steering KIA Optima 2016 4.G Repair Manual

813
Maintenance
Normal Maintenance Schedule (CONT.)
72,000 km (45,000 miles) or 36 months
❑Inspect air cleaner filter
❑Inspect all latch, hinges and locks
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake hoses/lines and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑ Replace climate control air filter (for evaporator and blower unit)
❑Replace engine oil and filter (2.4 GDI) *3
(72,000 km (45,000 miles) or 72 months)
❑Replace spark plugs (iridium coated), (1.6TGDI/2.0TGDI)
❑ Add fuel additive *4 (72,000 km (45,000 miles) or 72 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
84,000 km (52,500 miles) or 42 months
❑Inspect air cleaner filter
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑Replace engine oil and filter (2.4 GDI) *3
(84,000 km (52,500 miles) or 84 months)
❑ Add fuel additive *4 (84,000 km (52,500 miles) or 84 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
*3Engine oil (1.6 TGDI/2.0 TGDI) At first, replace at 5,000 km (3,000 miles) or
6 months, after that, every 8,000 km (5,000 miles) or 6 months.
*
4If 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.
❈ Inspect : Inspect and if necessary, adjust, correct, clean or replace.
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Maintenance
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8
96,000 km (60,000 miles) or 48 months
❑ Inspect all latch, hinges and locks
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake hoses/lines and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect brake fluid
❑Inspect fuel cap, fuel lines, fuel hoses and connections
❑Inspect fuel tank air filter (if equipped) *1
❑Inspect parking brake
❑Inspect vapor hose and fuel filler cap
❑Inspect valve clearance (if equipped) *2
(Every 96,000 km (60,000 miles) or 72 months)
❑Inspect drive belts
(First, 96,000 km (60,000 miles) or 72 months
after every 24,000 km (15,000 miles) or 24 months)
(Continued)
(Continued)
❑ Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑ Replace climate control air filter (for evaporator and blower unit)
❑Replace air cleaner filter
❑Replace engine oil and filter (2.4 GDI) *3
(96,000 km (60,000 miles) or 96 months)
❑Replace coolant (First, 96,000 km (60,000 miles) or 60 months
after every 48,000 km (30,000 miles) or 24 months)
❑ Add fuel additive *4 (96,000 km (60,000 miles) or 96 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
Normal Maintenance Schedule (CONT.)
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Maintenance
16
8
120,000 km (75,000 miles) or 60 months
❑ Inspect air cleaner filter
❑Inspect all latch, hinges and locks
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake hoses/lines and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect drive belts
(First, 96,000 km (60,000 miles) or 72 months
after every 24,000 km (15,000 miles) or 24 months)
❑ Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑ Inspect dual clutch transmission fluid (if equipped)
❑Replace climate control air filter (for evaporator and blower unit)
❑Replace engine oil and filter (2.4 GDI) *3
(120,000 km (75,000 miles) or 120 months)
❑ Add fuel additive *4 (120,000 km (75,000 miles) or 120 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
132,000 km (82,500 miles) or 66 months
❑Inspect air cleaner filter
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑Replace engine oil and filter (2.4 GDI) *3
(132,000 km (82,500 miles) or 132 months)
❑ Add fuel additive *4 (132,000 km (82,500 miles) or 132 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
*3Engine oil (1.6 TGDI/2.0 TGDI) At first, replace at 5,000 km (3,000 miles) or
6 months, after that, every 8,000 km (5,000 miles) or 6 months.
*
4If 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.
❈ Inspect : Inspect and if necessary, adjust, correct, clean or replace.
Normal Maintenance Schedule (CONT.)
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817
Maintenance
Normal Maintenance Schedule (CONT.)
156,000 km (97,500 miles) or 78 months
❑Inspect air cleaner filter
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑Replace engine oil and filter (2.4 GDI) *3
(156,000 km (97,500 miles) or 156 months)
❑ Add fuel additive *4 (156,000 km (97,500 miles) or 156 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
144,000 km (90,000 miles) or 72 months
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake hoses/lines and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect brake fluid
❑Inspect fuel cap, fuel lines, fuel hoses and connections
❑Inspect fuel tank air filter (if equipped) *1
❑Inspect parking brake
❑Inspect vapor hose and fuel filler cap
❑Inspect drive belts (First, 96,000 km (60,000 miles) or 72 months
after every 24,000 km (15,000 miles) or 24 months)
❑ Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑ Replace climate control air filter (for evaporator and blower unit)
❑Replace air cleaner filter
❑Replace engine oil and filter (2.4 GDI) *3
(144,000 km (90,000 miles) or 144 months)
(Continued)
*1Fuel tank air filter are considered to be maintenance free but periodic inspec-
tion is recommended for this maintenance schedule depends on fuel quality.
