Torque Motor Kia

2005 Kia Sportage EX
2005-06 ENGINE General - 2.0L - Sportage
2005-06 ENGINE
General - 2.0L - Sportage
GENERAL
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description Specifications (2.0 CVVT) Limit
General
Type In-line, DOHC
Number of cylinders 4
Bore 82mm (3.2283in)
Stroke 93.5mm (8.6811 in)
Total displacement 1,975 cc (120.5 cu.in)
Compression ratio 10.1: 1
Firing order 1-3-4-2
Valve timing
Opens
11°
(ATDC)
Intake valve
Closes
59°
(ABDC)
Opens
42°
(BBDC)
Exhaust valve
Closes
6°
(ATDC)
Cylinder head
Less than 0.03mm 0.06mm
Flatness of gasket surface
(0.0012in) (0.0024in)
Intake
(0.0059in) (0.0118in)
Flatness of manifold mounting surface
Exhaust
(0.0059in) (0.0118in)
11.000 ~ 11.018mm
STD
(0.4331 ~ 0.4338in)
11.050 ~ 11.068mm
0.05 OS
Valve guide hole diameter (Intake, (0.4350 ~ 0.4357in)
Exhaust) 11.250 ~ 11.268mm
0.25 OS
(0.4429 ~ 0.4436in)
11.500 ~ 11.518mm
0.50 OS
(0.4528 ~ 0.4535in)
33.000 ~ 33.025mm
STD
(1.2992 ~ 1.3002in)
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33.300 ~ 33.325mm
0.3 OS
(1.3110 ~ 1.3120in)
Intake valve seat ring hole diameter
33.600 ~ 33.625mm
0.6 OS
(1.3228 ~ 1.3238in)
28.500 ~ 28.521mm
STD
(1.1220 ~ 1.1229in)
28.800 ~ 28.821mm
Exhaust valve seat ring hole diameter 0.3 OS
(1.1339 ~ 1.1347in)
29.100 ~ 29.121mm
0.6 OS
(1.1457 ~ 1.1465in)
GENERAL SPECIFICATIONS
Description Specifications (2.0 CVVT) Limit
Camshaft
44.518 ~ 44.718mm
Intake
(1.7527 ~ 1.7605in)
Cam height
44.418 ~ 44.618mm
Exhaust
(1.7487 ~ 1.7566in)
27.964 ~ 27.980mm
Journal outer Diameter (Intake, Exhaust)
(1.1009 ~ 1.1016in)
0.02 ~ 0.061mm
Bearing oil clearance 0.1mm (0.0039in)
(0.0008 ~ 0.0024in)
0.10 ~ 0.20mm
End play
(0.0039 ~ 0.0079in)
Valve
Intake 114.34mm (4.5016in)
Valve length
Exhaust 116.8mm (4.5984in)
5.965 ~ 5.980mm
Intake
(0.2348 ~ 0.2354in)
Stem outer diameter
5.950 ~ 5.965mm
Exhaust
(0.2343 ~ 0.2348in)
Face angle 45° ~ 45°30'
Thickness of Valve Intake 1.15mm (0.0453in) 0.8mm (0.0315in)
head (margin) Exhaust 1.35mm (0.0531 in) 1.0mm (0.0394in)
0.020 ~ 0.050mm 0.10mm
Intake
Valve stem to Valve (0.0008 ~ 0.0020in) (0.0039in)
guide clearance 0.035 ~ 0.065mm 0.13mm (0.0051
Exhaust
(0.0014 ~ 0.0026in) in)
Valve guide
45.8 ~ 46.2mm
Intake
(1.8031 ~ 1.8189in)
Length
54.3 ~ 54.6mm
Exhaust
(2.1378 ~ 2.1496in)
Valve seat
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1.1 ~ 1.5mm
Intake
(0.0433 ~ 0.0591 in)
Width of seat contact
1.3 ~ 1.7mm
Exhaust
(0.0512 ~ 0.0669in)
Intake 45° ~ 45°30'
Seat angle
Exhaust 45° ~ 45°30'
Valve spring
Free length 48.86mm (1.9236in)
18.8+/-0.9kg/39.0mm
(41.4+/-2.0 lb/1.5354in)
Load
41.0+/-1.5kg/30.5mm
(90.4+/-3.3 lb/1.2008in)
Out of squareness Less than 1.5° 3°
Valve clearance
0.12~0.28mm
Intake 0.20mm (0.0079in)
Cold (20°C +/- 5°C) (0.0047~0.0110in)
(68°F +/- 9°F) 0.20~0.38mm
Exhaust 0.28mm (0.0110in)
(0.0079~0.0150in)
Cylinder block
82.00 ~ 82.03mm
Cylinder bore
(3.2283 ~ 3.2295in)
Total: Less than 0.05mm (0.0020in) Bore
Flatness of gasket surface
