2010 Kia Sportage EX

2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

2010 ENGINE

General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

GENERAL INFORMATION
SPECIFICATIONS

ENGINE MECHANICAL SYSTEM SPECIFICATIONS

Description Specifications Limit
General
Type V-type, DOHC
Number of cylinder 6
Bore 86.7mm (3.4133in.)
Stroke 75mm (2.9528in.)
Total displacement 2,656cc
Compression ratio 10 : 1
Firing order
Valve timing 1-2-3-4-5-6
Intake valve
Opens (BTDC) 6°
Closes (ABDC)
46°
Exhaust valve
Opens (BBDC) 38°
Closes (ATDC) 14°
Camshaft
Drive mechanism
Cogged type belt
Cam height
43.95 ~ 44.15mm (1.7303 ~
Intake 43.45mm (1.7106in.)
1.7382in.)
43.95 ~ 44.15mm (1.7303 ~
Exhaust 43.45mm (1.7106in.)
1.7382in.)
25.964 ~ 25.980mm (1.0222 ~
Journal diameter 25.914mm (1.0202in.)
1.0228in.)
0.02 ~ 0.061mm (0.0007 ~
Bearing oil clearance
0.0024in.)
0.1mm (0.0039in.)
0.1 ~ 0.15mm (0.0039 ~
End play
0.0059in.)
Cylinder head
Flatness of cylinder
head surface
Max. 0.03mm (0.0012in.) 0.05mm (0.0020in.)
Flatness of manifold
mounting surface
Intake Max. 0.15mm (0.0059in.) 0.15mm (0.0059in.)
Exhaust

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 2010 Kia Sportage EX
2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

Valve guides hole

Max. 0.15mm (0.0059in.)
diameter
11.05 ~ 11.068mm (0.435 ~
0.05 (0.002) O.S.
0.436in.)
11.25 ~ 11.268mm (0.443 ~
0.25 (0.010) O.S.
0.444in.)
0.50 (0.020) O.S. 0.15mm (0.0059in.)
11.50 ~ 11.518mm (0.453 ~
Intake valve seat ring
0.453in.)
hole diameter
0.3 (0.012) O.S.
33.300 ~ 33.325mm (1.311 ~
Exhaust valve seat
1.312in.)
ring hole diameter
28.600 ~ 28.621mm (1.126 ~
0.3 (0.012) O.S.
1.127in.)
Valve
Overall length
Intake 96.1mm (3.783in.)
Exhaust
97.15mm (3.825in.)
Stem diameter
5.965 ~ 5.98mm (0.235 ~
Intake
0.2354in.)
5.95 ~ 5.965mm (0.234 ~
Exhaust
0.235in.)
Face angle
45° ~ 45.5°
Margin
Intake 1.0mm (0.0394in.) 0.5mm (0.0197in.)
Exhaust
Clearance (Stem-to- 1.3mm (0.0512in.) 0.8mm (0.0315in.)
guide)
0.02 ~ 0.05mm (0.008 ~
Intake 0.10mm (0.0039in.)
0.0020in.)
0.030 ~ 0.065mm (0.0012 ~
Exhaust 0.13mm (0.0051in.)
0.0026in.)
Valve spring
Free length 42.5mm (1.6732in.) 41.5mm (1.6339in.)
Load 21kg/35mm (48.4lb/1.3780in.) 21.9kg/34mm (48.4lb/1.3386in.)
Out of squareness Max. 1.5° Max. 3°
Piston
86.68 ~ 86.71mm (3.413 ~
Diameter (Standard)
3.414in.)
Clearance (Piston-to-
0.01 ~ 0.03mm (0.0004 ~
cylinder)
0.0012in.)
Ring groove width
1.230 ~ 1.250mm (0.0484 ~
No. 1
0.0492in.)

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 2010 Kia Sportage EX
2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

1.220 ~ 1.250mm (0.0480 ~

No. 2
0.0488in.)
2.515 ~ 2.535mm (0.0990 ~
Oil
0.0998in.)
0.25mm (0.010in.), 0.50mm
Piston for service
(0.020in.)
Piston ring
Number of rings per
3
piston
Compression ring 2
Oil ring
1
Compression ring type
No. 1 Inner bevel type
No. 2 Under cut type
Oil ring type
3-piece type
Ring end gap
0.20 ~ 0.35mm (0.0079 ~
No. 1 0.8mm (0.031in.)
0.0138in.)
0.37 ~ 0.52mm (0.0146 ~
No. 2 0.8mm (0.031in.)
0.0205in.)
Oil ring side rail
0.2 ~ 0.7mm (0.0079 ~ 0.0276in.) 1.0mm (0.039in.)
Ring side clearance
0.04 ~ 0.08mm (0.0016 ~
No. 1 0.1mm (0.004in.)
0.0031in.)
0.03 ~ 0.07mm (0.0012 ~
No. 2
0.0028in.)
0.1mm (0.004in.)
0.25mm (0.010in.), 0.50mm
Rings for service
(0.020in.)
Connecting rod
Piston pin installation 2,450 ~ 12,225N
force (250 ~ 1,250kg, 551 ~ 2,755lb)
Side clearance (big 0.10 ~ 0.25mm (0.0039 ~
end) 0.0098in.)
0.4mm (0.016in.)
0.05mm or less/100mm
Bend
(0.0020in. or less/3.937in.)
0.018 ~ 0.036mm (0.0007 ~
Bearing oil clearance 0.1mm (0.004in.)
0.0014in.)
Crankshaft
61.982 ~ 62.000mm (2.4402 ~
Journal O.D.
2.4409in.)
47.982 ~ 48.000mm (1.8891 ~
Pin O.D.
1.8898in.)
Out-of-round, taper of
Max. 0.003mm (0.0012in.)
journal and pin
Taper of journal and Max. 0.005mm (0.00020in.)

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 2010 Kia Sportage EX
2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

pin
0.070 ~ 0.250mm (0.0028 ~
End play 0.4mm (0.016in.)
0.0098in.)
Main bearing of 0.004 ~ 0.022mm (0.0002 ~
0.1mm (0.004in.)
clearance 0.0009in.)
Cylinder block
Cylinder bore 86.7mm (3.4134in.)
Flatness of gasket
Max. 0.03mm (0.0012in.)
surface
0.05mm (0.002in.)
Out-of-round of
Max. 0.02mm (0.0008in.)
cylinder bore
Engine oil
Oil quantity
When replacing a short engine or a block
Total 4.8L (5.07US qt, 4.22lmp qt)
assembly
Oil pan 4.2L (4.44US qt, 3.70lmp qt) Including oil filter
If not available, refer to SELECTION OF
Drain and refill ENGINE OIL for the recommended API or
4.5L (4.76US qt, 3.96lmp qt)
Oil grade ILSAC classification and SAE viscosity
number.
Satisfy the requirement of the API or ILSAC
Recommendation 5W-20/GF4&SM
classification.
API SL, SM or above, ILSAC
Classification Refer to the "LUBRICATION SYSTEM "
GF3, GF4 or above
Recommended SAE viscosity
SAE viscosity grade Oil temperature in oil pan:
number
Oil pressure (at 800 98kPa (1.0kg/cm2 , 14.2psi) or 95±5°C (203±41°F)
RPM) above
Oil pump
0.100 ~ 0.181mm (0.0039 ~
Body clearance
0.0071in.)
0.040 ~ 0.095mm (0.0016 ~
Side clearance
0.0037in.)
Relief spring
Free height 43.8mm (1.724in.)
Load 4.6kg/39.3mm (10lb/1.548in.)
Oil filter
Type Cartridge, full flow
50kPa (7.3psi) or more
Engine oil pressure [Conditions : Oil temperature is
75 to 90°C (167 to 194°F)]
Engine coolant cooling, forced
Cooling method
circulation with electric fan
Cooling system
7.0lit (7.4U.S.qts., 6.1lmp.qts)
quantity

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2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

Thermostat
Type Wax pellet type with jiggle valve
Normal opening
82 ± 2.0°C (179.6 ± 3.6°F)
temperature
Opening temperature
80 ~ 84°C (176 ~ 183.2°F)
range
Wide open
95°C (203°F)
temperature
Radiator cap
Main valve opening 107.9 ± 14.7kPa (1.1 ±
pressure 0.15kg/cm2 , 15.65 ± 2.13psi)
Main valve closing
pressure 83.4kPa (0.85kg/cm2 , 12.1psi)
Vacuum valve
opening pressure -6.86kPa (-0.07kg/cm2 , -1.00psi)
Air cleaner
Type Dry
Element Paper type
Exhaust pipe
Muffler Expansion resonant type
Suspend system Rubber hangers

SERVICE STANDARDS

SERVICE STANDARDS
Standard value
Coolant concentration
Tropical areas 40%
Other areas 50%

COOLANT

COOLANT SPECIFICATIONS
Engine coolant Ethlylen glycol base for aluminum radiator

SEALANT

SEALANT SPECIFICATIONS
Engine coolant temperature sensor LOCTITE 262 or equivalent, Three bond No. 1324 or equivalent.
Oil pressure switch 3M ATD No. 8660 or Three bond No. 1141E
PCV valve LOCTITE 242 or equivalent

TIGHTENING TORQUE

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 2010 Kia Sportage EX
2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

