Engine KIA Rio 2005 2.G Service Manual

Emission Control SystemThe vehicle emission control system is covered by a
written limited warranty. Please see the warranty
information contained in the Warranty & Consumer
Information Manual in your vehicle.Vehicle ModificationsThis vehicle should not be modified. Modification of
your Kia 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.
Engine Exhaust Gas Precautions
(Carbon Monoxide)Engine exhaust gases contain carbon monoxide.
Though colorless and odorless, it is dangerous and
could be lethal, if inhaled.
 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 by an Authorized Kia Dealer.
If at all possible, do not drive with exhaust fumes
present. If you must, do so only with all windows
fully open. Have your vehicle checked and repaired
immediately.
 Do not operate the engine in confined or 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 to draw outside air into
the vehicle. Turn the engine off if you smell any
exhaust fumes.
 Never sit in a parked or stopped vehicle for an
extended time with the engine running.
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Operating Precautions for Catalytic ConvertersYour vehicle is equipped with a catalytic converter
emission control device.
Therefore, the following precautions must be observed:
 Use only UNLEADED FUEL.
 Do not park the vehicle over or near flammable
objects, such as dry grass, paper, leaves, etc. Under
certain conditions, they could be ignited by a hot
exhaust system.
 Do not operate the vehicle when there are signs of
engine malfunction, such as misfire or a noticeable
loss of performance.
 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 system. All inspections and
adjustments must be made by a qualified technician.
Failure to observe the above precautions could result in
damage to the catalytic converter and to your vehicle
and could void your warranties.
Before DrivingBefore entering vehicle:
 Be sure that all windows, outside mirror(s), and
outside lights are clean.
 Check the condition of the tires.
 Check under the vehicle for any sign of leaks.
 Be sure there are no obstacles behind you if you
intend to back up.
Driving Tips5-4
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Necessary InspectionsFluid levels, such as engine oil, engine coolant,
brake/clutch fluid, and washer fluid should be checked
on a regular basis, with the exact interval depending on
the fluid. Further details are provided in Maintenance,
Section 7.Before Starting Close and lock all doors.
 Position the seat so that all controls are easily
reached.
 Adjust the inside and outside rearview mirrors.
 Be sure that all lights work.
 Check all gauges.
 Check the operation of warning lights when the
ignition switch is turned to the ON position.
 Release the parking brake and make sure the brake
warning light goes out.
For safe operation, be sure you are familiar with your
vehicle and its equipment.
Drunk DrivingDrinking and driving is dangerous. Drunk driving is
the number one contributor to the highway death toll
each year. Alcohol impairs a driver’s judgment, vision
and muscular coordination. Even a small amount of
alcohol will affect a driver’s reflexes, perceptions and
judgment.
Please don’t drink and drive, or ride with a driver who
has been drinking. Choose a designated driver if you’re
with a group, or if you’re alone, call a cab.Drugs and DrivingDriving while under the influence of drugs is as
dangerous or more dangerous than driving under the
influence of alcohol, depending on the drug(s) used
and the quantity consumed. Don’t take drugs and drive.
If you are taking a prescription medicine, check with
your doctor or pharmacist regarding whether you may
operate a motor vehicle.
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Suggestions for Economical
OperationYour vehicle’s fuel economy is mainly dependent on
your style of driving, how you drive, where you drive
and when you drive.
Each of these factors has an effect on how many miles
(kilometers) you can get from a gallon (liter) of fuel.
To operate your vehicle as economically as possible,
use the following driving suggestions to help save
money in both fuel and repairs:
 Avoid lengthy warm-up idling. Once the engine
is running smoothly, begin driving. Remember,
though, that on cold days, engine warm-up may take
a little longer.
 Save fuel by accelerating slowly after stopping.
 Keep the engine in tune and follow the
recommended periodic maintenance schedule.
This will increase the life of all parts and lower your
operating costs.
 Do not use the air conditioner unnecessarily.
