cor-
rected. Call an Authorized Kia
Dealer for assistance. If you do not
find a leak or other problem, care-
fully add coolant to the reservoir.
If the engine frequently overheats,
have the cooling system checkedand repaired by an Authorized Kia Dealer.
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WARNING - Removing
radiator cap
Do not remove the radiator cap when the engine and radiator
are hot. Scalding hot coolant
and steam may blow out under
pressure. This could cause seri-
ous injury.

611
In case of an emergency
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Description Fuse rating Protected component
ATM 20A Automatic transaxle control
ECU1 10A Engine control unit
STOP 15A Stop light
F/WIPER 15A Front wiper
R/FOG 10A Rear fog light
F/FOG 15A Front fog light
LO HDLP 15A Headlight (low)
HI HDLP 15A Headlight (high)
A/CON 10A Air conditioner
F/PUMP 15A Fuel pump
T/OPEN 10A Trunk lid opener
FOLD 10A Outside rearview mirror folding
HORN 10A Horn
DEICE 15A Deicer
INJ 15A Injection
SNSR 10A O2 sensor
ECU2 30A Engine control unit
SPARE 10A spare fuse
SPARE 15A spare fuse
SPARE 20A spare fuse
SPARE 30A spare fuse
ABS2 30A Anti-lock brake system
ABS1 30A Anti-lock brake system
IP B+ 50A In panel B+
BLOWER 30A Blower
IGN2 30A Ignition
IGN1 30A IgnitionDescription Fuse rating Protected component
RAD 30A Radiator fan
COND 20A Condenser fan
ALT
120A (Gasoline)Alternator
140A (Diesel)
ATM - Automatic transaxle control relay
WIPER - Wiper relay
F/FOG - Front fog light relay
LO HDLP - Headlight relay (low)
HI HDLP - Headlight relay (high)
A/CON - Air conditioner relay
F/PUMP - Fuel pump relay
DRL - Daytime running light relay
COND2 - Condenser fan relay
HORN - Horn relay
MAIN - Main relay
START - Start motor relay
RAD - Radiator fan relay
COND - Condenser fan relay
Engine compartment

In case of an emergency
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6
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Driver-side knee bolster
Description Fuse rating Protected component
START 10A Start motor
SRF/D_LOCK 20A Sunroof, Door lock
RR FOG 10A Rear fog light
HAZARD 10A Hazard warning flasher
A/CON 10A Air conditioner
CLUSTER 10A Cluster
RKE 10A Remote keyless entry
S/HTR 20A Seat warmer
C/LIGHTER 15A Cigar lighter
A/BAG 15A Airbag
R/WIPER 15A Rear wiper
AUDIO 10A Audio
ABS 10A Anti-lock brake system
ACC/PWR 15A Accessory / Power socket
ROOM 15A Room lamp
IGN 10A Ignition
ECU 10A Engine control unit
TAIL RH 10A Tail light (right)
T/SIG 10A Turn signal light
RR/HTR 30A Rear window defroster
P/WDW LH 25A Power window (left)
HTD/MIRR 10A Outside rearview mirror heater
P/WDW RH 25A Power window (right)
TAIL LH 10A Tail light (left)Description Fuse rating Protected component
RR/HTR - Rear window defroster relay
RESISTOR - Resistor
P/WDW - Power window relay
ACC/PWR - Accessory / Power socket relay
TAIL - Tail light relay
Description Fuse rating Protected component
F/HEATER 30A Fuel filter heater
HEATER 3 40A PTC heater 3
HEATER 2 40A PTC heater 2
GLOW 60A Glow plug
HEATER 1 40A PTC heater 1
RELAY F/HEATER - Fuel filter heater relay
RELAY HEATER 3 - PTC heater relay 3
RELAY HEATER 2 - PTC heater relay 2
RELAY GLOW - Glow plug relay
RELAY HEATER 1 - PTC heater relay 1
Engine compartment (Diesel only)

615
In case of an emergency
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When towing your vehicle in an emergency without wheel dollies :
1. Set the ignition switch in the ACCposition.
2. Place the transaxle shift lever in N (Neutral).
3. Release the parking brake.
✽✽ NOTICE
Failure to place the transaxle shift
lever in N (Neutral) may cause inter-nal damage to the transaxle.
Tie-down hook
(for flatbed towing)
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Tie-down hook
CAUTION
Do not use the hooks under the
front of the vehicle for towingpurposes. These hooks aredesigned ONLY for transport tie- down. If the tie-down hooks areused for towing, the tie-downhooks will be damaged and this could lead to serious injury.

