engine KIA Opirus 2004 1.G Repair Manual

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Driving tips
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HLA (Hydraulic Lash Adjuster)
noiseThe engine HLA's keep the gap
between the valve and cam at zero
regardless of the valve expansion.
Occasionally, you may hear a tempo-
rary or continuous sound (clatter)
from the engine when starting or
idling. This noise will usually go away
by following a few simple steps:If the temporary sound occurs when
starting a cold engine:
This is a normal condition. This
sound will disappear after the engine
oil has reached normal operating
pressure.
If the sound occurs when starting the
engine after the engine has not been
operated for more than 48 hours; or
engine has been cranked excessively:
This condition may be caused by oil
draining from the HLA's. This allows
air to enter the HLA causing insuffi-
cient lubricating oil in the HLA. This
will usually disappear within 15 min-
utes with the engine running at
2000~3000 rpm. If the sound does
not disappear, have the engine oil
pressure, engine lubrication system
and HLA's inspected by an
Authorized Kia Dealer.
CAUTION
Do not run the engine at more
than 3000 rpm until the noisegoes away. Damage to theHLA's could occur.
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Driving tips
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Load-pulling components such as
the engine, transaxle, wheel assem-
blies, and tires are forced to work
harder against the load of the added
weight. The engine is required to
operate at relatively higher speeds
and under greater loads. This addi-
tional burden generates extra heat.
The trailer also adds considerably to
wind resistance, increasing the
pulling requirements.
If you do decide to pull a trailerHere are some important points if
you decide to pull a trailer:
 Consider using a sway control. Youcan ask a hitch dealer about sway
control.
 After your odometer indicates 800 km (500 miles) or more, you can
tow a trailer. For the first 800 km
(500 miles) that you tow a trailer,
don’t drive over 80 km/h (50 mph)
and don’t make starts at full throt-
tle. This helps your engine and
other parts of your vehicle “wear” in
at the heavier loads.
 The important considerations have to do with weight: Weight of the trailer
How heavy can a trailer safely be? It
should never weigh more than 907
kg (2000 lbs.) with trailer brakes. But
even that can be too heavy.
It depends on how you plan to use
your trailer. For example, speed, alti-
tude, road grades, outside tempera-
ture and how much your vehicle is
used to pull a trailer are all important.
The ideal trailer weight can also
depend on any special equipment
that you have on your vehicle.
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Driving tips
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Do not connect a trailer lighting sys-
tem directly to your vehicle’s lighting
system. Use only an approved trailer
wiring harness.
Your Authorized Kia Dealer can
assist you in installing the wiring har-
ness.
Driving on grades Reduce speed and shift to a lower
gear before you start down a long or
steep downgrade. If you don’t shift
down, you might have to use your
brakes so much that they would get
hot and no longer operate efficiently.
On a long uphill grade, shift down
and reduce your speed to around 70
km/h (45 mph) to reduce the possi-
bility of engine and transaxle over-
heating.
If your trailer weighs more than 453
kg (1000 lbs.) and you have an auto-
matic transaxle, you should drive in
D (Drive) when towing a trailer.
Operating your vehicle in D (Drive)
when towing a trailer will minimize
heat buildup and extend the life of
your transaxle.
✽ ✽NOTICE• When towing a trailer on steep
grades (in excess of 12%) pay close
attention to the engine coolant
temperature gauge to ensure the
engine does not overheat. If the
needle of the coolant temperature
gauge moves across the dial
towards “H” (HOT), pull over and
stop as soon as it is safe to do so,
and allow the engine to idle until it
cools down. You may proceed once
the engine has cooled sufficiently.
• You must decide driving speed depending on trailer weight and
uphill grade to reduce the possibil-
ity of engine and transaxle over-
heating.
CAUTION
Failure to use an approved trail-
er wiring harness could result indamage to the vehicle electricalsystem and/or personal injury.
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Parking on hills Generally, you should not park your
vehicle, with a trailer attached, on a
hill. People can be seriously or fatal-
ly injured, and both your vehicle and
the trailer can be damaged if they
begin a downhill trajectory. However, if you ever have to park
your trailer on a hill, here’s how to do
it:
1. Apply your brakes, but don’t shift
into gear.
2. Have someone place chocks under the trailer wheels.
3. When the wheel chocks are in place, release the brakes until the
chocks absorb the load.
4. Reapply the brakes. Apply your parking brake, and then shift to P
(Park) for an automatic transaxle.
5. Release the brakes.
When you are ready to leave after parking on a hill 1. With the automatic transaxle in P (Park), apply your brakes and hold
the brake pedal down while you:
 Start your engine;
 Shift into gear; and
 Release the parking brake.
2. Slowly remove your foot from the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the chocks.
WARNING
- Parking brake
It can be dangerous to get out of
your vehicle if the parking brake
is not firmly set.
If you have left the engine run-
ning, the vehicle can move sud-
denly. You or others could be
seriously or fatally injured.
WARNING
- Parking on a hill
Parking your vehicle on a hill
with a trailer attached could
cause serious injury or death,
should a down hill trajectory
happen.
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Maintenance when trailer tow-
ing Your vehicle will need service more
often when you regularly pull a trail-
er. Important items to pay particular
attention include engine oil, automat-
ic transaxle fluid, axle lubricant and
cooling system fluid. Brake condition
is another important item to frequent-
ly check. Each item is covered in this
manual, and the Index will help you
find them quickly. If you’re trailering,
it’s a good idea to review these sec-
tions before you start your trip.