 Slow down when driving on rough roads. For longer tire life and better fuel economy, always
keep the tires inflated to the recommended
pressures.
 Maintain a safe distance from other vehicles to
avoid sudden stops. This will reduce wear on brake
linings and pads and save fuel because extra fuel is
required to accelerate back to driving speed.
 Do not carry unnecessary weight in the vehicle.
 Do not rest your foot on the brake pedal while
driving. This can cause needless wear, possible
damage to the brakes, and poor fuel economy.
 Improper wheel alignment causes the tires to roll
at excessive angles, which results in faster tire wear.
It takes more power to overcome this improper
alignment, which wastes fuel.
 Open windows at high speeds can reduce fuel
economy.
 Crosswinds and headwinds reduce fuel economy. To
help offset some of this loss, slow down when
driving in these conditions.Driving Tips5-6
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Keeping a vehicle in good operating condition is
important both for economy and safety. Therefore,
have an Authorized Kia Dealer perform scheduled
inspections and maintenance.
Special Driving ConditionsHazardous DrivingWhen hazardous driving is encountered because of
water, snow, ice, mud, sand, or similar hazard, follow
these suggestions:
 Drive cautiously and allow extra distance for
braking.
 Avoid sudden movements in braking or steering.
 When braking in vehicles without anti-lock brakes,
depress the brake pedal with a controlled up-and-
down motion until the vehicle is stopped.
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WARNING - Engine OFF Motion
Never turn the engine OFF to coast down hills
or anytime the vehicle is in motion. The power
steering and power brakes will not function
without the engine running. Instead, downshift
to any appropriate gear for engine braking
effect.
✽
NOTICE
Do not pump the brake pedal on ABS equipped
vehicle.
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Driving Tips5-8Rocking the Vehicle
If it is necessary to rock the vehicle to free it from
snow, sand, or mud, move the shift lever of an
automatic transaxle from D (Drive) to R (Reverse) in a
repeat pattern while depressing the accelerator gently.
With a manual transaxle, move the shift lever back and
forth from 1 (First) to R (Reverse).
Do not race the engine. If you are still stuck after a
couple minutes of rocking, have the vehicle pulled out
by a tow vehicle to avoid engine overheating and
possible damage to the transaxle.
✽
NOTICE
Prolonged rocking may cause engine overheating,
transaxle damage or failure, and tire damage.
WARNING - Spinning Tires
Do not spin the wheels especially at speeds
more than 56 km/h (35 mph). Spinning the
wheels at high speeds when the vehicle is
stationary could cause a tire to overheat,
explode and injure bystanders.
 When starting from a stop in snow, mud, or sand,
use second gear and accelerate slowly to avoid
spinning the front wheels. Low gear may be used, if
necessary.
 Use sand, rock salt, tire chains, or other non-slip
material under the front wheels to provide traction
when stalled on ice, snow, or mud.
WARNING - Downshifting
Downshifting into first gear with a manual
transaxle or into low with an automatic
transaxle while driving on slippery surfaces
can cause an accident. The sudden change in
tire speed could cause the tires to skid. Be
careful when downshifting on slippery
surfaces.
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Driving Tips5-10
Snow Tires
When snow tires are used, select the size and
construction specified on the Tire Pressure Label. It is
strongly recommended that snow tires be used on all
four wheels, or poor handling may result. Snow tires
should not be operated at speeds exceeding 75 mph
(120 km/h).
These tires should be inflated 4 psi (28 kPa,
0.3 kg/cm
2) above the recommended pressures shown
on the Tire Specification/Pressure Label, but inflation
should never exceed the maximum cold-tire pressure
shown on the tire sidewalls.
Do not install studded tires without first checking
local, provincial and municipal regulations for
possible restrictions against their use.
WARNING - Snow Tire Size
Snow tires should be equivalent in size and
type to the vehicle’s standard tires. Otherwise,
the safety and handling of your vehicle may be
adversely affected.