TIGHTENING TORQUE SPECIFICATIONS

Item N.m kgf.cm lb-ft
Camshaft sprocket bolt 90 ~ 110 900 ~ 1,100 65 ~ 85
Cylinder head cover bolt 8 ~ 10 80 ~ 100 5.8 ~ 7.2
Main bearing cap bolt
270~300 + (90° 19.5~24 + (90°
M10 27~33 + (90°~94°)
~94°) ~94°)
130~190 + (90°
M8 13~19 + (90°~94°) 10~14 + (90°~94°)
~94°)
160~200 + (90°
Connecting rod bolt 16~20 + (90°~94°) 12~15 + (90°~94°)
~94°)
25 + (58°~62°) + 250 + (58°~62°) + 18 + (58°~62°) +
Cylinder head bolt (Cold engine)
(43° ~47°) (43° ~47°) (43° ~47°)
Oil pan drain plug 35 ~ 45 350 ~ 450 25 ~ 33
Lower oil pan bolt 10 ~ 12 100 ~ 120 7~9
Upper oil pan bolt
[10 x 38mm (0.937 x 1.4961in.)] 30 ~ 42 300 ~ 420 22 ~ 30
[8 x 22mm (0.3150 x 0.8661in.)] 19 ~ 28 190 ~ 280 14 ~ 20
[161.5mm (6.3582in.)] 5~7 50 ~ 70 4~5
[152.5mm (6.0039in.)] 5~7 50 ~ 70 4~5
Oil screen bolt 15 ~ 22 150 ~ 220 11 ~ 16
Oil pump case bolt 12 ~ 15 120 ~ 150 9 ~ 11
Oil relief valve plug 40 ~ 50 400 ~ 500 29 ~ 36
Oil pressure switch 15 ~ 22 150 ~ 220 11 ~ 16
Oil pressure cover screw 8 ~ 12 80 ~ 120 6~9
Oil filter 12 ~ 16 120 ~ 160 9 ~ 12
Drive plate and adapter 73 ~ 77 730 ~ 770 53 ~ 56
Air cleaner body installation bolt 8 ~ 12 80 ~ 120 6~9
Surge tank stay 15 ~ 20 150 ~ 200 11 ~ 14
Air intake surge tank to intake manifold
15 ~ 20 150 ~ 200 11 ~ 14
(bolt)
Air intake surge tank to intake manifold
15 ~ 20 150 ~ 200 11 ~ 14
(nut)
Intake manifold to cylinder head 19 ~ 21 190 ~ 210 14 ~ 15
Heat protector exhaust manifold 12 ~ 15 120 ~ 150 9 ~ 11
Exhaust manifold to cylinder head (Self-
30 ~ 35 300 ~ 350 22 ~ 26
locking nut)
Oil level gauge guide to engine 12 ~ 15 120 ~ 150 9 ~ 11
Water outlet fitting bolt 17 ~ 20 170 ~ 200 12 ~ 14
Power steering oil pump bracket to cylinder
17 ~ 26 170 ~ 260 12 ~ 19
head
Crank position sensor wheel screw 5~6 50 ~ 60 3.6 ~ 4.3
Engine mounting insulator bolt 50 ~ 65 500 ~ 650 36 ~ 47

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Engine mounting bracket nut 60 ~ 80 600 ~ 800 43 ~ 58

Engine mounting bracket bolt 60 ~ 80 600 ~ 800 43 ~ 58
Engine support bracket bolt 60 ~ 70 600 ~ 700 43 ~ 51
Front roll stopper bracket sub frame bolt 50 ~ 65 500 ~ 650 36 ~ 47
Front roll stopper insulator bolt and nut 50 ~ 65 500 ~ 650 36 ~ 47
Rear roll stopper bracket to sub frame 50 ~ 65 500 ~ 650 36 ~ 47
Rear roll stopper insulator bolt and nut 50 ~ 65 500 ~ 650 36 ~ 47
Transaxle mounting bracket bolt 50 ~ 65 500 ~ 650 36 ~ 47
Transaxle mounting insulator bolt 90 ~ 110 900 ~ 1,100 65 ~ 80
Fuel hose clamp to rear cylinder head
12 ~ 15 120 ~ 150 9 ~ 11
assembly
Transaxle mounting plate 10 ~ 12 100 ~ 120 7~9
Rear plate 10 ~ 12 100 ~ 120 7~9
Oil seal case 10 ~ 12 100 ~ 120 7~9
Crankshaft pulley bolt 180 ~ 190 1,800 ~ 1,900 130 ~ 138
Timing belt cover bolt 10 ~ 12 100 ~ 12 7~9
Engine hanger bracket to engine 20 ~ 27 200 ~ 270 14 ~ 20
Alternator mounting bracket to engine 20 ~ 30 200 ~ 300 14 ~ 22
Alternator mounting nut (Engine front case
20 ~ 30 200 ~ 300 14 ~ 22
side)
Alternator mounting bolt (Alternator
20 ~ 30 200 ~ 300 14 ~ 22
mounting bracket side)
Starter to transmission (nut) 20 ~ 30 200 ~ 300 14 ~ 22
Starter to transmission (bolt) 27 ~ 34 270 ~ 340 20 ~ 25
Drive belt pulley bolt 35 ~ 55 350 ~ 550 25 ~ 40
Drive belt tensioner bolt 20 ~ 27 200 ~ 270 14 ~ 20
Engine coolant pump to cylinder block bolt
15 ~ 22 150 ~ 200 11 ~ 16
(Head mark "7" mark)
Engine coolant temperature sensor 20 ~ 40 200 ~ 400 14 ~ 29
Engine coolant inlet fitting attaching bolt 17 ~ 20 170 ~ 200 12 ~ 14
Throttle body to surge tank bolt 15 ~ 20 150 ~ 200 11 ~ 14
Oxygen sensor to exhaust manifold 40 ~ 50 400 ~ 500 29 ~ 36
Front exhaust pipe to exhaust manifold nut 30 ~ 40 300 ~ 400 22 ~ 29
Front exhaust pipe to catalytic converter
40 ~ 60 400 ~ 600 29 ~ 43
bolt
Catalytic converter to center exhaust pipe
40 ~ 60 400 ~ 600 29 ~ 43
nut
Center exhaust pipe to main muffler nut 40 ~ 60 400 ~ 600 29 ~ 43
Main muffler hanger support bracket bolt 10 ~ 15 100 ~ 150 7 ~ 11
Delivery pipe installation bolt 10 ~ 15 100 ~ 150 7 ~ 11
Timing belt tensioner pulley bolt 43 ~ 55 430 ~ 550 31 ~ 40
Timing belt idler pulley bolt 50 ~ 60 500 ~ 600 36 ~ 43

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Timing belt tensioner arm fixed bolt 35 ~ 55 350 ~ 550 25 ~ 40

Auto tensioner fixed bolt 20 ~ 27 200 ~ 270 14 ~ 20
Accelerator cable bracket 4~6 40 ~ 60 3~4
Spark plug 20 ~ 30 200 ~ 300 14 ~ 22

COMPRESSION

NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy,
measure the compression pressure.

1. Warm up and stop engine

Allow the engine to warm up to normal operating temperature.

2. Remove ignition coils. (See IGNITION )

3. Remove spark plugs.

Using a 16mm plug wrench, remove the 6 spark plugs.

4. Check cylinder compression pressure

A. Insert a compression gauge into the spark plug hole.

Fig. 1: Checking Cylinder Compression Pressure

Courtesy of KIA MOTORS AMERICA, INC.

B. While cranking the engine, measure the compression pressure.

NOTE: Always use a fully charged battery to obtain engine speed of 250
RPM or more.

C. Repeat steps (A) through (B) for each cylinder.

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

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Compression pressure:

1,420kPa (14.5kgf/cm2 , 206 psi)

Minimum pressure:

1,270kPa (13kgf/cm2 , 184psi)

Difference between each cylinder:

100kPa (1.0kgf/cm2 , 15psi) or less

D. 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 steps (A) through (B) for cylinders with low
compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are
worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
5. Reinstall spark plugs. (See REPLACEMENT )
6. Install ignition coils. (See IGNITION )

TROUBLESHOOTING
TROUBLESHOOTING CHART
Symptom Suspect area Remedy (See)
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.
Repair or replace as required
(Carbon buildup on the valve stem)
Engine misfire with
Replace the timing chain and sprocket
abnormal valve train Excessive worn or mis-aligned timing chain
as required.
noise.
Replace the camshaft and valve
Worn camshaft lobes.
lifters.
Faulty cylinder head gasket and/or
Engine misfire with cranking or other damage to the Inspect the cylinder head and
coolant consumption cylinder head and engine block engine block for damage to the
cooling system. coolant passages and/or a faulty
Coolant consumption may or may not head gasket.

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 2010 Kia Sportage EX
2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

cause the engine to overheat. Repair or replace as required.

Worn valves, guides and/or valve stem oil
Repair or replace as required.
Engine misfire with seals.
excessive oil Worn piston rings. Inspect the cylinder for a loss
consumption (Oil consumption may or may not cause the of compression.
engine to misfire) Repair or replace as required.
Drain the oil.
Incorrect oil viscosity
Engine noise on Install the correct viscosity oil.
startup, but only Inspect the thrust bearing and
lasting a few seconds. Worn crankshaft thrust bearing. crankshaft.
Repair or replace as required.
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.
Replace the timing chain tensioner as
Upper engine noise, Worn timing chain tensioner, if applicable.
required.
regardless of engine
speed. Inspect the camshaft lobes.
Worn camshaft lobes. Replace the timing 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.
Low oil pressure. Repair or required.
Loose or damaged flywheel. Repair or replace the flywheel.
Inspect the oil pan.
Damaged oil pan, contacting the oil pump
screen. Inspect the oil pump screen.
Repair or replace as required.
Oil pump screen loose, damaged or Inspect the oil pump screen.
restricted. Repair or replace as required.
Inspect the piston, piston pin
Excessive piston-to-cylinder bore clearance. and cylinder bore.
Repair as required.
Inspect the piston, piston pin
Excessive piston pin-to-connecting rod
and the connecting rod.
clearance
Repair or replace as required.
Lower engine noise, Inspect the following components and
regardless of engine repair as required.

