- Pregto . Workshop Manual | FOREWORD Seneaioee i_General information This Workshop Manual provides information — Favgiing normal service, repairs, and maintenance, Engivie(d2 Engine) for all systems of the Pregio, " Engine(ata En This manual is organised into Groups covering = —— —— “Proeral systems. . Within each=Group, the |: Lubrication System(i2 Engine) : information is further divided into Sections. There is | Lubrication System(JTA Engine) i> ghe Section for each component or sub-system ee ine) Some Groups contain. a Service Section to cover “| Cooling System(s2 Engine) ’ Subgystome gainer o.several components or n s¥StemU2 Engine) > subsystems within the Group. In general, sacy |_ Cooling Systemeita Engine) Section contains an Outline Description, ine § [foubleshooting, Adjustments, - Remcval ;_dnleke and Exhaust Sy ; Installation, Disassembly, Assembly and Inspection procedures for the component covered in tne Section. “Diagnosis and. Testing is inclucted in ine first section of some Groups to help you. systematically locate and correct probiecs encountered. -In.most cases, Specifications are included al the end of each Settion 7o.810 in locating specitic subjects'in this manual, use the Table of Contents cn the following pages, 8 a lirther ai, tere is inden onthe feet page ot each Group which lists the Section tila lar sage Component covered within the group. this Group Section. breakdown is also indicated in the page number iocated at the top of each page, Example: 424-35 = (Group) 424, (Page) 36, gine} stom{sTA En lem{JTA Enging} ihe, Ce8erptions and specications containein this manual Kae vceatat a the tin this man was approved fr pining Ue Motors Corouration raserves the right to iscontinus ove, Kia Motors Corporation SEOUL, KOREA Alr Conditioner GS Ay Copyright © 2001, kia Motors Ccrporation ‘ Bi. rntezia Korea Fasano: WARNING oy Appropriate service methods and proper repair procedures are essential forthe safe, reliable operation of all motor vehicles as well as the personal safely of:the individual doing the repair. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well aS in the skill Of the-individual doing the work. This manual cannot possibly anticipate all such variations and provide’ advice or caution to each. ‘Accordingly, anyone who departs from the instruction provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools, or parts. The following list contains. general warnings that should always be followed while working on a vehicle. + Always wear safety glasses for eye protection. + Use Safely stands whenever a procedure requires underbody work. Be sure ignition switch is always off unless otherwise specified by a procedure. Set the parking brake when working on the vehicle. Operate the engine only in a well ventilated area. Keep clear of moving parts when engine is running + To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. + Do not smoke while working on a vehicle. CAUTION oo Severe engine and transaxle damage may resift from the use of poor quality fuels and lubricants that do not meet Kia speciticalions. You must always use high quality fuels and lubricants that meet the specifications described on the specification section in the relevant group of the Workshop Manual.bei | i sd GENERAL INFORMATION ot | ABBREVIATIONS enesanon 0 8 i FUNDAMENTAL PROCEDURE 0-8 i IDENTIFICATION NUMBER LO: 0-9 ’ YAGK AND SAFETY STAND POSITIONS |. 00- 7 fl. i” TOWING . 0o- 8 | SITS ~00- § \ i 00-7 | | i iFUNDAMENTAL PROCEDURES GENERAL. INFORMATION 00-3 fi * FUNDAMENTAL PROCEDURES - SYMBOLS ‘There are six symbols indicating ol, grease, and seatinl, These symbols show ‘materials during service. the points of aopiying such _ Symbol Meaning i Apply oll ‘New engine oll or gear oil as appropriate i Apply brake Muid Only brake tuid ! | 5 - | | | ‘Apply automatic transaxie tid Oniy ATE : i Apply grease Appropriate grease |x! | en | ea | oat Apply sealant Appropriate sealant Sa @ ‘Apply petroleum jely | ‘Appropriste Note . +, When speciall oll or grease is needed, this is shown in the illustration, NOTES, CAUTIONS; AND WARNINGS ‘eeu, ead through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS, Each one is there for a speciic purpose. NOTES give you added information that wis help you to complete a particular Pagedure, CAUTIONS are given to prevent you from making an error thar eoces damage the vehicle. WARNINGS remind you to be especially careful in those areas, where carelessness can cause personal in- Jury. The following ist contains some general WARNINGS you should icin ates you work on a vehicle, PROTECTION OF THE VEHICLE Always be sure to cover fenders, seals, ard ‘loor areas belore- | starting work,00-4 GENERAL INFORMATION FUNDAMENTAL PROCEDURES: ‘AWORD ABOUT SAFETY e The following precautions must be followed when jacking up the vehicle, 1. Block the wheels. 2. Use only the specified jacking positions. 3. Support the vehicle with safely stands. Start the engine only after making certain the engine compari- ‘ments clear of tools and people. ( PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be’ sure that all necessary tools’and measuring equipment ara f avallable before starting any work. | q SPECIAL TOOLS Use special tools when they. are required. REMOVAL OF PARTS While correcting a problem, try also to determine its cause. Begin work only alter first learning which parts and subassem- 4 biies must be removed and disassembled for replacement of re- pair. DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that wil not affect their performance or external appearance and ‘identified so that reassembly can be performed easily and eff- ciently.FUNDAMENTAL PROCEDURES GENERAL INFORMATION 00-5 INSPECTION OF PARTS: When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. | ARRANGEMENT OF PARTS ‘All disassembled parts should be carclully arranged for re~ assembly. Be sure to separate or otherwise identify the parts to be re- | placed from those that will be reused. J CLEANING PARTS FOR REUSE All parts to be reused should be carefully and thoroughly ‘ cleaned in the appropriate method. ‘ REASSEMBLY: Standard values, such as torques and cerlain adjustments, vow must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones \ 4. Oil seals 2. Gaskets 3. O-rings (4. Lock washers . 5. Cotter pins 6. Nylon nuts Depending on location : c 4. Sealant should be spplied or new gaskets used. 2. Oil should be applied to the moving components cf par’. 8. Specified oll or grease should be applied al the prescribed locations (such as oil seals) before reassemblyADJUSTMENTS. Use sultable gauges and/or testers when making adjustments. RUBBER PARTS AND TUBING . Prevent gasoline or oil from getting on rubber parts ar tubingJACK AND SAFETY STAND POSITIONS, VEHICLE LIFT POSITIONS GENERAL INFORMATION 00-7 Us JACK AND SAFETY STAND POSITION FRONT END . Jack position : Safety stand positions : At the front crossmember On both sides of the body trae —] ole | NT e/ C | | | Be == | ee i - mai) — “ANS000007 REAR END Jack position : Safety stand position : ‘At the center of the axle housing On both sides of the axle housing | Vey U vu "eS r : : uy VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS . + FRONT END REAR END | + Side sills Side sils ~~ | Ton) ~ i I i ° J aTOWING Proper towing’ equipment is necessary to provent damage ‘c the vehicle during any towing operation. Laws and regulations applicable to vehicles in tov srs: ni be observed. As a tule, towed vehicles should be px! wheels off the ground. he With elther actomatic or manual transaxle 41. Set the ignition switch in the ACC positice 2. Place the selector lever or shill lever in (veutral) 3. Release the parking brake. Caution +” The power assist for the brakes and steering are in- operable while the erigine is off. +: Do not use the hook loops under the front or rear of the vehicle for towing, ‘These hook loops are de- signed ONLY for transport tiedown. If tiedown hook loops are used for towing the front or rear skirt and bumper will be damaged. RE