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Servicing The Electrical System

  1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.
    NOTE: In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by the computer will be cleared. There fore, if necessary, read the diagnostic before removing the battery cable.
    Fig 1: Disconnecting Battery Ground Cable
    G04882030Courtesy of KIA MOTORS AMERICA, INC.
  2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to come into contact with any of the surrounding parts and then secure the harness by using a clamp.
    Fig 2: Identifying Cable And Wire Clamp
    G04882031Courtesy of KIA MOTORS AMERICA, INC.
  3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or something similar in order to protect if from damage.
    Fig 3: Section Of Wiring Harness
    G04882032Courtesy of KIA MOTORS AMERICA, INC.
  4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
    Fig 4: Pinching Wiring Harness
    G04882033Courtesy of KIA MOTORS AMERICA, INC.
  5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
    Fig 5: Caution For Relay, Sensor And Electrical Parts
    G04882034Courtesy of KIA MOTORS AMERICA, INC.
  6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.
    Fig 6: Caution For Electronic Parts
    G04882035Courtesy of KIA MOTORS AMERICA, INC.
  7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
    Fig 7: Identifying Connectors
    G04882036Courtesy of KIA MOTORS AMERICA, INC.
  8. When disconnecting a connector, be sure to grip only the connector, not the wires.
    Fig 8: Caution For Connectors
    G04882037Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.
    Fig 9: Pressing Connector
    G04882038Courtesy of KIA MOTORS AMERICA, INC.
  10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
    Fig 10: Connecting Connectors
    G04882039Courtesy of KIA MOTORS AMERICA, INC.
  11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until contacts the terminal, being careful not to damage the insulation of the wires.
    Fig 11: Inserting Test Probe Through Hole In Rubber Cap
    G04882040Courtesy of KIA MOTORS AMERICA, INC.
  12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the appropriate wire size.
    WIRE SIZE SPECIFICATIONS CHART

    Nominal size SAE gauge No. Permissible current
    In engine compartment Other areas
    0.3mm2 AWG 22 - 5A
    0.5mm2 AWG 20 7A 13A
    0.85mm2 AWG 18 9A 17A
    1.25mm2 AWG 16 12A 22A
    2.0mm2 AWG 14 16A 30A
    3.0mm2 AWG 12 21A 40A
    5.0mm2 AWG 10 31A 54A
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