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 2010 Kia Sportage EX
2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

speed The connecting rod bearings.

Excessive connecting rod bearing rod The connecting rods.
clearance The crankshaft.
The crankshaft journal.
Inspect the following components,
and repair as required.
Excessive crankshaft bearing clearance
The crankshaft bearing.
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 and
repair as required:

Excessive connecting rod bearing clearance The connecting rod bearings.

The connecting rods.
Engine noise under
The crankshaft
load
Inspect the following components,
and repair as required.
Excessive crankshaft bearing clearance The crankshaft bearings.
The crankshaft journals.
The cylinder block crankshaft
1. Remove spark plugs and check
for fluid.
Hydraulically locked cylinder
2. Inspect for broken head gasket.
Coolant/antifreeze in cylinder. 3. Inspect for cracked engine
Oil in cylinder. block or cylinder head.
Fuel in cylinder 4. Inspect for a sticking fuel
Engine will not injector and/or leaking fuel
crank-crankshaft will regulator.
not rotate Broken timing chain and/or timing chain 1. Inspect timing chain and gears.
gears. 2. Repair as required.
Material in cylinder
1. Inspect cylinder for damaged
Broken valve components and/or foreign
materials.
Piston material
2. Repair or replace as required.
Foreign material

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 2010 Kia Sportage EX
2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

1. Inspect crankshaft and

Seized crankshaft or connecting rod
connecting rod bearing.
bearings.
2. Repair as required.
1. Inspect connecting rods.
Bend or broken connecting rod.
2. Repair as required.
1. Inspect crankshaft.
Broken crankshaft
2. Repair as required.

SPECIAL SERVICE TOOLS

SPECIAL TOOLS

SPECIAL TOOLS REFERENCE CHART

Tool (Number and
Illustration Use
name)

Crankshaft front oil seal

installer Installation of the front oil seal
(09214-33000)

Camshaft oil seal installer

Installation of the camshaft oil seal
(09214-21000)

Valve guide installer Remove and installation of the valve

(09221-3F100 A/B) guide

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 2010 Kia Sportage EX
2010 ENGINE General Information (Engine Mechanical System-G2.7 DOHC) - Sportage

Valve stem oil seal

installer Installation of the valve stem oil seal
(09222-22001)

Valve spring compressor

& adaptor Removal and installation of the intake or
(09222-28000, 09222- exhaust valve
28100)

1. Installation of the engine rear oil

Crankshaft rear oil seal
seal
installer
(09231-33000) 2. Installation of the crankshaft rear
oil seal

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 2010 Kia Sportage EX
2010 ENGINE Cylinder Head Assembly (Engine Mechanical System-G2.7 DOHC) - Sportage

2010 ENGINE

Cylinder Head Assembly (Engine Mechanical System-G2.7 DOHC) - Sportage

COMPONENTS AND COMPONENTS LOCATION

COMPONENTS

Fig. 1: Identifying Cylinder Head Components With Torque Specifications

Courtesy of KIA MOTORS AMERICA, INC.

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 2010 Kia Sportage EX
2010 ENGINE Cylinder Head Assembly (Engine Mechanical System-G2.7 DOHC) - Sportage

Fig. 2: Identifying Valve And Camshaft Components With Torque Specifications

Courtesy of KIA MOTORS AMERICA, INC.

REPAIR PROCEDURES
REMOVAL

CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damaging the cylinder head, wait until the engine coolant
temperature drops below normal temperature before removing it.

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 2010 Kia Sportage EX
2010 ENGINE Cylinder Head Assembly (Engine Mechanical System-G2.7 DOHC) - Sportage

When handling a metal gasket, take care not to fold the gasket or
damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.

NOTE: Mark all wiring and hoses to avoid misconnection.

Inspect the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
(See REPAIR PROCEDURES ).

1. Remove the air duct (A).

Fig. 3: Identifying Air Duct

Courtesy of KIA MOTORS AMERICA, INC.

2. Remove the cowl grill and wiper motor. (Refer to FRONT WIPER MOTOR )
3. Remove the strut bar.
4. Disconnect the negative terminal from the battery.

Fig. 4: Disconnecting Negative Terminal From Battery

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 2010 Kia Sportage EX
2010 ENGINE Cylinder Head Assembly (Engine Mechanical System-G2.7 DOHC) - Sportage

Courtesy of KIA MOTORS AMERICA, INC.

5. Drain the engine coolant. (See REMOVAL )

Remove the radiator cap to speed draining.

6. Remove the engine cover.

7. Remove the intake air hose and air cleaner assembly.
1. Disconnect the AFS connector (A).
2. Disconnect the breather hose (B) from air cleaner hose.
3. Remove the intake air hose and air cleaner assembly (C).

Fig. 5: Identifying AFS Connector, Breather Hose And Air Cleaner Assembly
Courtesy of KIA MOTORS AMERICA, INC.

8. Remove the coolant reservoir tank (A).

Fig. 6: Identifying Coolant Reservoir Tank

Courtesy of KIA MOTORS AMERICA, INC.

9. Remove the upper radiator hose (A) and lower radiator hose (B).

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 2010 Kia Sportage EX
2010 ENGINE Cylinder Head Assembly (Engine Mechanical System-G2.7 DOHC) - Sportage

Fig. 7: Identifying Upper And Lower Radiator Hose

Courtesy of KIA MOTORS AMERICA, INC.

10. Remove the heater hoses (A) and throttle body heater hose (B).

Fig. 8: Identifying Heater Hoses And Throttle Body Heater Hose

Courtesy of KIA MOTORS AMERICA, INC.

11. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the
intake manifold.
1. TPS (Throttle Position Sensor) connector (A).
2. ISA (Idle Speed Actuator) connector (B).
3. PCSV (Purge Control Solenoid Valve) connector (C).
4. VIS actuator connector (D).
5. Injector connector (E).
6. Knock sensor connectors (F).
7. CMP (Camshaft Position Sensor) connector (G).
8. Oxygen sensor (rear 1st) connector (H).
9. PCSV (Purge Control Solenoid Valve) hose (I).

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Fig. 9: Identifying TPS (Throttle Position Sensor), ISA (Idle Speed Actuator) And PCSV
(Purge Control Solenoid Valve) Connector
Courtesy of KIA MOTORS AMERICA, INC.

10. ECT (Engine Coolant Temperature) sensor connector (A).

11. Ignition coil connector (B).
12. Crankshaft position sensor connector (C).
13. Oxygen sensor (front 2nd) connector (D).
14. Ground cable (E).

Fig. 10: Identifying ECT (Engine Coolant Temperature) Sensor, Ignition Coil And
Crankshaft Position Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.

15. Three fuel injector connectors (A).

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Fig. 11: Identifying Fuel Injector Connectors

Courtesy of KIA MOTORS AMERICA, INC.

16. Disconnect ground cable (A) from the cowl panel.

Fig. 12: Identifying Ground Cable

Courtesy of KIA MOTORS AMERICA, INC.

17. IAT (Intake Air Temperature) sensor connector (A).

18. VIS actuator connector (B).
19. Oxygen sensor (rear 2nd) connector (C).
20. Power steering pump switch (D).

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Fig. 13: Identifying IAT (Intake Air Temperature) Sensor, VIS Actuator And Oxygen Sensor
(Rear 2nd) Connector
Courtesy of KIA MOTORS AMERICA, INC.

21. Oxygen sensor (front 1st) connector (A).

22. Air conditioner compressor switch connector (B).
23. Oil pressure sensor connector (C).

Fig. 14: Identifying Oxygen Sensor (Front 1st), Air Conditioner Compressor Switch And Oil
Pressure Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.

12. Remove the fuel inlet hose (A) from delivery pipe.

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Fig. 15: Identifying Fuel Inlet Hose

Courtesy of KIA MOTORS AMERICA, INC.

13. Remove the brake booster vacuum hose (A).

Fig. 16: Identifying Brake Booster Vacuum Hose

Courtesy of KIA MOTORS AMERICA, INC.

14. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage.

Fig. 17: Identifying Accelerator Cable

Courtesy of KIA MOTORS AMERICA, INC.

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15. Remove the PCV hose (A).

Fig. 18: Identifying PCV Hose

Courtesy of KIA MOTORS AMERICA, INC.

16. Remove the intake manifold. (See REPAIR PROCEDURES )

17. Remove the power steering pump. (See POWER STEERING PUMP ).
18. Remove the exhaust manifold. (See REPAIR PROCEDURES )
19. Remove the timing belt. (See TIMING SYSTEM - 2.7L )
20. Remove the spark plug cable. (See IGNITION SYSTEM )
21. Remove the cylinder head covers (A).

Fig. 19: Identifying Cylinder Head Cover With Mounting Screw

Courtesy of KIA MOTORS AMERICA, INC.

22. Remove the camshaft sprocket.

23. Remove the camshaft bearing caps (A).

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Fig. 20: Identifying Camshaft Bearing Cap With Mounting Bolts (1 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

Fig. 21: Identifying Camshaft Bearing Cap With Mounting Bolts (2 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

24. Remove the camshafts (A).

Fig. 22: Identifying Camshafts (1 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 23: Identifying Camshafts (2 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

25. Remove the timing belt rear cover (A).

Fig. 24: Identifying Timing Belt Rear Cover

Courtesy of KIA MOTORS AMERICA, INC.

26. Remove the water temperature control assembly (A) and water pipe.

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Fig. 25: Identifying Water Temperature Control Assembly

Courtesy of KIA MOTORS AMERICA, INC.

27. Remove the cylinder head bolts, then remove the cylinder heads.
1. Uniformly loosen and remove the 8 cylinder head bolts on each cylinder head in several passes and
in the sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts
and plate washer.