to bore: Less than 0.03mm (0.0012in)
Piston
81.970 ~ 82.000mm
Piston outer diameter
(3.2272 ~ 3.2283in)
0.020 ~ 0.040mm
Piston to cylinder clearance
(0.0008 ~ 0.0016in)
1.23 ~ 1.25mm
No. 1 ring groove
(0.0484 ~ 0.0492in)
1.22 ~ 1.24mm
Ring groove width No. 2 ring groove
(0.0480 ~ 0.0488in)
2.51 ~ 2.53mm
Oil ring groove
(0.0988 ~ 0.0996in)
Piston ring
No. 1 ring 0.04 ~ 0.08mm (0.0016 ~ 0.0031 in) 0.1mm (0.0039in)
Side clearance No. 2 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in) 0.1mm (0.0039in)
Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in) 0.2mm (0.0079in)
0..23 ~ 0.38mm
No. 1 ring 1.0mm (0.0394in)
(0.0091 ~ 0.0150in)
End gap 0.33 ~ 0.48mm
No. 2 ring 1.0mm (0.0394in)
(0.0130 ~ 0.0189in)
Oil ring 0.20 ~ 0.60mm 1.0mm (0.0394in)
(0.0079 ~ 0.0236in)
Piston pin
20.001 ~ 20.006mm
Piston pin outer diameter
(0.7874 ~ 0.7876in)
20.016 ~ 20.021mm
Piston pin hole inner diameter
(0.7880 ~ 0.7882in)
0.010 ~ 0.020mm
Piston pin hole clearance
(0.0004 ~ 0.0008in)
Connecting rod small end hole inner 19.974 ~ 19.985mm
diameter (0.7864 ~ 0.7868in)
-0.032 ~ -0.016mm
Connecting rod small end hole clearance
(-0.0013 ~ -0.0006in)
350~1,350 kg
Piston pin press-in load
(772~2,976 lb)
Connecting rod
48.000 ~ 48.018mm
Connecting rod big end inner diameter
(1.8898 ~ 1.8905in)
0.024 ~ 0.044mm
Connecting rod bearing oil clearance
(0.0009 ~ 0.0017in)
0.10 ~ 0.25mm
Side clearance 0.4mm (0.0157in)
(0.0039 ~ 0.0098in)
Crankshaft
56.942 ~ 56.962mm
Main journal outer diameter
(2.2418 ~ 2.2426in)
44.946 ~ 44.966mm
Pin journal outer diameter
(1.7695 ~ 1.7703in)
0.028 ~ 0.048mm
Main bearing oil clearance 0.1mm (0.0039in)
(0.0011 ~ 0.0019in)
0.06 ~ 0.260mm
End play 0.3mm (0.0118in)
(0.0024 ~ 0.0102in)
Flywheel
0.13mm (0.0051
Runout 0.1mm (0.0039in)
in)
Oil pump
0.040 ~ 0.085mm
Inner rotor
(0.0016 ~ 0.0033in)
Side clearance
0.040 ~ 0.090mm
Outer rotor
(0.0016 ~ 0.0035in)
0.120 ~ 0.185mm
Body clearance
(0.0047 ~ 0.0073in)
Relief valve opening pressure 490+/-49.0kpa(5+/-0.5kg/cm2 , 71 +/-7.1
psi)
Free length 43.8mm (1.7244in)
3.7+/-0.4kg/40.1mm
(8.2+/-0.9 lb/1.5787in)
Relief spring Load 9.7+/-0.4kg/34.3mm
(21.4+/-0.9 lb/1.3504in)
Engine oil
Oil quantity (Total) 4.0 L (4.23 US qt, 3.52 lmp qt)
Oil quantity (Oil pan) 3.7 L (3.91 US qt, 3.26 lmp qt)
Oil quantity (Oil filter) 0.3 L (0.32 US qt, 0.26 lmp qt)
Oil quality Above SL, SJ
Oil pressure (Idle) 156.9kpa (1.6kg/cm2 , 22.8psi)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quantity 6.0 L (6.34 US qt, 5.28 lmp qt)
Type Wax pellet type
Opening
82+/-1.5°C(179.6+/-2.7°F)
Thermostat temperature
Pull opening
95°C (203°F)
temperature
Main valve opening 93.16 ~ 122.58kpa
pressure (0.95 ~ 1.25kg/cm2 , 13.51 ~ 17.78psi)
Radiator cap
Vacuum valve 0.98 ~ 4.90 kpa
opening pressure (0.01 ~ 0.05kg/cm2 , 0.14 ~ 0.71 psi)
Water temperature sensor
Type Thermister type
20°C (68°F) 2.45+/-0.14 kohm
Resistance
80°C (176°F) 0.3222 kohm
TIGHTENING TORQUE
TIGHTENING TORQUE SPECIFICATIONS

