Engine control KIA Forte 2012 1.G Service Manual

717
Maintenance
NORMAL MAINTENANCE SCHEDULE (CONT.)
216,000 km (135,000 miles) or 108 months
❑Rotate tires - including tire pressure and tread wear
(Every 12,000 km or 12 months)
❑ Inspect air cleaner filter
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake lines, hoses and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect power steering fluid and lines (if equipped)
❑Inspect power steering pump, belt and hoses (if equipped)
❑ Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Replace climate control air filter (if equipped)
❑Replace engine oil and filter
(216,000 km (135,000 miles) or 216 months)
❑Inspect drive belt *4
(First, 96,000 km or 72 months
after every 24,000 km or 24 months)
❑ Inspect add fuel additive (12,000 or 12 months) *3
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect all latch, hinges and locks
228,000 km (142,500 miles) or 114 months
❑Rotate tires - including tire pressure and tread wear
(Every 12,000 km or 12 months)
❑ Inspect air cleaner filter
❑Inspect vacuum hose
❑Replace engine oil and filter
(228,000 km (142,500 miles) or 228 months)
❑ Inspect add fuel additive (12,000 or 12 months) *3
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
*3: If TOP TIER Detergent Gasoline is not available, one bottle of additive is rec-
ommended. Additives are available from your authorized KIA dealer along
with information on how to use them. Do not mix other additives.
*
4: The drive belt should be replaced when cracks occur or tension is reduced excessively.

Maintenance
18
7
240,000 km (150,000 miles) or 120 months
❑ Rotate tires - including tire pressure and tread wear
(Every 12,000 km or 12 months)
❑ Inspect air conditioning refrigerant
❑Inspect brake fluid / clutch (if equipped) fluid
❑ Inspect brake lines, hoses and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect fuel filter *1
❑Inspect fuel tank, cap, canister, fuel lines, fuel hoses, connections
and vapor hose
❑ Inspect fuel tank air filter (if equipped) *1
❑Inspect power steering fluid and lines (if equipped)
❑Inspect power steering pump, belt and hoses (if equipped)
❑ Inspect parking brake
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect vacuum hose
❑Replace climate control air filter (if equipped)
❑Replace air cleaner filter
❑Replace engine oil and filter
(240,000 km (150,000 miles) or 240 months)
(Continued)
(Continued)
❑Replace engine coolant *5(First, 192,000 km (120,000 miles) or
120 months after every 48,000 km (30,000 miles) or 24 months)
❑ Inspect drive belt *4
(First, 96,000 km or 72 months
after every 24,000 km or 24 months)
❑ Inspect add fuel additive (12,000 or 12 months) *3
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect manual transaxle fluid (if equipped)
(Every 60,000 km or 48 months)
❑ Inspect all latch, hinges and locks
NORMAL MAINTENANCE SCHEDULE (CONT.)
No check, No service required
❑Automatic transaxle fluid
*1: Fuel filter & Fuel tank air filter are considered to be maintenance free\
but
periodic inspection is recommended for this maintenance schedule depends
on fuel quality. If there are some important safety matters like fuel flow
restriction, surging, loss of power, hard starting problem etc, replace the fuel
filter immediately regardless of maintenance schedule and consult an aut\
hor-
ized KIA dealer for details.
*
3: If TOP TIER Detergent Gasoline is not available, one bottle of additive is rec- ommended. Additives are available from your authorized KIA dealer along
with information on how to use them. Do not mix other additives.
*
4: The drive belt should be replaced when cracks occur or tension is reduced excessively.
*
5: When replacing coolant, use only a qualified coolant additive for your vehicle
and never mix hard water in the coolant filled at the factory. An improper
coolant mixture can result in serious malfunction or engine damage.

Maintenance
20
7
MAINTENANCE ITEMMAINTENANCE
OPERATIONMAINTENANCE INTERVALSDRIVING
CONDITION
MANUAL TRANSAXLE FLUID*REVERY 120,000 kmA, C, D, E, F, G, H, I, J
AUTOMATIC TRANSAXLE FLUID*REVERY 90,000 kmA, C, D, E, F, G, H, I
CLIMATE CONTROL AIR FILTER
(FOR EVAPORATOR AND BLOWER UNIT)RMORE FREQUENTLYC, E
SEVERE DRIVING CONDITIONS
A - Repeatedly driving shorts distanse of less than 8 km in normal tem-
perature or less than 16 km in freezing temperature
B - Extensive engine idling or low speed driving for long distances
C - Driving on rough, dusty, muddy, unpaved, graveled or salt-spread roads
D - Driving in areas using salt or other corrosive materials or in very cold weather E - Driving in sandy areas
F - Driving in heavy traffic area over 32°C (90°F)
G - Driving on uphill, downhill, or mountain road
H - Towing a Trailer, or using a camper, or roof rack
I - Driving as a patrol car, taxi, other commercial use or vehicle towing
J - Driving over 170 km/h
K - Frequently driving in stop-and-go conditions
* : if equipped

