steering KIA FORTE 2019 Repair Manual

635
What to do in an emergency
Removable towing hook
(if equipped)
1. Open the tailgate, and remove thetowing hook from the tool case.
2. Remove the hole cover pressing the lower (front) part of the cover
on the bumper.
3. Install the towing hook by turning it clockwise into the hole until it is
fully secured.
4. Remove the towing hook and install the cover after use.
Emergency towing
If towing is necessary, we recom-
mend you to have it done by an
authorized Kia dealer or a com-
mercial 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
towing 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 speed.
Also, the wheels, axles, power
train, steering and brakes must all
be in good 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.
OBD068013
■ Front
OBD068015
OBD068016
■ Front
■ Rear
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637
What to do in an emergency
Emergency towing precautions
Turn the ignition switch to ACC sothe steering wheel isn’t locked.
Place the transaxle shift lever in N (Neutral).
Release the parking bake.
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.
If the car is being towed with all four wheels on the ground, it can
be towed only from the front. Be
sure that the transaxle is in neutral.
Be sure the steering is unlocked by
placing the ignition switch in the
ACC position. A driver must be in
the towed vehicle to operate the
steering and brakes.CAUTION
- Intelligent Variable
Transmission (IVT)
Vehicles with Intelligent VariableTransmission (IVT) can only betowed to an ordinary vehiclewhen there is no IVT transmis-sion oil leakage. If towing to anordinary vehicle in the event ofoil leakage, the transmissionmay be damaged. If towing to anordinary vehicle in the event ofoil leakage, the transmissionmay be damaged.
CAUTION
- Intelligent Variable
Transmission
If the car is being towed with all four wheels on the ground,it can be towed only from thefront.
(Continued)
(Continued)Be sure that the transmissionis in neutral. Be sure the steer-ing is unlocked by placing theignition switch in the ACCposition. A driver must be inthe towed vehicle to operatethe steering and brakes.
To avoid serious damage to the Intelligent VariableTransmission limit the vehiclespeed to 15 km/h (10 mph) anddrive less than 1.5 km (1 mile)when towing.
Before towing, check the Intelligent VariableTransmission for fluid leaksunder your vehicle. If theIntelligent VariableTransmission fluid is leaking,flatbed equipment or a towingdolly must be used.
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Maintenance
Engine compartment . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Maintenance services . . . . . . . . . . . . . . . . . . . . . . . . 7-5
• Owner’s responsibility . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
• Owner maintenance precautions . . . . . . . . . . . . . . . . . 7-6
Owner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
• Owner maintenance schedule . . . . . . . . . . . . . . . . . . . 7-8
Scheduled maintenance service. . . . . . . . . . . . . . . 7-10
Explanation of scheduled maintenance items . . . 7-16
• Engine oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
• Drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16\
• Fuel filter (for gasoline) . . . . . . . . . . . . . . . . . . . . . . . 7-16
• Fuel lines, fuel hoses and connections . . . . . . . . . . . . 7-16
• Vapor hose and fuel filler cap . . . . . . . . . . . . . . . . . . 7-16
• Vacuum crankcase ventilation hoses . . . . . . . . . . . . . 7-17
• Air cleaner filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
• Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
• Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
• Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. 7-17
• Intelligent Variable Transmission (IVT) fluid . . . . . 7-17
• Manual transaxle fluid . . . . . . . . . . . . . . . . . . . . . . . . 7-18
• Brake hoses and lines . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
• Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19\
• Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
• Brake discs, pads, calipers and rotors. . . . . . . . . . . . 7-19
• Exhaust pipe and muffler . . . . . . . . . . . . . . . . . . . . . . 7-19
• Suspension mounting bolts . . . . . . . . . . . . . . . . . . . . . 7-19• Steering gear box, linkage &
boots/lower arm ball joint . . . . . . . . . . . . . . . . . . . . 7-20
• Drive shafts and boots. . . . . . . . . . . . . . . . . . . . . . . . . 7-20
• Air conditioning refrigerant . . . . . . . . . . . . . . . . . . . . 7-20
Checking fluid levels . . . . . . . . . . . . . . . . . . . . . . . 7-20
Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
• Checking the engine oil level . . . . . . . . . . . . . . . . . . . 7-21
• Changing the engine oil and filter . . . . . . . . . . . . . . . 7-22
Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
• Checking the coolant level . . . . . . . . . . . . . . . . . . . . . 7-23
• Changing the coolant . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Brake/clutch fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
• Checking the brake/clutch fluid level . . . . . . . . . . . . 7-26
Washer fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
• Checking the washer fluid level . . . . . . . . . . . . . . . . . 7-27
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
• Checking the parking brake. . . . . . . . . . . . . . . . . . . . 7-28
Air cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
• Filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Climate control air filter . . . . . . . . . . . . . . . . . . . . 7-31
• Filter inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
• Blade inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
• Blade replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7
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Maintenance
87
OWNER MAINTENANCE
The following lists are vehicle checks
and inspections that should be per-
formed by the owner or an author-
ized Kia dealer at the frequencies
indicated to help ensure safe,
dependable operation of your vehi-
cle.