Tightening torque
Item Quantity
N.m kgf.m lb-ft
Cylinder block
Engine support (front) bracket bolt 3 34.3 ~ 49.0 3.5 ~ 5.0 25.3 ~ 36.2
Engine support (rear) bracket bolt 2 34.3 ~ 49.0 3.5 ~ 5.0 25.3 ~ 36.2
Engine support bracket stay plate bolt 1 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Engine mounting
Engine mounting bracket and body
3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt
Engine mounting insulator and engine
1 58.8 ~ 78.5 6.0 ~ 8.0 43.4 ~ 57.9
mounting support bracket fixing nut
Engine mounting support bracket and
1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
engine support bracket fixing bolt
Engine mounting support bracket and

2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
engine support bracket fixing nut
Transaxle mounting bracket and body
4 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt
Transaxle mounting insulator and
1 88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
transaxle support bracket fixing bolt
Front roll stopper bracket and sub frame
3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt
Front roll stopper insulator and front
roll stopper support bracket fixing bolt, 1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
nut
Rear roll stopper bracket and sub frame
3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
fixing bolt
Rear roll stopper insulator and rear roll
1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
stopper support bracket fixing bolt, nut
Main moving system
Connecting rod cap nut 8 49.0 ~ 52.0 5.0 ~ 5.3 36.2 ~ 38.3
Crankshaft main bearing cap bolt 27.5~31.4+60° 2.8~3.2+60° 20.3~23.1+60°
10
~64° ~64° ~64°
Flywheel bolt (M/T) 6 117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 94.0
Drive plate bolt (A/T) 6 117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 94.0
Timing belt
Timing belt upper cover bolt 4 7.8 ~9.8 0.8 ~1.0 5.8 ~7.2
Timing belt lower cover bolt 5 7.8 ~9.8 0.8 ~1.0 5.8 ~7.2
Timing belt under cover bolt 3 9.8 ~11.8 1.0 ~1.2 7.2 ~8.7
Crankshaft pulley bolt 1 166.7 ~176.5 17.0 ~18.0 123.0 ~130.2
Camshaft sprocket bolt 1 98.1 ~117.7 10.0 ~12.0 72.3 ~86.8
Timing belt tensioner bolt 1 42.2 ~53.9 4.3 ~5.5 31.1 ~39.8
Timing belt idler bolt 1 42.2 ~53.9 4.3 ~5.5 31.1 ~39.8
Cylinder head
Engine cover bolt 5 3.9 ~5.9 0.4 ~0.6 2.9 ~4.3
Cylinder head cover bolt 12 7.8 ~9.8 0.8 ~1.0 5.8 ~7.2
Camshaft bearing cap bolt 22 13.7 ~14.7 1.4 ~1.5 10.1 ~10.8
Exhaust camshaft and CVVT assembly
1 64.7 ~76.5 6.6 ~7.8 47.7 ~56.4
fixing bolt
Timing chain auto tensioner bolt 2 7.8 ~9.8 0.8 ~1.0 5.8 ~7.2
OCV (oil control valve) bolt 1 9.8 ~11.8 1.0 ~1.2 7.2 ~8.7
OCV (oil control valve) filter 1 40.2 ~ 50.0 4.1 ~ 5.1 29.7 ~ 36.9
Cylinder head bolt (10 X 99) 22.6~26.5+60° 2.3~2.7+60° 16.6~19.5+60°
8
~65°+60°~65° ~65°+60°~65° ~65°+60°~65°
Cylinder head bolt (12 X 151) 27.5~31.4+60° 2.8~3.2+60° 20.3~23.1+60°
2
~65°+60°~65° ~65°+60°~65° ~65°+60°~65°
Cooling system
Water pump pulley bolt 4 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Water pump bolt (8 X 20) 1 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
Water pump bolt (8 X 35) 2 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
Water pump and alternator brace fixing
2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
bolt (8 X 45)
Alternator brace and cylinder block
2 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
fixing bolt
Thermostat housing bolt 1 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Thermostat housing nut 1 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Water temperature sensor 1 19.6 ~ 39.2 2.0 ~ 4.0 14.5 ~ 28.9
Water inlet fitting nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Lubrication system
Oil filter 1 11.8 ~ 15.7 1.2 ~ 1.6 8.7 ~ 11.6