Fig. 26: Cylinder Head Bolts Loosening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Head warpage or cracking could result from removing bolts in

an incorrect order.

2. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden
blocks on a bench.

CAUTION: Be careful not to damage the contact surfaces of the cylinder

head and cylinder block.

REPLACEMENT

VALVE GUIDE

1. Using the SST (09221-3F100A), withdraw the old valve guide toward the bottom of cylinder head.

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Fig. 27: Removing Valve Guide Using SST (09221-3F100A)

Courtesy of KIA MOTORS AMERICA, INC.

2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
3. Using the SST (09221-3F100A/B), press-fit the valve guide. The valve guide must be press-fitted from
the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in
length.

OVERSIZE VALVE GUIDE HOLE SPECIFICATIONS

Over size mm (in.) Size mark Oversize valve guide hole size mm (in.)
11.05 ~ 11.068
0.05 (0.002) 5
(0.4350 ~ 0.4357)
11.25 ~ 11.268
0.25 (0.010) 25
(0.4429 ~ 0.4436)
11.50 ~ 11.518
0.50 (0.020) 50
(0.4528 ~ 0.4535)

Valve guide length

Intake : 39mm (1.535in.)

Exhaust : 43mm (1.693in.)

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Fig. 28: Installing Valve Guide Using SST (09221-3F100A)

Courtesy of KIA MOTORS AMERICA, INC.

4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.

DISASSEMBLY

NOTE: Identify HLA (Hydraulic Lash Adjuster), valves, valve springs as they are
removed so that each item can be reinstalled in its original position.

1. Remove HLAs (A).

Fig. 29: Identifying HLAs

Courtesy of KIA MOTORS AMERICA, INC.

2. Remove valves.
1. Using SST (09222-28000, 09222-28100), compress the valve spring and remove retainer lock.

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Fig. 30: Removing Valves Using SST (09222-28000, 09222-28100)

Courtesy of KIA MOTORS AMERICA, INC.

2. Remove the spring retainer.

3. Remove the valve spring.
4. Remove the valve.
5. Using needle-nose pliers, remove the oil seal.
6. Using a magnetic finger, remove the spring seat.

INSPECTION

CLEANING

1. Clean top surfaces of pistons and cylinder block.

1. Turn the crankshaft, and bring each piston to top dead center (TDC).

Using a gasket scraper, remove all the carbon from the piston top surface.

2. Using a gasket scraper, remove all the gasket material from the cylinder block surface.
3. Using compressed air, blow carbon and oil from the bolt holes.
2. Remove gasket material.

Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

CAUTION: Be careful not to scratch the cylinder block contact surface.

3. Clean combustion cambers.

Using a wire brush, remove all the carbon from the combustion cambers.

CAUTION: Be careful not to scratch the cylinder block contact surface.

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4. Clean cylinder heads.

Using a soft brush and solvent. thoroughly clean the cylinder head.

5. Clean valves.
1. Using a gasket scraper, chip off any carbon from the valve head.
2. Using a wire brush thoroughly clean the valve.

CYLINDER HEAD

1. Inspect for flatness.

Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block for
warpage.

Flatness of cylinder head gasket surface

Standard : Less than 0.03mm (0.0012 in.)

Limit : 0.05mm (0.0020 in.)

Fig. 31: Measuring Flatness Of Cylinder Head Gasket Surface

Courtesy of KIA MOTORS AMERICA, INC.

2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If
cracked, replace the cylinder head.

VALVE AND VALVE SPRING

1. Inspect valve stems and valve guides.

1. Using a caliper gauge, measure the inside diameter or the valve guide.

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Valve guide inside.

Fig. 32: Measuring Inside Diameter Or Valve Guide

Courtesy of KIA MOTORS AMERICA, INC.

2. Using a micrometer, measure the diameter of the valve stem.

Fig. 33: Measuring Diameter Of Valve Stem

Courtesy of KIA MOTORS AMERICA, INC.

3. Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.

Valve stem-to-guide clearance

[Standard]

Intake : 0.02 ~ 0.05mm (0.0008 ~ 0.0020in.)

Exhaust : 0.030 ~ 0.065mm (0.0012 ~ 0.0026in.)

[Limit]

Intake : 0.1mm (0.0040in.)

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Exhaust : 0.13mm (0.0051in.)

If the clearance is greater than maximum, replace the valve and valve guide.

2. Inspect valves.
1. Check the valve is ground to the correct valve face angle.
2. Check that the surface of the valve for wear.

If the valve face is worn, replace the valve.

3. Check the valve head margin thickness.

If the margin thickness is less than minimum, replace the valve.

Margin

[Standard]

Intake : 1.0mm (0.0394in.)

Exhaust : 1.3mm (0.0512in.)

[Limit]

Intake : 0.5mm (0.0197in.)

Exhaust : 0.8mm (0.0315in.)

Fig. 34: Identifying Valve Head Margin

Courtesy of KIA MOTORS AMERICA, INC.

4. Check the surface of the valve stem tip for wear.

If the valve stem tip is worn, replace the valve.

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3. Inspect valve seats

Check the valve seat for evidence of overheating and improper contact with the valve face.

Replace the seat if necessary.

Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact
width should be within specifications and centered on the valve face.

4. Inspect valve springs.

1. Using a steel square, measure the out-of-square of the valve spring.
2. Using a vernier calipers, measure the free length of the valve spring.

Valve spring

[Standard]

Free height : 42.5mm (1.6732in.)

Load : 21kg/35mm (48.4kg/1.378mm)

[Limit]

Free height : -1.0mm (-0.0394 in.)

Out-of-square : 3°

Fig. 35: Measuring Valve Spring Free Length

Courtesy of KIA MOTORS AMERICA, INC.

If the free length is not as specified, replace the valve spring.

CAMSHAFT

1. Inspect cam lobes.

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Using a micrometer, measure the cam lobe height.

Cam height

[Standard value]

Intake : 43.95 ~44.15mm (1.7303 ~ 1.7382in.)

Exhaust : 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)

Fig. 36: Measuring Cam Lobe Height

Courtesy of KIA MOTORS AMERICA, INC.

If the cam lobe height is less than minimum, replace the camshaft.

2. Inspect cam journals.

Using a micrometer, measure the journal diameter.

Journal diameter

Standard value

25.964 ~ 25.980mm (1.0222 ~ 1.0228in.)

If the journal diameter is not as specified, check the oil clearance.

3. Inspect camshaft bearings.

Check that bearing for flaking and scoring. If the bearings are damaged, replace the bearing caps and
cylinder head as a set.

4. Inspect camshaft journal oil clearance.

1. Clean the bearing caps and camshaft journals.
2. Place the camshafts on the cylinder head.

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3. Lay a strip of plastigage across each of the camshaft journal.

Fig. 37: Inspecting Camshaft Journal Oil Clearance

Courtesy of KIA MOTORS AMERICA, INC.

4. Install the bearing caps. (See 3 )

CAUTION: Do not turn the camshaft.

5. Remove the bearing caps.

6. Measure the plastigage at its widest point.

Bearing oil clearance

Standard value : 0.02 ~ 0.061mm (0.0008 ~ 0.0024in.)

Limit : 0.1mm (0.0039in.)

Fig. 38: Measuring Plastigage At Its Widest Point

Courtesy of KIA MOTORS AMERICA, INC.

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If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.

7. Completely remove the plastigage.

8. Remove the camshafts.
5. Inspect camshaft end play.
1. Install the camshafts. (See 6 ).
2. Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play

Standard value : 0.1 ~ 0.15mm (0.004 ~ 0.0059in.)

Fig. 39: Measuring Camshaft End Play

Courtesy of KIA MOTORS AMERICA, INC.

If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.

3. Remove the camshafts.

REASSEMBLY

NOTE: Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating
surfaces.
Replace oil seals with new ones.

1. Install valves.
1. Install the spring seats.
2. Using SST (09222-22001), push in a new oil seal.

NOTE: Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the
valve guides.

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Fig. 40: Installing Oil Seal Using SST (09222-22001)

Courtesy of KIA MOTORS AMERICA, INC.

3. Install the valve, valve spring and spring retainer.

NOTE: Place valve springs so that the side coated with enamel faces toward
the valve spring retainer and then installs the retainer.

4. Using the SST (09222-28000, 09222-28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the
valve spring compressor.

Fig. 41: Compressing Spring Using SST (09222-28000, 09222-28100)

Courtesy of KIA MOTORS AMERICA, INC.

5. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to
ensure proper seating of the valve and retainer lock.

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Fig. 42: Checking Proper Seating Of Valve And Retainer Lock

Courtesy of KIA MOTORS AMERICA, INC.

2. Install HLAs.

Check that the HLA rotates smoothly by hand.

Fig. 43: Identifying HLAs

Courtesy of KIA MOTORS AMERICA, INC.

INSTALLATION

NOTE: Thoroughly clean all parts to be assembled.

Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC. (See REPAIR
PROCEDURES ).

1. Install the cylinder head gaskets on the cylinder block.

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Fig. 44: Cylinder Head Gasket Installation Position

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Be careful of the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.

Tightening torque

25N.m (250kgf.cm, 18lb-ft) + 60° + 45°

1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
2. Install the plate washer to the cylinder head bolt.
3. Install and uniformly tighten the cylinder head bolts on each cylinder head in several passes and in
the sequence shown, then repeat for the other side, as shown.

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Fig. 45: Cylinder Head Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

If any of the cylinder head bolts dose not meet the torque specification, repeat the cylinder head
bolt torque tightening sequence.

Torque : 25N.m (250kgf.cm, 18lb-ft)

Fig. 46: Tightening Cylinder Head Bolt

Courtesy of KIA MOTORS AMERICA, INC.