Any adverse conditions should be
brought to the attention of your deal-
er as soon as possible.
These Owner Maintenance Checks
are generally not covered by war-
ranties and you may be charged for
labor, parts and lubricants used.Owner maintenance schedule
When you stop for fuel:
Check the engine oil level.
Check the coolant level in coolantreservoir.
Check the windshield washer fluid level.
Look for low or under-inflated tires.
While operating your vehicle:
Note any changes in the sound of the exhaust or any smell of
exhaust fumes in the vehicle.
Check for vibrations in the steering wheel. Notice any increased steer-
ing effort or looseness in the steer-
ing wheel, or change in its straight-
ahead position.
Notice if your vehicle constantly turns slightly or “pulls” to one side
when traveling on smooth, level
road.
When stopping, listen and check for unusual sounds, pulling to one
side, increased brake pedal travel
or “hard-to-push” brake pedal.
If any slipping or changes in the operation of your transmission
occurs, check the transmission
fluid level.
Check manual transaxle operation, including clutch operation.
Check the parking brake.
Check for fluid leaks under your vehicle (water dripping from the air
conditioning system during or after
use is normal).
WARNING- Hot coolant
Be careful when checking your
engine coolant level when the
engine is hot. Scalding hot
coolant and steam may blow
out under pressure.
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Maintenance
12
7
Number of months or driving distance, whichever comes first
Months1224364860728496108120132144156168180
Miles×1,0007.51522.530 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5
Km×1,00012 24 36 48 60 72 84 96 108 120 132 144 156 168 180
Rotate tiresRotate every 12,000 km (7,500 miles)
Climate control air filterRRRRRRRRRRRRRRR
Vacuum hoseIIIIIIIIIIIIIII
Coolant (Engine)At first, replace at 192,000 km (120,000 miles) or 10 years,
after that, replace every 48,000 km (30,000 miles) or 24 months
Battery conditionIIIIIIIIIIIIIII
Brake lines, hoses and connections
(including booster)IIIIIIIIIIIIIII
Brake discs and padsIIIIIIIIIIIIIII
Steering gear rack, linkage and bootsIIIIIIIIIIIIIII
Drive shaft and boots-I-I-I-I-I-I-I-
Suspension ball joints and mounting
boltsIIIIIIIIIIIIIII
Air conditioner compressor/refrigerantIIIIIIIIIIIIIII
Exhaust systemIIIIIIIIIIIIIII
MAINTENANCE INTERVALS
MAINTENANCE
ITEM
Normal Maintenance Schedule - Non Turbo Models(CONT.)
I : Inspect and if necessary, adjust, correct, clean or replace.
R : Replace or change.
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Maintenance
14
7
Maintenance Under Severe Usage Conditions - Non Turbo Models
The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer
to the chart below for the appropriate maintenance intervals.
R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if neces\
sary
MAINTENANCE ITEMMAINTENANCE
OPERATIONMAINTENANCE INTERVALSDRIVING
CONDITION
Engine oil and
engine oil filterNu 2.0L MPIREvery 6,000 km (3,750 miles) or 6 monthsA, B, C, D, E,
F, G, H, I, J, K
Air cleaner filterRMore frequentlyC, E
Spark plugs RMore frequentlyA, B, F, G, H, I, K
Intelligent Variable Transmission (IVT) fluidREvery 96,000 km (60,000 miles)A, C, D, E,
F, G, H, I, J
Manual transmission fluidREvery 120,000 km (75,000 miles)C, D, E, F, G, H, I, J
Brake discs and pads, calipers and rotorsIMore frequentlyC, D, E, G, H
Parking brake (Hand type)IMore frequentlyC, D, G, H
Steering gear rack, linkage and bootsIMore frequentlyC, D, E, F, G
Suspension ball joints and mounting boltsIMore frequentlyC, D, E, F, G
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Maintenance
20
7
CHECKING FLUID LEVELS
Steering gear box, linkage &
boots/lower arm ball joint
With the vehicle stopped and engine
off, check for excessive free-play in
the steering wheel.
Check the linkage for bends or dam-
age. Check the dust boots and ball
joints for deterioration, cracks, or
damage. Replace any damaged
parts.
Drive shafts and boots
Check the drive shafts, boots and
clamps for cracks, deterioration, or
damage. Replace any damaged
parts and, if necessary, repack the
grease.
Air conditioning refrigerant
Check the air conditioning lines and
connections for leakage and damage. When checking engine oil, engine
coolant, brake fluid, and washer fluid,
always be sure to clean the area
around any filler plug, drain plug, or
dipstick before checking or draining
any lubricant or fluid. This is espe-
cially important in dusty or sandy
areas and when the vehicle is used
on unpaved roads. Cleaning the plug
and dipstick areas will prevent dirt
and grit from entering the engine and
other mechanisms that could be
damaged.
