Kia VISTO User manual

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GENERAL INFORMATION
GENERAL EATC0100
HOW TO USE THIS MANUAL
This manual is divided into 21 sections. The first page of each section is marked with a black tab at the edge of the
page. You can quickly find the first page of each section without looking through the whole table of contents.
Each section includes the essential removal, installation, adjustment and maintenance procedures for servicing all
body styles. This information is correct at the time of publication.
An INDEX is provided on the first page of each section to guide you to the appropriate item.
TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the
cause. The repair for each possible cause is referred to in the remedy column to lead you to the solution quickly.
DEFINITION OF TERMS
Standard Value (Service standard)
Indicates the value used when a part or assembled item should be inspected, or the value to which a part or
assembled item should be adjusted after reinstallation. It is given by a tolerance.
Service Limit
Indicates the maximum or minimum value that a part or assembled item must meet when inspected. It is a value
established beyond the standard value.
NOTE, WARNING , CAUTION, ABBREVIATION
NOTE
Information needed in reference to a repair service.
CAUTION
Information about an activit
y
that could cause dama
g
e to the vehicle.
WARNING
Information about an activity that could cause injury or damage to the driver, occupants or
repairman.
ABBREVIATIONS
SOHC : Single Over Head Camshaft
VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number (VIN) is located on the top of the fire wall.

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VEHICLE IDENTIFICATION NUMBER
The vehicle identification number consists of 17 digits.
1. W.I.C. (World manufacturer's Identification Code)
KMH - Hyundai Motor Company, Korea
2. Vehicle Line
A : ATOS
3. Model & Series
F : Standard (L)
G : Deluxe (GL)
H : Super deluxe (GLS)
4. Body Type
5 : Sedan 5DR
5. Restraint system
0 - Both sides (None)
1 - Both sides (A/Belt)
2 - Both sides (P/Belt)
3 - Driver side : A/ Belt + A/Bag, Passenger side : P/Belt
4 - A/ Belt + A/ Bag (Driver side + Passenger side)
5 - Depowered A/Bag
NOTE
A/Belt : Active belt
P/Belt : Passive belt
A/Bag : Air bag
6. Engine type
G : G 1.0 S
7. Check digit or others
P : LHD (Left Hand Driver)
R : RHD (Right Hand Driver0
8. Production year
Y - 2000 Model Year, 2 - 2002 Model Year
1 - 2001 Model Year, 3 - 2003 Model Year
9. Production plant
U - Ulsan (Korea)
10. Vehicle production sequence number
000001 - 999999

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ENGINE IDENTIFICATION NUMBER LOCATION
The engine identification number is stamped on the right front side of the top edge of the cylinder block.
DESCRIPTION OF ENGINE IDENTIFICATION NUMBER
The engine identification number consists of 11 digits.
1. Engine fuel
G - Gasoline
2. Engine range
4 - In line 4 cycle 4 cylinder
3. Engine development order
H : Epsilon engine
4. Engine capacity
C : 999cc
5. Production year
X - 1999
Y - 2000
1 - 2001
2 - 2002
6. Engine production sequence number
000001 - 999999
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas before starting work.

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CAUTION
The support rod must be inserted into the hole near the edge of the hood whenever you inspect the
engine compartment to prevent the hood from falling and causing passible injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure
the hood is firmly latched before driving the vehicle.
A WORD ABOUT SAFETY
The following precautions must be followed when jacking up the vehicle.
1. Block the wheels.
2. Place a jack under the specified jacking point.
3. Support the vehicle with safety stands (jack stands) Refer to the page GI-10.
4. Start the engine when engine compartment is clear.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT
Be sure that all necessary tools and measuring equipment are available before starting work.
SPECIAL TOOLS
Use special tools when they are required.
REMOVAL OF PARTS
First find the cause of the problem and then determine whether removal or disassembly is required before starting
the job.
DISASSEMBLY
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled
in a way that will not affect their performance or external appearance.

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1. Inspection of parts
Each part, when removed, should be carefully inspected for malfunction, deformation, damage, and other
problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.
3. Cleaning parts for reuse
All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.
PARTS
When replacing parts, use HYUNDAI genuine parts.

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REPLACEMENT
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
Depending on their location.
1. Sealant should be applied to gaskets.
2. Oil should be applied to the moving components of parts.
3. Specified oil or grease should be applied to the prescribed locations (oil seals, etc.) before assembly.

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ADJUSTMENT
Use gauges and testers to adjust correctly the parts to standard values correctly.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wires when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully. Be careful not to drop them or hit them against other parts.
RUBBER PARTS AND TUBES
Always prevent gasoline or oil from touching rubber parts or tubing.

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MEASURING BODY DIMENSIONS
1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending
3. For measuring dimensions, both projected dimensions and actual-measurement dimensions are used in this
manual.
DIMENSIONS PROJECTED
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface,
and are the reference dimensions used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long
as the different value in height of the two surfaces.
MEASURING ACTUAL DIMENSIONS
1. These dimensions indicate the actual linear distance between measurement points, and are used as the
reference dimensions when a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement.
NOTE
Check the probes and
g
au
g
e itself to make sure there is no free pla
y
.

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MEASUREMENT POINT
Measurements should be taken at the center of the hole.
CHECKING CABLES AND WIRES
1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the
vehicle's body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to prevent contact with sharp corners of the vehicle body, etc. or hot
parts (exhaust manifold, etc.)
9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other
rotating or moving parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the
vehicle body and the engine.
CHECKING FUSES
A blade type fuse has test taps provided to allow checking the fuse itself without removing it from the fuse block.
The fuse is good if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other
lead is grounded. (Turn the ignition switch so that the fuse circuit becomes operative.)