In case of an emergency
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Towing with a vehicle other
than a tow truck
If towing is necessary, we recom-
mend you to have it done by an
Authorized Kia dealer or a commer-
cial tow truck service.
If towing service is not available in an
emergency, your vehicle may be
temporarily towed using a cable or
chain secured to the emergency tow-ing hook under the front or rear of the
vehicle. Use extreme caution when
towing the vehicle. A driver must be
in the vehicle to steer it and operate
the brakes. Towing in this manner may be done
only on hard-surfaced roads for a
short distance and at low speeds.
Also, the wheels, axles, power train,
steering and brakes must all be ingood condition.
Do not use the tow hooks to pull a
vehicle out of mud, sand or other
conditions from which the vehicle
cannot be driven out under its own
power.
Avoid towing a vehicle heavier than the vehicle doing the towing.
The drivers of both vehicles should communicate with each other fre-
quently.
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1LDN4021

In case of an emergency
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6
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When your vehicle is being
towed by another vehicle
other than a tow truck (in case
of an emergency)
Turn the ignition switch to ACC so
the steering wheel isn’t locked.
Place the transaxle shift lever in N (Neutral).
Release the parking bake.
Vehicles equipped with automatic transaxles should not exceed 45 km/h (28 mph) and should not be
towed more than 80 km (50 miles).
Vehicles equipped with manual transaxle should not be towed in
excess of 88 km/h (55 mph) and
should not be towed more than645 km (400 miles). Press the brake pedal with more
force than normal since you will
have reduced brake performance.
More steering effort will be required because the power steer-
ing system will be disabled.
If you are driving down a long hill, the brakes may overheat and brake
performance will be reduced. Stop
often and let the brakes cool off.
✽✽ NOTICE
To prevent internal damage to the
transaxle, never tow your vehicle
from the rear (backwards) with all
four tires in contact with the sur-face.
Tips for towing a stuck vehicle
The following methods are effective
when your vehicle is stuck in mud,sand or similar substances that pre-
vent the vehicle from being driven
out under its own power.
Remove the soil and sand, etc. from the front and the back of the
tires.
Place a stone or wood under the tires.

In case of an emergency
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Tire replacement
1. Park on a level surface and apply
the parking brake firmly.
2. Shift the shift lever into R (Reverse) with manual transaxle
or P (Park) with automatic
transaxle.
3. Activate the hazard warning flash- er.
WARNING - Changing
tires
Never attempt vehicle repairs in the traffic lanes of a public
road or highway.
Always move the vehicle com- pletely off the road and onto
the shoulder before trying to
change a tire. The jack should
be used on level firm ground
whenever possible. If you can-
not find a firm, level place off
the road, call a towing service
company for assistance.
Do not exceed the jack’s max- imum permissible load: 700 kg(1,540 lbs.).
Be sure to use the correct front and rear jacking posi-
tions on the vehicle; never use
the bumpers or any other part
of the vehicle for jack support.
(Continued)(Continued)
The vehicle can easily roll offthe jack causing serious
injury or death. No person
should place any portion of
their body under a vehicle that
is supported only by a jack ;
use vehicle support stands.
Do not start or run the engine while the vehicle is on the
jack.
Do not allow anyone to remain in the vehicle while it is on the
jack.
Make sure any children pres- ent are in a secure place away
from the road and from the
vehicle to be raised with the
jack.
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621
In case of an emergency
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4. Remove the wheel lug nut wrench,jack, jack handle, and spare tire
from the vehicle.
5. Block both the front and rear of the wheel that is diagonally opposite
the jack position. 6. Loosen the wheel lug nuts coun-
terclockwise one turn each, but do
not remove any nut until the tire
has been raised off the ground.
WARNING - Changing a tire
To prevent vehicle movement
while changing a tire, always
set the parking brake fully, and
always block the wheel diago-
nally opposite the wheel being
changed.
It is recommended that the wheels of the vehicle be
chocked, and that no person
should remain in a vehicle that
is being jacked.
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623
In case of an emergency
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11. Once the wheel lug nuts havebeen tightened, lower the vehicle
fully to the ground and continue to
tighten the lug nuts until they are
fully secured. Tighten the wheel
lug nuts firmly in a “X” pattern.
If you are unsure of the tightness
of the wheel lug nuts, have them
checked at the nearest service
station. The specified tightening
Improperly tight-
ened wheel lug nuts could cause
brake pedal vibration while brak-ing. To prevent the jack, jack handle,
wheel lug nut wrench and spare tire
from rattling while the vehicle is in
motion, store them properly.
1LDN4017
CAUTION
Your vehicle has metric threads
on the wheel studs and nuts. Make certain during wheelremoval that the same nutsremoved are reinstalled - or, if replaced, that nuts with metricthreads and the same chamferconfiguration are used. Installation of a non-metricthread nut on a metric stud orvice-versa will not secure thewheel to the hub properly and will damage the stud so that itmust be replaced.
Note that most lug nuts do nothave metric threads. Be sure to use extreme care in checkingfor thread style before installingaftermarket lug nuts or wheels.If in doubt, consult an Authorized Kia Dealer.
WARNING - Wheel studs
If the studs are damaged, they
may lose their ability to retain
the wheel. This could lead to theloss of the wheel and a colli-sion.
WARNING
Check the inflation pressures as
soon as possible after installing
the spare tire. Adjust it to the
specified pressure, if necessary.
Refer to Section 8, Specifications.

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10
Maintenance services / 7-3 Normal maintenance schedule / 7-5
Maintenance under severe usage conditions / 7-8
Owner maintenance / 7-10Engine compartment / 7-13
Engine oil and oil filter / 7-16Engine cooling system / 7-19Brakes and clutch / 7-22Parking brake / 7-23Drive belts / 7-24
Power steering / 7-25
Steering wheel / 7-26Manual transaxle / 7-26Automatic transaxle / 7-28Lubricants and fluids / 7-31
Fuel filter / 7-32
Air cleaner / 7-33
Air conditioner air filter / 7-35
Wiper blades / 7-37
Maintenance