Maintenance
26
7
Check the condition and connections of
all cooling system hoses and heater
hoses. Replace any swollen or deterio-
rated hoses.
The coolant level should be filled
between F (MAX) and L (MIN) marks on
the side of the coolant reservoir when the
engine is cool.
If the coolant level is low, add enough
specified coolant to provide protection
against freezing and corrosion. Bring the
level to F (MAX), but do not overfill. If fre-
quent coolant addition is required, see an
authorized KIA dealer for a cooling sys-
tem inspection.
G070101AHM-EU
Recommended engine coolant
Use only soft (destilled) water in the
coolant mixture.
The engine in your vehicle has alu- minum engine parts and must be pro-
tected by an ethylene-glycol-based
coolant to prevent corrosion and freez-
ing.
DO NOT USE alcohol or methanol coolant or mix them with the specified
coolant.
Do not use a solution that contains more than 60% antifreeze or less than
35% antifreeze, which would reduce
the effectiveness of the solution.
For mixture percentage, refer to the fol-
lowing table.
OTD079050L
-15°C (5°F) 35 65
-25°C (-13°F) 40 60
-35°C (-31°F) 50 50
-45°C (-49°F) 60 40
Ambient
Temperature Mixture Percentage (volume)
Antifreeze Water
WARNING
The electric motor (cool-
ing fan) is controlled by
engine coolant tempera-
ture, refrigerant pres-
sure and vehicle speed.
It may sometimes operate even
when the engine is not running.
Use extreme caution when working
near the blades of the cooling fan
so that you are not injured by a
rotating fan blades. As the engine
coolant temperature decreases, the
electric motor will automatically
shut off. This is a normal condition.

727
Maintenance
G070200ATD
Changing the coolant
Have the coolant changed by an author-
ized KIA dealer according to the
Maintenance Schedule at the beginning
of this section.
WARNING
Radiator cap
Do not remove the radiator cap
when the engine and radiator are
hot. Scalding hot coolant and
steam may blow out under pres-
sure causing serious injury.
CAUTION
Put a thick cloth or fabric aroundthe radiator cap before refilling the coolant in order to prevent thecoolant from overflowing into engine parts such as the alternator.
WARNING -Coolant
Do not use radiator coolant or antifreeze in the washer fluid
reservoir.
Radiator coolant can severely obscure visibility when sprayed
on the windshield and may cause
loss of vehicle control or damage
to paint and body trim.
OTD071007
OTD072007A
■ Type A
■Type B

Maintenance
36
7
G130300ATD
Reset items
Items should be reset after the battery
has been discharged or the battery has
been disconnected.
Auto down window (See section 4)
Sunroof (See section 4)
Trip computer (See section 4)
Climate control system
(See section 4)
Clock (See section 4)
Audio (See section 4)
(Continued)
Disconnect the battery charger in the following order.
1. Turn off the battery charger main switch.
2. Unhook the negative clamp from the negative battery terminal.
3. Unhook the positive clamp from the positive battery terminal.
Before performing maintenance or recharging the battery, turn off
all accessories and stop the
engine.
The negative battery cable must be removed first and installed
last when the battery is discon-
nected.WARNING- Rechargingbattery
When recharging the battery,
observe the following precautions:
The battery must be removed
from the vehicle and placed in an
area with good ventilation.
Do not allow cigarettes, sparks, or flame near the battery.
Watch the battery during charg- ing, and stop or reduce the charg-
ing rate if the battery cells begin
gassing (boiling) violently or if
the temperature of the electrolyte
of any cell exceeds 49°C (120°F).
Wear eye protection when check- ing the battery during charging.
(Continued)

Maintenance
50
7
FUSES
G210000ATD
A vehicle’s electrical system is protected
from electrical overload damage by
fuses. This vehicle has 2 fuse panels, one locat-
ed in the driver’s side panel bolster, the
other in the engine compartment near
the battery.
If any of your vehicle’s lights, acces-
sories, or controls do not work, check the
appropriate circuit fuse. If a fuse has
blown, the element inside the fuse will
melt.
If the electrical system does not work,
first check the driver’s side fuse panel.
Always replace a blown fuse with one of
the same rating.
If the replacement fuse blows, this indi-
cates an electrical problem. Avoid using
the system involved and immediately
consult an authorized KIA dealer.
Three kinds of fuses are used: blade type
for lower amperage rating, cartridge type, and multi fuse for higher amperage rat-ings.
OHDC078019
Normal
Normal
Blade type
Cartridge type
Multi fuse Blown
Blown
Normal Blown
WARNING - Fuse replace- ment
Never replace a fuse with any-
thing but another fuse of the
same rating.
A higher capacity fuse could cause damage and possibly a
fire.
Never install a wire instead of the proper fuse - even as a temporary
repair. It may cause extensive
wiring damage and a possible fire.
CAUTION
Do not use a screwdriver or any
other metal object to remove fusesbecause it may cause a short circuit and damage the system.