Winter Driving We recommend that you carry emergency
equipment. Some things you might include are tire
chains, a window scraper, windshield de-icer, a bag
of sand or salt, flares, a small shovel and jumper
cables.
 Make sure you have sufficient ethylene glycol
coolant in the radiator.
 Check the battery condition and cables. Cold
temperatures reduce the capacity of any battery, so it
must be in top shape to provide enough winter
starting power.
 Make sure the engine oil viscosity is suitable for
cold weather.
 Check the ignition system for loose connections and
damage.
 Use antifreeze-formulated windshield washer fluid
and make sure you have sufficient fluid for your
trip. (Do not use engine coolant antifreeze.)
 Do not use the parking brake if it might freeze. This
is most likely to happen after driving in slushy or
wet conditions and temperatures drop into the
freezing range. When parking, shift to P (Park) with
automatic transaxle, or to 1 (First) or R (Reverse)
with a manual transaxle and block the rear wheels.
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Road WarningHazard Warning FlasherThe hazard warning flasher serves as a warning to
other drivers to exercise extreme caution when
approaching, overtaking, or passing your vehicle. It
should be used whenever emergency repairs are being
made or when the vehicle is stopped near the edge of a
roadway.
Depress the flasher switch with the ignition switch in
any position. The flasher switch is located in the center
console. All turn signal lights will flash
simultaneously.
•The hazard warning flasher will operate whether
your vehicle is running or not.
The turn signals do not operate when the hazard
flasher is
ON
.
Care must be taken when using the hazard warning
flasher while the vehicle is being towed. Local
regulations may prohibit using it in this manner.
OverheatingIf your temperature gauge indicates overheating, if you
experience a loss of power, or if you hear a loud
knocking or pinging noise, the engine has probably
overheated. You should follow these procedures if you
experience any of these symptoms.
1. Turn the hazard warning flasher ON, then drive to
the nearest safe location and stop your vehicle; set
the automatic transaxle in P (Park), or shift the
manual transaxle to neutral and apply the parking
brake.
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2. Make sure the air conditioner is off.
3. If coolant or steam is boiling out of the radiator,
stop the engine, then turn the ignition switch to the
ON position. Do not restart the engine. The radiator
cooling fan will automatically operate with the
ignition switch in the ON position. If the cooling
fan does not operate, 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 reservoir 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 problem that may have
caused the engine to overheat, do not operate the
engine until the problem has been corrected. Call
an Authorized Kia Dealer for assistance.
If you do not find a leak or other problem, carefully
add coolant to the reservoir.
If the engine frequently overheats, have the cooling
system checked and repaired.
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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 serious injury.
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4. Turn off all unnecessary electrical loads.
5. Connect the jumper cables in the exact sequence
shown in the illustration on the previous page.
First, connect one end of a jumper cable to the
positive terminal (+) of the discharged battery ,
then the other end of the same cable to the positive
terminal (+) on the booster battery . Next,
connect one end of the other jumper cable to the
negative terminal (–) of the booster battery , then
the other end to a solid, stationary, metallic point
(for example, the engine lifting bracket) away
from the battery. Do not connect the jumper cable
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 discharged battery. Do
not allow the jumper cables to contact anything
except the correct battery terminals or the correct
ground. Do not lean over the battery when making
connections.6. Start the engine of the vehicle with the booster
battery and run it at 2,000 rpm. Then, start the
engine of the vehicle with the discharged battery.
If the cause of your battery discharging is not apparent
(for example, having left the lights on accidentally),
you should have your vehicle checked by an Authorized
Kia Dealer.
Push-StartingA vehicle equipped with an automatic transaxle cannot
be started by pushing. A vehicle equipped with a
manual transaxle should not be push-started because it
could damage the emission control system. Follow the
directions for jump starting.
In Case Of An Emergency6-6
CAUTION
Never tow a vehicle to start it. A sudden surge
forward when the engine starts could cause a
collision with the tow vehicle.
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