Front case bolt (8 X 20) 4 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Front case bolt (8 X 25) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Front case bolt (8 X 38) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Front case bolt (8 X 45) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pan bolt (6 X 16) 15 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 50) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 118) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan and transaxle fixing bolt 3 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
Oil pan drain bolt 1 39.2 ~ 44.1 4.0 ~ 4.5 28.9 ~ 32.5
Oil screen bolt 2 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Oil pressure switch 1 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Intake and exhaust system
Intake manifold and cylinder head
9 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6
fixing nut
Intake manifold stay bolt 4 17.7 ~ 24.5 1.8 ~ 2.5 13.0 ~ 18.1
Exhaust manifold and cylinder head
9 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
fixing nut
O2 sensor to exhaust manifold 1 49.0 ~ 58.8 5.0 ~ 6.0 36.2 ~ 43.4
Exhaust manifold heat cover and
4 16.7 ~ 21.6 1.7 ~ 2.2 12.3 ~ 15.9
exhaust manifold fixing bolt
Air cleaner assembly fixing bolt 3 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Throttle body and surge tank fixing bolt 4 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Exhaust manifold and front muffler
2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
fixing bolt
Front muffler fixing clip bolt 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Front muffler and center muffler fixing
2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
nut
Center muffler and main muffler fixing
2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
nut
COMPRESSION PRESSURE INSPECTION
NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy,
measure the compression pressure.
1. Start the engine and allow to warm up to operating temperature (about five minutes).
Stop the engine.
2. Disconnect the ignition coil connectors and the spark plug cables.
Fig. 1: Disconnecting Ignition Coil Connectors And Spark Plug Cables

Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the four spark plugs using a 16mm spark plug wrench.
4. Check the cylinder compression pressure.
1. Insert a compression gauge into the spark plug hole.
Fig. 2: Checking Cylinder Compression Pressure

2. Fully open the throttle.

3. While cranking the engine, measure the compression pressure.
NOTE: Always use a fully charged battery to obtain engine speed of 250rpm
or more.
4. Repeat step 1 through 3 for each cylinder.
NOTE: This measurement must be done in as short a time as possible.
Compression pressure:
1,422kPa (14.5kg/cm2 , 206psi) (250~400 RPM)
Minimum pressure:
1,275kPa (13.0kg/cm2 , 185psi)
Difference between each cylinder:
98kPa (1.0kg/cm2 , 14psi) or less
5. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat step 1 through 3 for cylinders with low
compression.
l If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are
worn or damaged.
l If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
5. Reinstall the spark plugs.
6. Connect the ignition coil connectors and the spark plug cables.
TIMING BELT TENSION ADJUSTMENT
1. Remove the engine cover.
Fig. 3: Removing Engine Cover

2. Remove the RH front wheel.

3. Remove the bolts (B) and RH side cover (A).
Fig. 4: Removing Bolts And RH Side Cover

4. Loosen the water pump pulley bolts.
Fig. 5: Loosening Water Pump Pulley Bolts

5. Remove the alternator drive belt. (See CHARGING SYSTEM )

6. Remove the air conditioner compressor drive belt. (See DRIVE BELT )
7. Remove the power steering pump drive belt. (See CHECKING POWER STEERING BELT
TENSION )
8. Remove the water pump pulley.
9. Remove the 4 bolts (B) and timing belt upper cover (A).
Fig. 6: Loosening Bolts And Timing Belt Upper Cover

10. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover. Check that
the timing mark of camshaft sprocket is aligned with the timing mark of cylinder head cover. (No.1
cylinder compression TDC position)
Fig. 7: Aligning Crankshaft Pulley Groove Marks With Timing Belt Cover Timing Mark (1 Of 2)
Fig. 8: Aligning Crankshaft Pulley Groove Marks With Timing Belt Cover Timing Mark (2 Of 2)
11. Remove the crankshaft pulley bolt (B) and crankshaft pulley (A).
Fig. 9: Removing Crankshaft Pulley Bolt And Crankshaft Pulley

12. Remove the 5 bolts (B) and timing belt lower cover (A).
Fig. 10: Removing Bolts And Timing Belt Lower Cover

13. Temporarily loosen the tensioner pulley (A) by center bolt.
Fig. 11: Loosening Tensioner Pulley By Center Bolt

14. Adjust the timing belt tension.

1. Rotate the crankshaft clockwise (view from the front) through angle equivalent to two teeth (18°)
of camshaft sprocket (A).
Fig. 12: Rotating Crankshaft Clockwise

2. Using a hex-wrench, apply tension to the timing belt in the clockwise direction so that there is no
slack in the belt on the tension side.
Fig. 13: Applying Tension To Timing Belt

3. Tighten the tensioner bolt.
Tightening torque:
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
4. Recheck the belt tension. When applying about 5 lbs of force, the belt should move no more than
0.16 to 0.24 inch (4 to 6mm).
Fig. 14: Rechecking Belt Tension

15. Turn the crankshaft two turns in the operating direction (clockwise) and realign the crankshaft sprocket
and camshaft sprocket timing mark.
16. Install the timing belt lower cover (A) with bolts (B).
Tightening torque:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Fig. 15: Turning Crankshaft In Operating Direction

17. Install the crankshaft pulley (A) with bolt (B).
Tightening torque:
166.7 ~ 176.5N.m (17.0 ~ 18.0kgf.m, 123.0 ~ 130.2lb-ft)
Fig. 16: Installing Crankshaft Pulley With Bolt

18. Install the timing belt upper cover (A) with bolts (B).
Tightening torque:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Fig. 17: Installing Timing Belt Upper Cover With Bolts

19. Install the water pump pulley.

20. Install the power steering pump drive belt. (See CHECKING POWER STEERING BELT TENSION )
21. Install the air conditioner compressor drive belt. (See DRIVE BELT )
22. Install the alternator drive belt. (See CHARGING SYSTEM )
23. Install the RH side cover (A) with bolts (B)
Fig. 18: Installing RH Side Cover With Bolts

24. Install the RH front wheel.
Tightening torque:
88.3 ~ 107.9N.m (9 ~ 11kgf.m, 65.1 ~ 79.6lb-ft)
25. Install the engine cover (A) with bolts.
Tightening torque:
3.9 ~ 5.9N.m ( 0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
Fig. 19: Installing Engine Cover

VALVE CLEARANCE INSPECTION AND ADJUSTMENT
MLA (MECHANICAL LASH ADJUSTER)
NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature: (20°C+/-5°C [68°F+/-9°F]) and cylinder head is installed on cylinder
block.
1. Remove the engine cover.
Fig. 20: Removing Engine Cover

2. Remove the bolts (B) and timing belt upper cover (A).
Fig. 21: Removing Timing Belt Upper Cover

3. Remove the cylinder head cover.

1. Disconnect the spark plug cables and do not pull on the cable by force.
NOTE: Pulling on or bending the cables may damage the conductor inside.
Fig. 22: Disconnecting Spark Plug Cables

2. Remove the PCV (Positive Crankcase Ventilation) hose (A) and the breather hose (B) from the
cylinder head cover.
Fig. 23: Removing Positive Crankcase Ventilation Hose And Breather Hose From Cylinder
Head Cover
3. Remove the accelerator cable (A) from the cylinder head cover.
Fig. 24: Removing Accelerator Cable From Cylinder Head Cover

4. Loosen the cylinder head cover bolts (B) and then remove the cover (A) and gasket.
Fig. 25: Removing Cylinder Head Cover And Gasket