757
Maintenance
Engine compartment fuse panel
Description Fuse ratingProtected component
ALT125AGenerator, Fuse (MDPS, HTD GLASS, C/FAN, ABS 2, BLOWER, IGN 1, FOG LP (FR), ABS 1)
MDPS 80A EPS Control Module
ABS 2 40A ESC Control Module, ABS Control Module
C/FAN 40A C/Fan LO/HI Relay
BLOWER 40A Blower Relay
HTD GLASS 40A I/P Junction Box (Rear Defogger Relay) IGN 2 30A Ignition Switch, Start Relay, Button Relay Box (ESCL Relay)
BATT 1 50AI/P Junction Box (Fuse (TAIL LAMP (LH/RH), P/WDW DR, P/WDW ASS, FOG LP (RR)/SSB,
SMK, PDM), Tail Lamp Relay, Power Window Relay)
ABS 1 40A ESC Control Module, ABS Control Module
IGN 1 30A Ignition Switch, Button Relay Box (ESCL Relay (IGN1))
BATT 2 50AI/P Junction Box (Power Connector (AUDIO, ROOM LP LAMP), FUSE (STOP LP, DEICER,
HAZARD LP, DR LOCK, TRUNK OPEN))
ECU 30A Engine Control Relay
FOG LP (FR) 10A Multipurpose Check Connector, Front Fog Relay, Battery Sensor H/LP HI 20A H/LP (HI) Relay,
HORN 10A Horn Relay
H/LP LO(LH) 10A Head Lamp LH
H/LP LO(RH) 10A Head Lamp RH SPARE 10A -
SNSR 3 10A ECM, PCM, Vehicle Speed Sensor, Pulse Generator 'A', Stop Lamp Switch
ABS 10A Multipurpose Check Connector, ESC Control Module, ABS Control Module
ECU 3 15A Ignition Coil (#1~#4), Condenser, PCM
MULTI
FUSE
FUSE

Maintenance
66
7
G270201AUN
Canister
Fuel vapors generated inside the fuel
tank are absorbed and stored in the
onboard canister. When the engine is
running, the fuel vapors absorbed in the
canister are drawn into the surge tank
through the purge control solenoid valve.
G270202AHM
Purge Control Solenoid Valve (PCSV)
The purge control solenoid valve is con-
trolled by the Engine Control Module
(ECM); when the engine coolant temper-
ature is low during idling, the PCSV clos-
es so that evaporated fuel is not taken
into the engine. After the engine warms
up during ordinary driving, the PCSV
opens to introduce evaporated fuel to the
engine.
G270300AUN
3. Exhaust emission control
system
The Exhaust Emission Control System is
a highly effective system which controls
exhaust emissions while maintaining
good vehicle performance.
G270301AUN
Vehicle modifications
This vehicle should not be modified.
Modification of your vehicle could affect
its performance, safety or durability and
may even violate governmental safety
and emissions regulations.
In addition, damage or performance
problems resulting from any modification
may not be covered under warranty.
G270302AUN
Engine exhaust gas precautions
(carbon monoxide)
Carbon monoxide can be present with other exhaust fumes. Therefore, if you
smell exhaust fumes of any kind inside
your vehicle, have it inspected and
repaired immediately. If you ever sus-
pect exhaust fumes are coming into
your vehicle, drive it only with all the
windows fully open. Have your vehicle
checked and repaired immediately.
WARNING- Exhaust
Engine exhaust gases contain car-
bon monoxide (CO). Though color-
less and odorless, it is dangerous
and could be lethal if inhaled.
Follow the instructions on this
page to avoid CO poisoning.

767
Maintenance
Do not operate the engine in confinedor closed areas (such as garages) any
more than what is necessary to move
the vehicle in or out of the area.
When the vehicle is stopped in an open area for more than a short time
with the engine running, adjust the
ventilation system (as needed) to draw
outside air into the vehicle.
Never sit in a parked or stopped vehi- cle for any extended time with the
engine running.
When the engine stalls or fails to start, excessive attempts to restart the
engine may cause damage to the
emission control system.G270303AAM
Operating precautions for catalyticconverters (if equipped)
Your vehicle is equipped with a catalytic
converter emission control device.
Therefore, the following precautions
must be observed:
Use only UNLEADED FUEL for gaso- line engines.
Do not operate the vehicle when there are signs of engine malfunction, such
as misfire or a noticeable loss of per-
formance. Do not misuse or abuse the engine.
Examples of misuse are coasting with
the ignition off and descending steep
grades in gear with the ignition off.
Do not operate the engine at high idle speed for extended periods (5 minutes
or more).
Do not modify or tamper with any part of the engine or emission control sys-
tem. All inspections and adjustments
must be made by an authorized KIA
dealer.
Avoid driving with a extremely low fuel level. Running out of fuel could cause
the engine to misfire, damaging the
catalytic converter.
Failure to observe these precautions
could result in damage to the catalytic
converter and to your vehicle.
Additionally, such actions could void your
warranties.
WARNING- Fire
A hot exhaust system can ignite
flammable items under your vehi-
cle. Do not park, idle or drive the
vehicle over or near flammable
objects, such as grass, vegetation,
paper, leaves, etc.