*
3Engine oil (1.6 TGDI/2.0 TGDI) At first, replace at 5,000 km (3,000 miles) or
6 months, after that, every 8,000 km (5,000 miles) or 6 months.
*
4If 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.
❈ Inspect : Inspect and if necessary, adjust, correct, clean or replace.
(Continued)
❑Replace spark plugs (iridium coated), (1.6TGDI/2.0TGDI)
❑Replace coolant (First, 96,000 km (60,000 miles) or 60 months
after every 48,000 km (30,000 miles) or 24 months)
❑ Add fuel additive *4 (144,000 km (90,000 miles) or 144 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
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Maintenance
18
8
168,000 km (105,000 miles) or 84 months
❑ Inspect air cleaner filter
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake hoses/lines and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect drive belts
(First, 96,000 km (60,000 miles) or 72 months
after every 24,000 km (15,000 miles) or 24 months)
❑ Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑ Replace climate control air filter (for evaporator and blower unit)
❑Replace spark plugs (iridium coated) (2.4 GDI)
❑Replace engine oil and filter (2.4 GDI) *3
(168,000 km (105,000 miles) or 168 months)
❑ Add fuel additive *4 (168,000 km (105,000 miles) or 168 months
❑Rotate tire position (Every 12,000 km (7,500 miles))
180,000 km (112,500 miles) or 90 months
❑Inspect air cleaner filter
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑Inspect dual clutch transmission fluid (if equipped)
❑Replace engine oil and filter (2.4 GDI) *3
(180,000 km (112,500 miles) or 180 months)
❑ Add fuel additive *4 (180,000 km (112,500 miles) or 180 months
❑Rotate tire position (Every 12,000 km (7,500 miles))
*3Engine oil (1.6 TGDI/2.0 TGDI) At first, replace at 5,000 km (3,000 miles) or
6 months, after that, every 8,000 km (5,000 miles) or 6 months.
*
4If 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.
❈ Inspect : Inspect and if necessary, adjust, correct, clean or replace.
Normal Maintenance Schedule (CONT.)
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819
Maintenance
Normal Maintenance Schedule (CONT.)
192,000 km (120,000 miles) or 96 months
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake hoses/lines and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect brake fluid
❑Inspect fuel cap, fuel lines, fuel hoses and connections
❑Inspect fuel tank air filter (if equipped) *1
❑Inspect parking brake
❑Inspect vapor hose and fuel filler cap
❑Inspect valve clearance (if equipped) *2
(Every 96,000 km (60,000 miles) or 72 months)
❑Inspect drive belts (First, 96,000 km (60,000 miles) or 72 months
after every 24,000 km (15,000 miles) or 24 months)
❑ Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑ Replace climate control air filter (for evaporator and blower unit)
❑Replace air cleaner filter
(Continued)
*1Fuel tank air filter are considered to be maintenance free but periodic inspec-
tion is recommended for this maintenance schedule depends on fuel quality.
*
2Inspect for excessive tappet noise and/or engine vibration and adjust if nec-
essary.
*
3Engine oil (1.6 TGDI/2.0 TGDI) At first, replace at 5,000 km (3,000 miles) or
6 months, after that, every 8,000 km (5,000 miles) or 6 months.
*
4If 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.
❈ Inspect : Inspect and if necessary, adjust, correct, clean or replace.
204,000 km (127,500 miles) or 102 months
❑Inspect air cleaner filter
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑Replace engine oil and filter (2.4 GDI) *3
(204,000 km (127,500 miles) or 204 months)
❑ Add fuel additive *4 (204,000 km (127,500 miles) or 204 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
(Continued)
❑Replace engine oil and filter (2.4 GDI) *3
(192,000 km (120,000 miles) or 192 months)
❑Replace coolant (First, 96,000 km (60,000 miles) or 60 months
after every 48,000 km (30,000 miles) or 24 months)
❑ Add fuel additive *4 (192,000 km (120,000 miles) or 192 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
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Maintenance
20
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Normal Maintenance Schedule (CONT.)
216,000 km (135,000 miles) or 108 months
❑ Inspect air cleaner filter
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake hoses/lines and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect drive belts
(First, 96,000 km (60,000 miles) or 72 months
after every 24,000 km (15,000 miles) or 24 months)
❑ Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑ Replace climate control air filter (for evaporator and blower unit)
❑Replace engine oil and filter (2.4 GDI) *3
(216,000 km (135,000 miles) or 216 months)
❑Replace spark plugs (iridium coated), (1.6TGDI/2.0TGDI)
❑ Add fuel additive *4 (216,000 km (135,000 miles) or 216 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
228,000 km (142,500 miles) or 114 months
❑Inspect air cleaner filter
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑Replace engine oil and filter (2.4 GDI) *3
(228,000 km (142,500 miles) or 228 months)
❑ Add fuel additive *4 (228,000 km (142,500 miles) or 228 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
*3Engine oil (1.6 TGDI/2.0 TGDI) At first, replace at 5,000 km (3,000 miles) or
6 months, after that, every 8,000 km (5,000 miles) or 6 months.