Don’t forget to also maintain your
trailer and hitch. Follow the mainte-
nance schedule that accompanied
your trailer and check it periodically.
Preferably, conduct the check at the
start of each day’s driving. Most
importantly, all hitch nuts and bolts
should be tight.
✽ ✽NOTICEDue to higher load during trailer
usage, overheating might occur in
hot days or during uphill driving. If
the coolant gauge indicates over-
heating, switch off the A/C and stop
the vehicle in a safe area to cool
down the engine.
OVERLOADING
CAUTION
The gross axle weight rating
(GAWR) and the gross vehicleweight rating (GVWR) for yourvehicle are on the manufactur-er's label attached to the dri-ver's door. Exceeding these rat-ings can cause an accident orvehicle damage. You can calcu-late the weight of your load byweighing the items (or people)before putting them in the vehi-cle. Be careful not to overloadyour vehicle.
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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)
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, allow
the 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 you
find a major leak or another prob-
lem that may have caused the
engine to overheat, do not operate
the 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 KiaDealer.
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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.
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In case of an emergency66Jump starting procedure 1. Make sure the booster battery is12-volt and that its negative termi-
nal is grounded.
2. If the booster battery is in another vehicle, do not allow the vehicles
to touch.
3. Turn off all unnecessary electrical loads.
4. Connect the jumper cables in the exact sequence shown in the pre-
vious illustration. First connect one
end of a jumper cable to the posi-
tive terminal of the discharged bat-
tery (
➀), then connect the other
end to the positive terminal on the
booster battery (
➁). Proceed to
connect one end of the other
jumper cable to the negative ter-
minal of the booster battery (
➂),
then the other end to a solid, sta-
tionary, metallic point (for exam-
ple, the engine lifting bracket)
away from the battery (
➃). Do not
connect it to or near any part that
moves when the engine is
cranked. Do not connect the
jumper cable from the negative
terminal of the booster battery to
the negative terminal of the dis-
charged battery. Do not allow the jumper cables to
contact anything except the cor-
rect battery terminals or the cor-
rect ground. Do not lean over the
battery when making connections.
5. Start the engine of the vehicle with the booster battery and let it run at
2,000 rpm, then start the engine of
the vehicle with the discharged
battery.
If the cause of your battery discharg-ing is not apparent, you should haveyour vehicle checked by anAuthorized Kia Dealer.
Refer to illustration on page 6-5.
Push-starting Vehicles equipped with automatic
transaxle cannot be push-started.
Follow the directions in this section
for jump-starting.
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CAUTION
Never tow a vehicle to start itbecause the sudden surge for-ward when the engine startscould cause a collision with thetow vehicle.
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67
In case of an emergency
ELECTRICAL CIRCUIT PROTECTION Fuses A vehicle’s electrical system is pro-
tected from electrical overload dam-
age by fuses.
This vehicle has two fuse panels,
one located in the driver's side knee
bolster, the other in the engine com-
partment 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 be melted.
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
indicates an electrical problem. Avoid
using the system involved and imme-
diately consult an Authorized Kia
Dealer.
Two kinds of fuses are used: stan-
dard for lower amperage rating andmain for higher amperage ratings.
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MMSA6003
Standard
Main fuse
Normal Normal Blown
Blown
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In case of an emergency86Fuse replacement
1. Turn the ignition switch and allother switches off.
2. Pull the suspected fuse straight out. Use the removal tool provided
on the main fuse box in the engine
compartment.
3. Check the removed fuse; replace it if it is blown.
Spare fuses are provided in thefuse panel.
4. Push in a new fuse of the same rating, and make sure it fits tightly
in the clips.
If it fits loosely, consult an Authorized
Kia Dealer.
If you do not have a spare, use a fuse of the same rating from a circuityou may not need for operating thevehicle, such as the radio or roomlamp fuse.If the headlights or other electrical
components do not work and the
fuses are OK, check the fuse block in
the engine compartment. If a fuse is
blown, it must be replaced.
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1GHA402
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
possibly a fire.
 Do not use a screwdriver or any other metal object to
remove fuses because it may
cause a short circuit and dam-
age the system.
Driver - side knee bolster
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In case of an emergency
To check the fuse or relay in the
engine compartment, remove the
engine compartment shroud.1. Turn the ignition switch and all
other switches off.
2. Remove the fuse box cover by removing the bolt on the cover and
unhooking the tab on one end and
tilting the cover back toward the
other end.
3. Check the fuses. If one is blown, replace it with a new one of the
same rating.
✽ ✽NOTICEAfter checking the fuse box in the
engine compartment, securely
install the fuse box cover. If not,
electrical failures may occur from
water leaking in.
Main fuseIf the BATT (60A) or ALT (140A) fuse
are blown, it must be removed as fol-
lows:
1. Disconnect the negative battery
cable.
2. Remove the screws shown in the picture above.
3. Replace the fuse with a new one of the same rating.
4. Reinstall in the reverse order of removal.
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1GHA404
1GHA411
1GHA405
Engine compartment
➀
➁
➂➀
Junction Box
➁ Main Fuse
➂ Relay Box
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