4. Retighten the cylinder head bolts by 60° in the numerical order shown.
5. Retighten the cylinder head bolts by 45° in the numerical order shown.
4. Install the water pipe and water temperature control assembly (A).

Tightening torque

Water temperature control

15 ~ 20N.m (150 ~ 200kgf.cm, 11 ~ 14lb-ft)

Fig. 47: Identifying Water Pipe And Water Temperature Control Assembly With Mounting Screws
Courtesy of KIA MOTORS AMERICA, INC.

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5. Install the timing belt rear cover (A).

Tightening torque

Timing belt rear cover

10 ~ 12N.m (100 ~ 120kgf.cm, 7 ~ 9lb-ft)

Fig. 48: Identifying Timing Belt Rear Cover With Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.

6. Install the camshafts.

1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain
sprocket as shown.

Fig. 49: Identifying Intake And Exhaust Timing Chain Sprocket

Courtesy of KIA MOTORS AMERICA, INC.

2. Install the camshaft (A).

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Fig. 50: Identifying Camshaft

Courtesy of KIA MOTORS AMERICA, INC.

3. Install the camshaft bearing caps (A).

Tightening torque

M6 (38mm):

10 ~ 12N.m (100 ~ 120kgf.cm, 7 ~ 9lb-ft) (Mark7)

M6 (50mm):

14 ~ 16N.m (140 ~ 160kgf.cm, 10 ~ 12lb-ft) (Mark10)

Fig. 51: Identifying Camshaft Bearing Caps With Mounting Bolts

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Apply new engine oil to the thrust portion and journal of the
camshafts.
Apply a light coat of engine oil on the threads and under the
heads of the bearing cap bolts.

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7. Using the SST (09214-21000), install the camshaft bearing oil seal.

Fig. 52: Installing Camshaft Bearing Oil Seal Using SST (09214-21000)
Courtesy of KIA MOTORS AMERICA, INC.

8. Install the camshaft sprocket.

1. Temporarily install the camshaft sprocket bolts.
2. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft
sprocket bolts.

Tightening torque

Camshaft sprocket bolt

90 ~ 110N.m (900 ~ 1100kgf.cm, 65 ~80lb-ft)

9. Install semi-circular packing.

10. Install the cylinder head cover.
1. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).

Fig. 53: Identifying Cylinder Head Cover Gasket

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Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Before installing the head cover gasket, thoroughly clean the
head cover gasket and the groove.
When installing, make sure the head cover gasket is seated
securely in the corners of the recesses with no gap.

2. Apply liquid gasket to the head cover gasket at the corners of the recess.

NOTE: Use liquid gasket, loctite No. 5699.

Check that the mating surfaces are clean and dry before
applying liquid gasket.
After assembly, wait at least 30 minutes before filling the engine
with oil.

3. Install the cylinder head covers (A) with the 16 bolts. Uniformly tighten the bolts in several passes.

Tightening torque

8 ~ 10N.m (80 ~ 100kgf.cm, 6 ~ 7.4lb-ft)

Fig. 54: Identifying Cylinder Head Cover With Mounting Bolt

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 55: Cylinder Head Cover Bolts Tightening Pattern

Courtesy of KIA MOTORS AMERICA, INC.

11. Install the spark plug cable. (See IGNITION SYSTEM )

12. Install the timing belt. (See REPAIR PROCEDURES ).
13. Install the exhaust manifold. (See INSTALLATION )
14. Install the power steering pump. (See POWER STEERING PUMP )
15. Install the intake manifold. (See INSTALLATION )
16. Install the PCV hose (A).

Fig. 56: Identifying PCV Hose

Courtesy of KIA MOTORS AMERICA, INC.

17. Install the accelerator cable.

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Fig. 57: Identifying Accelerator Cable

Courtesy of KIA MOTORS AMERICA, INC.

18. Install the brake booster vacuum hose (A).

Fig. 58: Identifying Brake Booster Vacuum Hose

Courtesy of KIA MOTORS AMERICA, INC.

19. Install the fuel inlet hose (A).

Fig. 59: Identifying Fuel Inlet Hose

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Courtesy of KIA MOTORS AMERICA, INC.

20. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake
manifold.
1. Oil pressure sensor connector (C).
2. Air conditioner compressor switch connector (B).
3. Oxygen sensor (front 1st) connector (A).

Fig. 60: Identifying Oil Pressure Sensor, Air Conditioner Compressor Switch And Oxygen
Sensor (Front 1st) Connector
Courtesy of KIA MOTORS AMERICA, INC.

4. Power steering pump switch (D).

5. Oxygen sensor (rear 2nd) connector (C).
6. VIS actuator connector (B).
7. IAT (Intake Air Temperature) sensor connector (A).

Fig. 61: Identifying Power Steering Pump Switch With Oxygen Sensor (Rear 2nd) And VIS
Actuator Connector
Courtesy of KIA MOTORS AMERICA, INC.

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8. Connect the ground cable (A) to the cowl panel.

Fig. 62: Identifying Ground Cable

Courtesy of KIA MOTORS AMERICA, INC.

9. Three fuel injector connectors (A).

Fig. 63: Identifying Fuel Injector Connectors

Courtesy of KIA MOTORS AMERICA, INC.

10. Ground cable (E).

11. Oxygen sensor connector (D).
12. Crankshaft position sensor connector (C).
13. Ignition coil connector (B).
14. ECT sensor connector (A).

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Fig. 64: Identifying ECT Sensor, Ignition Coil And Crankshaft Position Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.

15. PCSV (Purge Control Solenoid Valve) hose (I).

16. Oxygen sensor (rear 1st) connector (H).
17. CMP (Camshaft position sensor) connector (G).
18. Knock sensor connector (F).
19. Injector connector (E).
20. VIS actuator connector (D).
21. PCSV (Purge Control Solenoid Valve) connector (C).
22. ISA connector (B).
23. TPS connector (A).

Fig. 65: Identifying ISA, TPS, VIS Actuator And PCSV (Purge Control Solenoid Valve)
Connector
Courtesy of KIA MOTORS AMERICA, INC.

21. Install the heater hoses (A) and throttle body heater hose (B).

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Fig. 66: Identifying Heater Hoses And Throttle Body Heater Hose
Courtesy of KIA MOTORS AMERICA, INC.

22. Install the upper radiator hose (A) and lower radiator hose (B).

Fig. 67: Identifying Upper And Lower Radiator Hose

Courtesy of KIA MOTORS AMERICA, INC.

23. Install the coolant reservoir tank (A).

Fig. 68: Identifying Coolant Reservoir Tank

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Courtesy of KIA MOTORS AMERICA, INC.

24. Install the intake air hose and air cleaner assembly.
1. Install the intake air hose and air cleaner assembly (C).
2. Connect the breather hose (B) from air cleaner hose.
3. Connect the AFS connector (A).

Fig. 69: Identifying AFS Connector, Breather Hose With Intake Air Hose And Air Cleaner
Assembly
Courtesy of KIA MOTORS AMERICA, INC.

25. Install the engine cover.

26. Connect the negative terminal to the battery.

Fig. 70: Connecting Negative Terminal To Battery

Courtesy of KIA MOTORS AMERICA, INC.

27. Install the strut bar.

28. Install the cowl grill and wiper motor. (Refer to FRONT WIPER MOTOR )
29. Install the air duct (A).

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Fig. 71: Identifying Air Duct

Courtesy of KIA MOTORS AMERICA, INC.

30. Fill with engine coolant.

31. Start the engine and check for leaks.
32. Recheck engine coolant level and oil level.

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 2010 Kia Sportage EX
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2010 ENGINE

Cylinder Block (Engine Mechanical System-G2.7 DOHC) - Sportage

COMPONENTS AND COMPONENTS LOCATION

COMPONENT

Fig. 1: Identifying Cylinder Block Components With Torque Specifications (1 Of 2)

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Courtesy of KIA MOTORS AMERICA, INC.

Fig. 2: Identifying Cylinder Block Components With Torque Specifications (2 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

REPAIR PROCEDURES
DISASSEMBLY

1. A/T : remove drive plate.

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2. Install engine to engine stand for disassembly (A).

3. Remove timing belt. (See TIMING SYSTEM - 2.7L ).
4. Remove cylinder head. (See CYLINDER HEAD ASSEMBLY - 2.7L )
5. Remove oil level gauge assembly.
6. Remove the alternator. (See ALTERNATOR ).
7. Remove the air compressor. (See COMPRESSOR )
8. Remove the power steering pump bracket (A).

Fig. 3: Locating Power Steering Pump Bracket

Courtesy of KIA MOTORS AMERICA, INC.

9. Remove water pump. (See REPAIR PROCEDURES )

10. Remove knock sensors (A).

Fig. 4: Locating Knock Sensors

Courtesy of KIA MOTORS AMERICA, INC.

11. Remove the lower oil pan (A).

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Fig. 5: Locating Lower Oil Pan

Courtesy of KIA MOTORS AMERICA, INC.

12. Remove oil screen.

Remove the 2 bolts (B), oil screen (A) and gasket.

Fig. 6: Locating Bolts And Oil Screen

Courtesy of KIA MOTORS AMERICA, INC.

13. Remove the upper oil pan (A).

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Fig. 7: Locating Upper Oil Pan

Courtesy of KIA MOTORS AMERICA, INC.

14. Check the connecting rod end play. (See CONNECTING ROD AND CRANKSHAFT )
15. Remove the connecting rod caps and check oil clearance. (See CONNECTING ROD AND
CRANKSHAFT )
16. Remove piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

NOTE: Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.

17. Remove front case. (See REPAIR PROCEDURES )

18. Remove oil seal case.

Remove the 3 bolts (B) and oil seal case (A).

Fig. 8: Locating Bolts And Oil Seal Case

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Courtesy of KIA MOTORS AMERICA, INC.