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763
Maintenance
Fuse NameFuse ratingCircuit Protected
MODULE 510ACrash Pad Switch, Head Lamp Left Handle side/Right Handle side, Auto Transmission Shift Lever Indicator,
Electro Chromic Mirror, Audio/Video & Navigation Head Unit, Air Conditioner Control Module, Rear Seat
Warmer Control Module, Front Seat Warmer Control Module, Front Air Ventilation Seat Control Module
DOOR LOCK20ADoor Lock/Unlock Relay, ICM (Integrated Circuit Module) Relay Box (Two Turn Unlock Relay)
IBU 115AIBU (Integrated Body Control Unit)
BRAKE SWITCH10AIBU (Integrated Body Control Unit), Stop Lamp Switch
IG125AEngine Room Junction Block (Fuse - ABS 3, ECU 5, SENSOR 4, TCU 2)
WIPER (LO/HI)10AEngine Room Junction Block (Front Wiper (Low) Relay), Front Wiper Motor, ECM (Engine Control
Module)/PCM (Power train Control Module), IBU (Integrated Body Control Unit)
AIR CONDITIONER17.5AEngine Room Junction Block (Blower, PTC Heater), Air Conditioner Control Module
AIR BAG 210ASRS (Supplemental Restraint System) Control Module
WASHER15AMultifunction Switch
MDPS7.5AMDPS (Motor Driven Power Steering) Unit
MODULE 77.5ARear Seat Warmer Control Module, Front Seat Warmer Control Module, Front Air Ventilation Seat Control
Module
SUNROOF 115ASunroof Motor
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Maintenance
66
7
Engine room compartment fuse panel
Fuse Name Fuse ratingCircuit Protected
MULTI
FUSE-1ALTERNATOR
200A
(NU 2.0L AKS) 150A
(GAMMA 1.6L T-GDI)
Fuse : BURGLAR ALARM, ABS1, ABS2, POWER OUTLET1, Alternator
MDPS80AMDPS (Motor Driven Power Steering) Unit
MULTI
FUSE-2
B+560AFuse : ECU 3, ECU 4, HORN, WIPER, A/C, Engine Control Relay
B+260AInstrument Panel Junction Block
B+360AInstrument Panel Junction Block
B+450AInstrument Panel Junction Block (Fuse : POWER WINDOW LH, POWER WINDOW RH,
TRUNK, SUNROOF 1, SEAT HEATER FRONT, AMP, POWER SEAT DRIVER)
COOLING FAN 160A[GAMMA 1.6L T-GDI] Cooling Fan 1 Relay
REAR HEATED40ARear Heated Relay
BLOWER40ABLOWER Relay
IG140AIgnition Switch, PDM #2 (ACC) Relay, PDM #3 (IG1) Relay
IG240AIgnition Switch, PDM #4 (IG2) Relay
MULTI
FUSE-3PTC HEATER50APTC Heater Relay
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797
Maintenance
Cleaning the upholstery and inte-rior trim
Vinyl
Remove dust and loose dirt from
vinyl with a whisk broom or vacuum
cleaner. Clean vinyl surfaces with a
vinyl cleaner.
Fabric
Remove dust and loose dirt from fab-
ric with a whisk broom or vacuum
cleaner. Clean with a mild soap solu-
tion recommended for upholstery or
carpets. Remove fresh spots imme-
diately with a fabric spot cleaner. If
fresh spots do not receive immediate
attention, the fabric can be stained
and its color can be affected. Also, its
fire-resistant properties can be
reduced if the material is not proper-
ly maintained.
Using anything but recommended
cleaners and procedures may affect
the fabric’s appearance and fire-
resistant properties.
Cleaning the lap/shoulder beltwebbing
Clean the belt webbing with any mild
soap solution recommended for
cleaning upholstery or carpet. Follow
the instructions provided with the
soap. Do not bleach or re-dye the
webbing because this may weaken it.
Cleaning the interior windowglass
If the interior glass surfaces of the
vehicle become fogged (that is, cov-
ered with an oily, greasy or waxy
film), they should be cleaned with a
glass cleaner. Follow the directions
on the glass cleaner container.
CAUTION- Rear window
Do not scrape or scratch theinside of the rear window. Thismay result in damage of the rearwindow defroster grid.
CAUTION - Electrical
components
Never allow water or other liq-uids to come in contact withelectrical/electronic compo-nents inside the vehicle as thismay damage them.
CAUTION - Leather
When cleaning leather products(steering wheel, seats etc.), useneutral detergents or low alco-hol content solutions. If you usehigh alcohol content solutionsor acid/alkaline detergents, thecolor of the leather may fade orthe surface may get stripped off.
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