*
4If 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.
❈ Inspect : Inspect and if necessary, adjust, correct, clean or replace.
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821
Maintenance
Normal Maintenance Schedule (CONT.)
240,000 km (150,000 miles) or 120 months
❑Inspect battery condition
❑Inspect cooling system hoses and connections
❑Inspect clutch (if equipped) and brake pedal free play
❑Inspect vacuum hose
❑Inspect air conditioning refrigerant
❑Inspect brake hoses/lines and connections (including booster)
❑Inspect drive shafts and boots
❑Inspect exhaust pipe and muffler
❑Inspect front brake disc/pads, calipers
❑Inspect rear brake disc/pads
❑Inspect steering gear box, linkage & boots/lower arm ball joint,
upper arm ball joint
❑ Inspect suspension mounting bolts
❑Inspect brake fluid
❑Inspect fuel cap, fuel lines, fuel hoses and connections
❑Inspect fuel tank air filter (if equipped) *1
❑Inspect parking brake
❑Inspect vapor hose and fuel filler cap
❑Inspect drive belts
(First, 96,000 km (60,000 miles) or 72 months
after every 24,000 km (15,000 miles) or 24 months)
❑ Inspect intercooler, in/out hose, air intake hose
- Turbo GDI (Every 12,000 km (7,500 miles) or 12 months)
❑Inspect dual clutch transmission fluid (if equipped)
❑ Replace climate control air filter (for evaporator and blower unit)
(Continued)
(Continued)
❑Replace air cleaner filter
❑Replace engine oil and filter (2.4 GDI) *3
(240,000 km (150,000 miles) or 240 months)
❑Replace coolant (First, 96,000 km (60,000 miles) or 60 months
after every 48,000 km (30,000 miles) or 24 months)
❑ Add fuel additive *4 (240,000 km (150,000 miles) or 240 months)
❑Rotate tire position (Every 12,000 km (7,500 miles))
No check, No service required
❑Automatic transmission fluid (if equipped)
*1Fuel tank air filter are considered to be maintenance free but periodic inspec-
tion is recommended for this maintenance schedule depends on fuel quality.
*
3Engine oil (1.6 TGDI/2.0 TGDI) At first, replace at 5,000 km (3,000 miles) or
6 months, after that, every 8,000 km (5,000 miles) or 6 months.
*
4If 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.
❈ Inspect : Inspect and if necessary, adjust, correct, clean or replace.
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Maintenance
22
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Maintenance Under Severe Usage Conditions
Severe Driving Conditions
A - Repeatedly driving short distance of less than 8 km (5 miles) in normal
temperature or less than 16 km (10 miles) 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 (106 mph)
K - Frequently driving in stop-and-go conditions
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 filter (2.4 GDI)REvery 6,000 km (3,750 miles) or 6 monthsA, B, C, D, E, F, G,
H, I, J, K
Engine oil and filter (1.6 TGDI/2.0 TGDI)REvery 5,000 km (3,000 miles) or 3 months
Air cleaner filterRMore frequentlyC, E
Spark plugsRMore frequentlyB, H
Automatic transmission fluidREvery 96,000 km (60,000 miles)A, C, E, F, G, I
Dual clutch transmission fluid REvery 120,000 km (75,000 miles)A, C, E, F, G, H, I, J
Front brake disc/pads, calipersIMore frequentlyC, D, G, H
Rear brake disc/padsIMore frequentlyC, D, G, F
Parking brakeIMore frequentlyC, D, G, H
Steering gear box, linkage & boots/lower arm ball joint,
upper arm ball jointIMore frequentlyC, D, E, F, G, H, I
Drive shafts and bootsIEvery 12,000 km (7,500 miles) or 6 monthsC, D, E, F, G, H, I, J
Climate control air filter (for evaporator and blower unit)RMore frequentlyC, E
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Maintenance
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8
Brake discs, pads, calipers
and rotors
Check the pads for excessive wear,
discs for run out and wear, and
calipers for fluid leakage.
Exhaust pipe and muffler
Visually inspect the exhaust pipes,
muffler and hangers for cracks, dete-
rioration, or damage. Start the
engine and listen carefully for any
exhaust gas leakage. Tighten con-
nections or replace parts as neces-
sary.
Suspension mounting bolts
Check the suspension connections
for looseness or damage. Retighten
to the specified torque.
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 dam-
age.
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