19. Check the crankshaft end play. (See CONNECTING ROD AND CRANKSHAFT )
20. Remove crankshaft bearing cap and check oil clearance. (See CONNECTING ROD AND
CRANKSHAFT )

Fig. 9: Removing Crankshaft Bearing Cap

Courtesy of KIA MOTORS AMERICA, INC.

21. Lift the crankshaft (A) out of the engine, being careful not to damage journals.

NOTE: Arrange the main bearings and trust washers in the correct order.

Fig. 10: Locating Crankshaft

Courtesy of KIA MOTORS AMERICA, INC.

22. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and
pin as a set.

23. Remove piston rings.

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1. Using a piston ring expender, remove the 2 compression rings.

2. Remove the 2 side rails and oil ring by hand.

NOTE: Arrange the piston rings in the correct order only.

24. Disconnect connecting rod from piston.

DISASSEMBLY

1. A/T : remove drive plate.

2. Install engine to engine stand for disassembly (A).
3. Remove timing belt. (See TIMING SYSTEM - 2.7L ).
4. Remove cylinder head. (See CYLINDER HEAD ASSEMBLY - 2.7L )
5. Remove oil level gauge assembly.
6. Remove the alternator. (See ALTERNATOR ).
7. Remove the air compressor. (See COMPRESSOR )
8. Remove the power steering pump bracket (A).

Fig. 11: Locating Power Steering Pump Bracket

Courtesy of KIA MOTORS AMERICA, INC.

9. Remove water pump. (See REMOVAL )

10. Remove knock sensors (A).

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Fig. 12: Locating Knock Sensors

Courtesy of KIA MOTORS AMERICA, INC.

11. Remove the lower oil pan (A).

Fig. 13: Locating Lower Oil Pan

Courtesy of KIA MOTORS AMERICA, INC.

12. Remove oil screen.

Remove the 2 bolts (B), oil screen (A) and gasket.

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Fig. 14: Locating Bolts, Oil Screen And Gasket

Courtesy of KIA MOTORS AMERICA, INC.

13. Remove the upper oil pan (A).

Fig. 15: Locating Upper Oil Pan

Courtesy of KIA MOTORS AMERICA, INC.

14. Check the connecting rod end play. (See CONNECTING ROD AND CRANKSHAFT )
15. Remove the connecting rod caps and check oil clearance. (See CONNECTING ROD AND
CRANKSHAFT )
16. Remove piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

NOTE: Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.

17. Remove front case. (See REPAIR PROCEDURES )

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18. Remove oil seal case.

Remove the 3 bolts (B) and oil seal case (A).

Fig. 16: Locating Bolts And Oil Seal Case

Courtesy of KIA MOTORS AMERICA, INC.

19. Check the crankshaft end play. (See Place of identification mark (Crankshaft bearing) )
20. Remove crankshaft bearing cap and check oil clearance. (See CONNECTING ROD AND
CRANKSHAFT )

Fig. 17: Checking Oil Clearance

Courtesy of KIA MOTORS AMERICA, INC.

21. Lift the crankshaft (A) out of the engine, being careful not to damage journals.

NOTE: Arrange the main bearings and trust washers in the correct order.

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Fig. 18: Locating Crankshaft

Courtesy of KIA MOTORS AMERICA, INC.

22. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and
pin as a set.

23. Remove piston rings.

1. Using a piston ring expender, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.

NOTE: Arrange the piston rings in the correct order only.

24. Disconnect connecting rod from piston.

INSPECTION

CONNECTING ROD AND CRANKSHAFT

1. Check the connecting rod end play.

Using a dial indicator, measure the end play while moving the connecting rod back and forth.

Standard end play : 0.1~ 0.25mm (0.004 ~ 0.010in.)

Maximum end play : 0.4mm (0.016in.)

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Fig. 19: Measuring End Play

Courtesy of KIA MOTORS AMERICA, INC.

A. If out-of-tolerance, replace the connecting rod assembly.

B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
3. Remove the connecting rod cap and bearing half.
4. Clean the crank pin and bearing.
5. Place plastigage across the crank pin.
6. Reinstall the bearing half and cap, and torque the bolts.

Tightening torque

16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15lb-ft) + 90°

NOTE: Do not turn the crankshaft.

7. Remove the 2 bolts, connecting rod cap and bearing half.

8. Measure the plastigage at its widest point.

Standard oil clearance

0.018 ~ 0.036mm (0.0007 ~ 0.0014in.)

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Fig. 20: Measuring Plastigage At Its Widest Point

Courtesy of KIA MOTORS AMERICA, INC.

9. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column),
and recheck the clearance.

CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.

CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Connecting rod mark location

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Fig. 21: Identifying Connecting Rod Mark Location

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CONNECTING ROD

CLASS MARK INSIDE DIAMETER
51.000 ~ 51.006mm
0 A
(2.0079 ~ 2.0081in.)
51.006 ~ 51.012mm
1 B
(2.0081 ~ 2.0083in.)
51.012 ~ 51.018mm
2 C
(2.0083 ~ 2.0086in.)

Crankshaft pin mark location

Fig. 22: Identifying Crankshaft Pin Mark Location

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CRANKSHAFT
CLASS MARK OUTSIDE DIAMETER OF PIN
47.994 ~ 48.000mm
I A
(1.8895 ~ 1.8898in.)

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47.988 ~ 47.994mm
II B
(1.8893 ~ 1.8895in.)
47.982 ~ 47.988mm
III C
(1.8890 ~ 1.8893in.)

Place of identification mark (Connecting rod bearing)

Fig. 23: Identifying Identification Mark (Connecting Rod Bearing)

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CONNECTING ROD BEARING

CLASS MARK THICKNESS OF BEARING
1.500 ~ 1.503mm
A BLUE
(0.0590 ~ 0.0591in.)
1.497 ~ 1.500mm
B BLACK
(0.0589 ~ 0.0590in.)
1.494 ~ 1.497mm
C NONE
(0.0588 ~ 0.0589in.)
1.491 ~ 1.494mm
D GREEN
(0.0587 ~ 0.0588in.)
1.488 ~ 1.491mm
E YELLOW
(0.0586 ~ 0.0587in.)

(11) Selection

CRANKSHAFT IDENTIFICATION MARK REFERENCE CHART

ASSEMBLING
CRANKSHAFT CONNECTING ROD
CLASSIFICATION OF
IDENTIFICATION MARK IDENTIFICATION MARK
BEARING
0 (A) E (YELLOW)
I (A) 1 (B) D (GREEN)
2 (C) C (NONE)
0 (A) D (GREEN)
II (B) 1 (B) C (NONE)

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2 (C) B (BLACK)
0 (A) C (NONE)
III (C) 1 (B) B (BLACK)
2 (C) A (BLUE)

3. Check the crankshaft bearing oil clearance.

1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
2. Clean each main journal and bearing half with a clean shop tower.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and caps, then torque the bolts.

Tightening torque

M8

13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lb-ft) + 90°

M10

27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lb-ft) + 90°

NOTE: Do not turn the crankshaft.

5. Remove the cap and bearing again, and measure the widest part of the plastigage.

Standard oil clearance

0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)

Fig. 24: Measuring Widest Part Of Plastigage

Courtesy of KIA MOTORS AMERICA, INC.

6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column),
and recheck the clearance.

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CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.

CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Connecting rods

1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly
match. When a new connecting rod is installed, make sure that the notches for holding the bearing in
place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as
well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to
the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted
should be replaced.

Allowable bend of connecting rod

0.05mm/100mm (0.0020 in./3.94 in.) or less

Allowable twist of connecting rod

0.1mm/100mm (0.0039 in./3.94 in.) or less

Letters have been stamped on the end of the block as a mark for the size of each of the 4 main journal
bores.

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Fig. 25: Identifying Letters Stamped On End Of Block

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CYLINDER BLOCK

CLASS MARK INSIDE DIAMETER
66.000 ~ 66.006mm
a A
(2.5984 ~ 2.5986in.)
66.006 ~ 66.012mm
b B
(2.5986 ~ 2.5989in.)
66.012 ~ 66.018mm
c C
(2.5989 ~ 2.5991in.)

Crankshaft journal mark location

Fig. 26: Identifying Crankshaft Journal Mark Location

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CRANKSHAFT
CLASS MARK OUTSIDE DIAMETER OF JOURNAL
61.994 ~ 62.000mm
I A
(2.4407 ~ 2.4409in.)

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61.988 ~ 61.994mm
II B
(2.4405 ~ 2.4407in.)
61.982 ~ 61.988mm
III C
(2.4402 ~ 2.4405in.)

Place of identification mark (Crankshaft bearing)

Fig. 27: Identifying Identification Mark (Crankshaft Bearing)

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CRANKSHAFT BEARING

CLASS MARK THICKNESS OF BEARING
2.007 ~ 2.010mm
A BLUE
(0.0790 ~ 0.0791in.)
2.004 ~ 2.007mm
B BLACK
(0.0789 ~ 0.0790in.)
2.001 ~ 2.004mm
C NONE
(0.0788 ~ 0.0789in.)
1.998 ~ 2.001mm
D GREEN
(0.0787 ~ 0.788in.)
1.995 ~ 1.998mm
E YELLOW
(0.0785 ~ 0.0787in.)

CRANKSHAFT BEARING SELECTION CHART

ASSEMBLING
CRANKSHAFT CRANKSHAFT BORE
CLASSIFICATION OF
IDENTIFICATION MARK IDENTIFICATION MARK
BEARING
a (A) E (YELLOW)
I (A) b (B) D (GREEN)
c (C) C (NONE)
a (A) D (GREEN)
II (B) b (B) C (NONE)
c (C) B (BLACK)
a (A) C (NONE)

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b (B) B (BLACK)
III (C)
c (C) A (BLUE)

4. Check crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.

Standard end play

0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)

Limit : 0.30mm (0.0118in.)