4. Set No. 1 cylinder to TDC/compression.

1. Turn the crankshaft pulley and align its groove with the timing mark" T" of the lower timing belt
cover.
Fig. 26: Aligning Crankshaft Pulley Groove Marks With Lower Timing Belt Cover Timing
Mark (1 Of 2)
2. Check that the hole of the camshaft timing pulley (A) is aligned with the timing mark of the bearing
cap.
If not, turn the crankshaft one revolution (360°).
Fig. 27: Aligning Crankshaft Pulley Groove Marks With Lower Timing Belt Cover Timing
Mark (2 Of 2)
5. Inspect the valve clearance.

1. Check only the valve indicated as shown. [No. 1 cylinder: TDC/compression]. Measure the valve
clearance.
Fig. 28: Inspecting Valve Clearance (1 Of 2)

l Using a thickness gauge, measure the clearance between the tappet shim and the base circle
of camshaft.
l Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting shim.
Valve clearance
[Specification]
Engine coolant temperature: (20°C +/- 5°C[68°F +/- 9°F])
Intake: 0.20mm (0.0079in)
Exhaust: 0.28mm (0.0110in)
[Limit]
Intake: 0.12 ~ 0.28mm (0.0047 ~ 0.0110in)
Exhaust: 0.20 ~ 0.38mm (0.0079 ~ 0.0150in)
2. Turn the crankshaft pulley one revolution (360°) and align the groove with the timing mark "T" of
lower timing belt cover.
3. Check only valves indicated as shown. [No. 4 cylinder: TDC/compression]. Measure the valve
clearance. (See procedure step 1 )
Fig. 29: Inspecting Valve Clearance (2 Of 2)

6. Adjust the intake and exhaust valve clearance.

1. Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve is upward.
2. Using the SST(09220 - 2D000), press down the valve lifter and place the stopper between the
camshaft and valve lifter and remove the special tool.
Fig. 30: Adjusting Intake And Exhaust Valve Clearance

3. Remove the adjusting shim with a small screw driver (A) and magnet (B).
Fig. 31: Removing Adjusting Shim And Magnet

4. Measure the thickness of the removed shim using a micrometer.
Fig. 32: Measuring Shim Thickness

5. Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
Valve clearance
(Engine coolant temperature: 20°C +/- 5°C[68°F +/- 9°F])
T: Thickness of removed shim
A: Measured valve clearance
N: Thickness of new shim
Intake: N = T + [A - 0.20mm(0.0079in)]
Exhaust: N = T + [A - 0.28mm(0.0110in)]
6. Select a new shim with a thickness as close as possible to the calculated value. (Refer to Fig. 33
and Fig. 34 )
NOTE: Shims are available in 20 size increments of 0.04mm (0.0016in) from

2.00mm (0.0787in) to 2.76mm (0.1087in)
7. Place a new adjusting shim on the valve lifter.

8. Using the SST(09220 - 2D000), press down the valve lifter and remove the stopper.
9. Recheck the valve clearance.
Valve clearance
(Engine coolant temperature: 20°C +/- 5°C[68°F +/- 9°F])
[Specification]
Intake: 0.20mm (0.0079in)
Exhaust: 0.28 mm (0.0110in)
[Limit] (After adjusting valve clearance)
Intake: 0.17 ~ 0.23mm (0.0067 ~ 0.0091 in)
Exhaust: 0.25 ~ 0.31mm (0.0098 ~ 0.0122in)
Fig. 33: Adjusting Shim Selection Chart (Exhaust)

Fig. 34: Adjusting Shim Selection Chart (Intake)

TROUBLESHOOTING
TROUBLESHOOTING
Symptom Suspect area Remedy
Loose or improperly installed engine Repair or replace the flywheel as
flywheel. required.
Engine misfire with Worn piston rings. Inspect the cylinder for a loss of
abnormal internal (Oil consumption may or may not cause the compression.
lower engine noises. engine to misfire.) Repair or replace as required.
Replace the crankshaft and bearings
Worn crankshaft thrust bearings.
as required.
Stuck valves.
(Carbon buildup on the valve stem can cause Repair or replace as required.
Engine misfire with the valve not to close properly.)
abnormal valve train Replace the timing chain and
Excessive worn or mis-aligned timing chain.
noise. sprocket as required.
Replace the camshaft and valve
Worn camshaft lobes.
lifters.
l Faulty cylinder head gasket and/or