Fig. 28: Checking Crankshaft End Play

Courtesy of KIA MOTORS AMERICA, INC.

If the end play is greater than maximum, replace the thrust bearings as a set.

Thrust bearing thickness

2.05 ~ 2.09mm (0.081 ~ 0.082in.)

Inspect main journals and crank pins

Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter

61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)

Crank pin diameter

47.982 ~ 48.000mm (1.8890 ~ 1.8898in.)

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Fig. 29: Measuring Diameter Of Each Main Journal And Crank Pin
Courtesy of KIA MOTORS AMERICA, INC.

CYLINDER BLOCK

1. Remove gasket material.

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2. Clean cylinder block

Using a soft brush and solvent, thoroughly clean the cylinder block.

3. Inspect top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket
for warpage.

Flatness of cylinder block gasket surface

Standard : Less than 0.03mm (0.0012 in.)

Limit : 0.05mm (0.0020 in.)

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Fig. 30: Measuring Surface Contacting Cylinder Head Gasket For Warpage
Courtesy of KIA MOTORS AMERICA, INC.

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratches.

If deep scratches are present, replace the cylinder liner.

5. Inspect cylinder bore diameter

Using a cylinder bore gauge, measure the cylinder bore diameter at position A, B and C in the thrust and
axial directions.

Standard diameter

86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)

Fig. 31: Measuring Cylinder Bore Diameter At Position A, B And C In Thrust And Axial Directions
Courtesy of KIA MOTORS AMERICA, INC.

6. Check the cylinder bore size code (A) on the cylinder block bottom face.

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Fig. 32: Checking Cylinder Bore Size Code On Cylinder Block Bottom Face
Courtesy of KIA MOTORS AMERICA, INC.

CYLINDER BORE SIZE CODE REFERENCE CHART

Class Cylinder bore inner diameter Size code
A 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) A
B 86.71 ~ 86.72mm (3.4137 ~ 3.4141in.) B
C 86.72 ~ 86.73mm (3.4141 ~ 3.4145in.) C

7. Check the piston size code (A) on the piston top face.

Fig. 33: Checking Piston Size Code On Piston Top Face

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Stamp the grade mark of basic diameter with rubber stamp.

PISTON DIAMETER REFERENCE CHART

Class Piston diameter Size code
A 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) A
B 86.69 ~ 86.70mm (3.4130 ~ 3.4133in.) None

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C 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) C

8. Select the piston related to cylinder bore class.

Clearance : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

Boring Cylinder

1. Oversize pistons should be selected according to the largest bore cylinder.

CYLINDER BORE REFERENCE CHART

Identification Mark Size
0.25 0.25mm (0.010in.)
0.50 0.50mm (0.0250in.)

NOTE: The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D., calculate the new bore size.

New bore size = Piston O.D + 0.01 to 0.03mm

(0.0004 to 0.0012 in.) (clearance between piston and

cylinder) - 0.01 mm (0.0004 in.) (honing margin.)

4. Bore each of the cylinders to the calculated size.

CAUTION: To prevent distortion that may result from temperature rise during
honing, bore the cylinder holes in the firing order.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.

Standard : 0.01 ~ 0.03mm (0.0004 ~ 0.0012 in.)

NOTE: When boring the cylinders, finish all of the cylinders to the same oversize.
Do not bore only one cylinder to the oversize.

PISTON AND RINGS

1. Clean piston
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.

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3. Using solvent and a brush, thoroughly clean the piston.

NOTE: Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 38.5mm (1.516in.) from the top land of
the piston.

Standard diameter

86.68 ~ 86.71mm (3.4126 ~ 3.4138in.)

Fig. 34: Measuring Piston Outside Diameter

Courtesy of KIA MOTORS AMERICA, INC.

3. Calculate the difference between the cylinder bore diameter and the piston diameter.

Piston-to-cylinder clearance

0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.

Piston ring side clearance

No. 1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031 in.)

No. 2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0028 in.)

Limit

No. 1 : 0.1mm (0.004in.)

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No. 2 : 0.1mm (0.004in.)

Fig. 35: Measuring Clearance Between New Piston Ring And Wall Of Ring Groove
Courtesy of KIA MOTORS AMERICA, INC.

If the clearance is greater than maximum, replace the piston.

5. Inspect piston ring end gap.

To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.
If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder
bore diameter against the wear limits , If the bore is over the service limit, the cylinder block must be
rebored. (See Boring Cylinder ).

Piston ring end gap

Standard

No. 1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)

No. 2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)

Limit

Oil ring : 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)

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Fig. 36: Inspecting Piston Ring End Gap

Courtesy of KIA MOTORS AMERICA, INC.

PISTON PINS

1. Measure the diameter of the piston pin.

Piston pin diameter

21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)

Fig. 37: Measuring Diameter Of Piston Pin

Courtesy of KIA MOTORS AMERICA, INC.

2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance

0.007 ~ 0.022mm (0.00027 ~ 0.00086in.)

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3. Check the difference between the piston pin diameter and the connecting rod small end diameter.

Piston pin-to-connecting rod interference

0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)

OIL PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter.

If there is no continuity, replace the oil pressure switch.

Fig. 38: Checking Continuity Between Terminal And Body With An Ohmmeter
Courtesy of KIA MOTORS AMERICA, INC.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) vacuum is applied through the oil hole, the switch is
operating properly. Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

Fig. 39: Checking Continuity Between Terminal And Body With An Ohmmeter
Courtesy of KIA MOTORS AMERICA, INC.

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INSPECTION

CONNECTING ROD AND CRANKSHAFT

1. Check the connecting rod end play.

Using a dial indicator, measure the end play while moving the connecting rod back and forth.

Standard end play : 0.1~ 0.25mm (0.004 ~ 0.010in.)

Maximum end play : 0.4mm (0.016in.)

Fig. 40: Measuring End Play While Moving Connecting Rod Back And Forth
Courtesy of KIA MOTORS AMERICA, INC.

A. If out-of-tolerance, replace the connecting rod assembly.

B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
3. Remove the connecting rod cap and bearing half.
4. Clean the crank pin and bearing.
5. Place plastigage across the crank pin.
6. Reinstall the bearing half and cap, and torque the bolts.

Tightening torque

16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15 lbf.ft) + 90°

NOTE: Do not turn the crankshaft.

7. Remove the 2 bolts, connecting rod cap and bearing half.

8. Measure the plastigage at its widest point.

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Standard oil clearance

0.018 ~ 0.036mm (0.0007 ~ 0.0014in.)

Fig. 41: Measuring Plastigage At Its Widest Point

Courtesy of KIA MOTORS AMERICA, INC.

9. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column),
and recheck the clearance.

CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.

CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Connecting rod mark location

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Fig. 42: Identifying Connecting Rod Mark Location

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CONNECTING ROD

CLASS MARK INSIDE DIAMETER
51.000 ~ 51.006mm
0 A
(2.0079 ~ 2.0081in.)
51.006 ~ 51.012mm
1 B
(2.0081 ~ 2.0083in.)
51.012 ~ 51.018mm
2 C
(2.0083 ~ 2.0086in.)

Crankshaft pin mark location

Fig. 43: Identifying Crankshaft Pin Mark Location

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CRANKSHAFT
CLASS MARK OUTSIDE DIAMETER OF PIN
47.994 ~ 48.000mm
I A
(1.8895 ~ 1.8898in.)

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47.988 ~ 47.994mm
II B
(1.8893 ~ 1.8895in.)
47.982 ~ 47.988mm
III C
(1.8890 ~ 1.8893in.)

Place of identification mark (Connecting rod bearing)

Fig. 44: Identifying Identification Mark (Connecting Rod Bearing)

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CONNECTING ROD BEARING

CLASS MARK THICKNESS OF BEARING
1.500 ~ 1.503mm
A BLUE
(0.0590 ~ 0.0591in.)
1.497 ~ 1.500mm
B BLACK
(0.0589 ~ 0.0590in.)
1.494 ~ 1.497mm
C NONE
(0.0588 ~ 0.0589in.)
1.491 ~ 1.494mm
D GREEN
(0.0587 ~ 0.0588in.)
1.488 ~ 1.491mm
E YELLOW
(0.0586 ~ 0.0587in.)

11. Selection

CRANKSHAFT BEARING SELECTION REFERENCE CHART

ASSEMBLING
CRANKSHAFT CONNECTING ROD
CLASSIFICATION OF
IDENTIFICATION MARK IDENTIFICATION MARK
BEARING
0 (A) E (YELLOW)
I (A) 1 (B) D (GREEN)
2 (C) C (NONE)
0 (A) D (GREEN)
II (B) 1 (B) C (NONE)

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2 (C) B (BLACK)
0 (A) C (NONE)
III (C) 1 (B) B (BLACK)
2 (C) A (BLUE)

3. Check the crankshaft bearing oil clearance.

1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
2. Clean each main journal and bearing half with a clean shop tower.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and caps, then torque the bolts.

Tightening torque

M8

13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14 lbf.ft) + 90°

M10

27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24 lbf.ft) + 90°

NOTE: Do not turn the crankshaft.

5. Remove the cap and bearing again, and measure the widest part of the plastigage.

Standard oil clearance

0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)

Fig. 45: Measuring Widest Part Of Plastigage

Courtesy of KIA MOTORS AMERICA, INC.

6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column),
and recheck the clearance.

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CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.

CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Connecting rods

1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly
match. When a new connecting rod is installed, make sure that the notches for holding the bearing in
place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as
well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to
the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted
should be replaced.