l Inspect the cylinder head and
cracking or other damage to the
engine block for damage to the
Engine misfire with cylinder head and engine block
coolant passages and/or a
coolant consumption cooling system.
faulty head gasket.
l Coolant consumption may or may not
l Repair or replace as required.
cause the engine to overheat.
Worn valves, valve guides and/or valve stem
Repair or replace as required.
Engine misfire with oil seals.
excessive oil Worn piston rings. Inspect the cylinder for a loss of
consumption (Oil consumption may or may not cause the compression
engine to misfire) Repair or replace as required.
Drain the oil.
Incorrect oil viscosity.
Engine noise on start- Refill with the correct viscosity oil.
up, but only lasting a Inspect the thrust bearing and
few seconds. Worn crankshaft thrust bearing. crankshaft.
Low oil pressure. Repair or replace as required.
Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or Replace the timing chain and
damaged sprocket teeth. sprockets.
Upper engine noise, Worn timing chain tensioner, if applicable. Replace the timing chain tensioner
regardless of engine as required.
speed. Inspect the camshaft lobes. Replace
Worn camshaft lobes. the camshaft and valve lifters as
required.
Inspect the valves and valve guides,
Worn valve guides or valve stems.
then repair as required.
Stuck valves. (Carbon on the valve stem or Inspect the valves and valve guides,
valve seat may cause the valve to stay open.) then repair as required.
Repair or replace damaged
Low oil pressure.
components as required.
Loose or damaged flywheel. Repair or replace the flywheel.
Inspect the oil pan.
Damaged oil pan, contacting the oil pump
Inspect the oil pump screen.
screen.
Oil pump screen loose, damaged or Inspect the oil pump screen.
restricted. Repair or replace as required.
Inspect the piston and cylinder bore.
Excessive piston-to-cylinder bore clearance.
Repair as required.
Inspect the piston, piston pin and the
Excessive piston pin-to-bore clearance. connecting rod.
Lower engine noise, Inspect the following components
regardless of engine and repair as required.

speed.
l The connecting rod bearings.
Excessive connecting rod bearing clearance. l The connecting rods.
l The crankshaft.
l The crankshaft journal.
Inspect the following components

and repair as required.
Excessive crankshaft bearing clearance.
l The crankshaft bearings.
l The crankshaft journals.
Verify the piston pins and

Incorrect piston, piston pin and connecting connecting rods are installed
rod installation. correctly.
Repair as required.
Low oil pressure. Repair or replace as required.
Inspect the following components
Excessive connecting rod bearing clearance. l The connecting rod bearings.

l The connecting rods.
Engine noise under l The crankshaft.

load. Inspect the following components
Excessive crankshaft bearing clearance. l The crankshaft bearings.

l The crankshaft journals.
l The cylinder block crankshaft

bearing bore.
Hydraulically locked cylinder. Remove spark plugs and check for
fluid. Inspect for broken head gasket.
l Coolant/antifreeze in cylinder. Inspect for cracked engine block or
cylinder head.
l Oil in cylinder.
Inspect for a sticking fuel injector
l Fuel in cylinder. and/or leaking fuel regulator.
Engine will not crank, Broken timing chain and/or timing chain Inspect timing chain and gears.
(crankshaft will not gears. Repair as required.
rotate) Foreign material in cylinder.
Inspect cylinder for damaged
l Broken valve. components and/or foreign materials.
l Piston material. Repair or replace as required.
l Foreign material.
Seized crankshaft or connecting rod Inspect crankshaft and connecting
bearings. rod bearing.

Inspect connecting rods.
Bent or broken connecting rod.
Inspect crankshaft.
Broken crankshaft.
SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS DESCRIPTIONS
Tool (Number and name) Illustration Use
Crankshaft front oil seal installer Fig. 35 Installation of the front oil seal
(09214-32000)
Crankshaft front oil seal guide Fig. 36 Installation of the front oil seal
(09214-32100)
Valve clearance adjust tool set Fig. 37 Removal and installation of the
(09220-2D000) tappet shim
Camshaft oil seal installer Fig. 38 Installation of the camshaft oil
(09221-21000) seal
Valve guide remover Fig. 39 Removal and installation of the
(09221-3F100 (A)) valve guide
Valve guide installer
(09221-3F100 (B))
Valve stem oil seal installer Fig. 40 Installation of the valve stem oil
(09222-22001) seal
Valve spring compressor Fig. 41 Removal and installation of the
(09222-28000) intake or exhaust valve
Valve spring compressor adaptor
(09222-28100)
Crankshaft rear oil seal installer Fig. 42 Installation of the crankshaft rear
(09231-21000) oil seal
Fig. 35: View Of Crankshaft Front Oil Seal Installer

Fig. 36: View Of Crankshaft Front Oil Seal Guide

Fig. 37: View Of Valve Clearance Adjust Tool Set

Fig. 38: View Of Camshaft Oil Seal Installer

Fig. 39: View Of Valve Guide Remover

Fig. 40: View Of Valve Stem Oil Seal Installer

Fig. 41: View Of Valve Spring Compressor

Fig. 42: View Of Crankshaft Rear Oil Seal Installer


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2005 Kia Sportage EX

2005-06 ENGINE General - 2.0L - Sportage

General - 2.0L - Sportage

jueves, 29 de agosto de 2019 10:43:10

TIGHTENING TORQUE SPECIFICATIONS

Engine mounting support bracket and

COMPRESSION PRESSURE INSPECTION

Stop the engine.

Fig. 1: Disconnecting Ignition Coil Connectors And Spark Plug Cables

Fig. 2: Checking Cylinder Compression Pressure

2. Fully open the throttle.

4. Repeat step 1 through 3 for each cylinder.

NOTE: This measurement must be done in as short a time as possible.

1,422kPa (14.5kg/cm2 , 206psi) (250~400 RPM)

1,275kPa (13.0kg/cm2 , 185psi)

Difference between each cylinder:

98kPa (1.0kg/cm2 , 14psi) or less

TIMING BELT TENSION ADJUSTMENT

1. Remove the engine cover.

Fig. 3: Removing Engine Cover

2. Remove the RH front wheel.

Fig. 4: Removing Bolts And RH Side Cover

4. Loosen the water pump pulley bolts.

Fig. 5: Loosening Water Pump Pulley Bolts

5. Remove the alternator drive belt. (See CHARGING SYSTEM )

Fig. 6: Loosening Bolts And Timing Belt Upper Cover

Fig. 9: Removing Crankshaft Pulley Bolt And Crankshaft Pulley

Fig. 10: Removing Bolts And Timing Belt Lower Cover

13. Temporarily loosen the tensioner pulley (A) by center bolt.

Fig. 11: Loosening Tensioner Pulley By Center Bolt

14. Adjust the timing belt tension.

Fig. 12: Rotating Crankshaft Clockwise

Fig. 13: Applying Tension To Timing Belt

3. Tighten the tensioner bolt.

42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)

Fig. 14: Rechecking Belt Tension

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Fig. 15: Turning Crankshaft In Operating Direction

17. Install the crankshaft pulley (A) with bolt (B).

166.7 ~ 176.5N.m (17.0 ~ 18.0kgf.m, 123.0 ~ 130.2lb-ft)

Fig. 16: Installing Crankshaft Pulley With Bolt

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Fig. 17: Installing Timing Belt Upper Cover With Bolts

19. Install the water pump pulley.

Fig. 18: Installing RH Side Cover With Bolts

24. Install the RH front wheel.

88.3 ~ 107.9N.m (9 ~ 11kgf.m, 65.1 ~ 79.6lb-ft)

25. Install the engine cover (A) with bolts.

3.9 ~ 5.9N.m ( 0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

Fig. 19: Installing Engine Cover

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

MLA (MECHANICAL LASH ADJUSTER)

1. Remove the engine cover.

Fig. 20: Removing Engine Cover

Fig. 21: Removing Timing Belt Upper Cover

3. Remove the cylinder head cover.

Fig. 22: Disconnecting Spark Plug Cables

Fig. 24: Removing Accelerator Cable From Cylinder Head Cover

Fig. 25: Removing Cylinder Head Cover And Gasket

4. Set No. 1 cylinder to TDC/compression.

If not, turn the crankshaft one revolution (360°).

5. Inspect the valve clearance.

Fig. 28: Inspecting Valve Clearance (1 Of 2)