Allowable bend of connecting rod

0.05mm/100mm (0.0020 in./3.94 in.) or less

Allowable twist of connecting rod

0.1mm/100mm (0.0039 in./3.94 in.) or less

Letters have been stamped on the end of the block as a mark for the size of each of the 4 main journal
bores.

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Fig. 46: Identifying Letters Stamped On End Of Block

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CYLINDER BLOCK

CLASS MARK INSIDE DIAMETER
66.000 ~ 66.006mm
a A
(2.5984 ~ 2.5986in.)
66.006 ~ 66.012mm
b B
(2.5986 ~ 2.5989in.)
66.012 ~ 66.018mm
c C
(2.5989 ~ 2.5991in.)

Crankshaft journal mark location

Fig. 47: Identifying Crankshaft Journal Mark Location

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CRANKSHAFT
CLASS MARK OUTSIDE DIAMETER OF JOURNAL
61.994 ~ 62.000mm
I A
(2.4407 ~ 2.4409in.)

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61.988 ~ 61.994mm
II B
(2.4405 ~ 2.4407in.)
61.982 ~ 61.988mm
III C
(2.4402 ~ 2.4405in.)

Place of identification mark (Crankshaft bearing)

Fig. 48: Identifying Identification Mark (Crankshaft Bearing)

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CRANKSHAFT BEARING

CLASS MARK THICKNESS OF BEARING
2.007 ~ 2.010mm
A BLUE
(0.0790 ~ 0.0791in.)
2.004 ~ 2.007mm
B BLACK
(0.0789 ~ 0.0790in.)
2.001 ~ 2.004mm
C NONE
(0.0788 ~ 0.0789in.)
1.998 ~ 2.001mm
D GREEN
(0.0787 ~ 0.788in.)
1.995 ~ 1.998mm
E YELLOW
(0.0785 ~ 0.0787in.)

CRANKSHAFT BEARING SELECTION CHART

ASSEMBLING
CRANKSHAFT CRANKSHAFT BORE
CLASSIFICATION OF
IDENTIFICATION MARK IDENTIFICATION MARK
BEARING
a (A) E (YELLOW)
I (A) b (B) D (GREEN)
c (C) C (NONE)
a (A) D (GREEN)
II (B) b (B) C (NONE)
c (C) B (BLACK)

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a (A) C (NONE)
III (C) b (B) B (BLACK)
c (C) A (BLUE)

4. Check crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.

Standard end play

0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)

Limit : 0.30mm (0.0118in.)

Fig. 49: Measuring Thrust Clearance While Prying Crankshaft Back And Forth With Screwdriver
Courtesy of KIA MOTORS AMERICA, INC.

If the end play is greater than maximum, replace the thrust bearings as a set.

Thrust bearing thickness

2.05 ~ 2.09mm (0.081 ~ 0.082in.)

5. Inspect main journals and crank pins

Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter

61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)

Crank pin diameter

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47.982 ~ 48.000mm (1.8890 ~ 1.8898in.)

Fig. 50: Measuring Diameter Of Each Main Journal And Crank Pin
Courtesy of KIA MOTORS AMERICA, INC.

CYLINDER BLOCK

1. Remove gasket material.

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2. Clean cylinder block

Using a soft brush and solvent, thoroughly clean the cylinder block.

3. Inspect top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket
for warpage.

Flatness of cylinder block gasket surface

Standard : Less than 0.03mm (0.0012 in.)

Limit : 0.05 mm (0.0020 in.)

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Fig. 51: Measuring Surface Contacting Cylinder Head Gasket For Warpage
Courtesy of KIA MOTORS AMERICA, INC.

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratches.

If deep scratches are present, replace the cylinder liner.

5. Inspect cylinder bore diameter

Using a cylinder bore gauge, measure the cylinder bore diameter at position A, B and C in the thrust and
axial directions.

Standard diameter

86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)

Fig. 52: Measuring Cylinder Bore Diameter At Position A, B And C In Thrust And Axial Directions
Courtesy of KIA MOTORS AMERICA, INC.

6. Check the cylinder bore size code (A) on the cylinder block bottom face.

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Fig. 53: Checking Cylinder Bore Size Code On Cylinder Block Bottom Face
Courtesy of KIA MOTORS AMERICA, INC.

CYLINDER BORE INNER DIAMETER REFERENCE CHART

Class Cylinder bore inner diameter Size code
A 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) A
B 86.71 ~ 86.72mm (3.4137 ~ 3.4141in.) B
C 86.72 ~ 86.73mm (3.4141 ~ 3.4145in.) C

7. Check the piston size code (A) on the piston top face.

Fig. 54: Checking Piston Size Code On Piston Top Face

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Stamp the grade mark of basic diameter with rubber stamp.

PISTON DIAMETER REFERENCE CHART

Class Piston diameter Size code
A 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) A
B 86.69 ~ 86.70mm (3.4130 ~ 3.4133in.) None

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C 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) C

8. Select the piston related to cylinder bore class.

Clearance : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

Boring Cylinder

1. Oversize pistons should be selected according to the largest bore cylinder.

CYLINDER BORE REFERENCE CHART

Identification Mark Size
0.25 0.25mm (0.010in.)
0.50 0.50mm (0.0250in.)

NOTE: The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D., calculate the new bore size.

New bore size = Piston O.D + 0.01 to 0.03mm

(0.0004 to 0.0012 in.) (clearance between piston and

cylinder) - 0.01 mm (0.0004 in.) (honing margin.)

4. Bore each of the cylinders to the calculated size.

CAUTION: To prevent distortion that may result from temperature rise during
honing, bore the cylinder holes in the firing order.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.

Standard : 0.01 ~ 0.03mm (0.0004 ~ 0.0012 in.)

NOTE: When boring the cylinders, finish all of the cylinders to the same oversize.
Do not bore only one cylinder to the oversize.

PISTON AND RINGS

1. Clean piston
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.

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3. Using solvent and a brush, thoroughly clean the piston.

NOTE: Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 38.5mm (1.516in.) from the top land of
the piston.

Standard diameter

86.68 ~ 86.71mm (3.4126 ~ 3.4138in.)

Fig. 55: Measuring Piston Outside Diameter

Courtesy of KIA MOTORS AMERICA, INC.

3. Calculate the difference between the cylinder bore diameter and the piston diameter.

Piston-to-cylinder clearance

0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.

Piston ring side clearance

No. 1 : 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)

No. 2 : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)

Limit

No. 1 : 0.1mm (0.004in.)

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No. 2 : 0.1mm (0.004in.)

Fig. 56: Measuring Clearance Between New Piston Ring And Wall Of Ring Groove
Courtesy of KIA MOTORS AMERICA, INC.

If the clearance is greater than maximum, replace the piston.

5. Inspect piston ring end gap.

To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.
If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder
bore diameter against the wear limits , If the bore is over the service limit, the cylinder block must be
rebored. (See Boring Cylinder ).

Piston ring end gap

Standard

No. 1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)

No. 2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)

Limit

Oil ring : 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)

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Fig. 57: Inspecting Piston Ring End Gap

Courtesy of KIA MOTORS AMERICA, INC.

PISTON PINS

1. Measure the diameter of the piston pin.

Piston pin diameter

21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)

Fig. 58: Measuring Diameter Of Piston Pin

Courtesy of KIA MOTORS AMERICA, INC.

2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance

0.007 ~ 0.022mm (0.00027 ~ 0.00086in.)

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3. Check the difference between the piston pin diameter and the connecting rod small end diameter.

Piston pin-to-connecting rod interference

0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)

OIL PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter.

If there is no continuity, replace the oil pressure switch.

Fig. 59: Checking Continuity Between Terminal And Body With An Ohmmeter
Courtesy of KIA MOTORS AMERICA, INC.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) is applied through the oil hole, the switch is operating
properly.

Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

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Fig. 60: Checking Continuity Between Terminal And Body With An Ohmmeter
Courtesy of KIA MOTORS AMERICA, INC.

REASSEMBLY

NOTE: Thoroughly clean all parts to assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating
surfaces.
Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble piston and connecting rod.

1. Use a hydraulic press for installation.
2. The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of
the engine.

Fig. 61: Locating Piston Front Mark And Connecting Rod Front Mark
Courtesy of KIA MOTORS AMERICA, INC.

2. Install piston rings.

1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown.

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Fig. 62: Identifying Piston Rings End Positions

Courtesy of KIA MOTORS AMERICA, INC.

3. Install connecting rod bearings.

1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
2. Install the bearings in the connecting rod and connecting rod cap.

Fig. 63: Locating Bearings And Connecting Rod Cap

Courtesy of KIA MOTORS AMERICA, INC.

4. Install main bearings.

NOTE: Upper 1, 2, 3, 4 bearings have an oil groove of oil holes; Lower bearings do
not.

1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings
(A).

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Fig. 64: Locating Upper Bearings

Courtesy of KIA MOTORS AMERICA, INC.

2. Align the bearing claw with the claw groove of the main bearing cap (A), and push in the 4 lower
bearings (B).

Fig. 65: Locating Main Bearing Cap And Lower Bearings

Courtesy of KIA MOTORS AMERICA, INC.

5. Install thrust bearings.

Install the 2 thrust bearings (A) under the No. 3 journal position of the cylinder block with the oil grooves
facing outward.

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Fig. 66: Locating Thrust Bearings

Courtesy of KIA MOTORS AMERICA, INC.

6. Place crankshaft (A) on the cylinder block.

Fig. 67: Locating Crankshaft

Courtesy of KIA MOTORS AMERICA, INC.

7. Place main bearing caps on cylinder block.

8. Install main bearing cap bolts.

NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
If any of the bearing cap bolts in broken or deformed, replace it.

Tightening torque

Main bearing cap bolt

M8 : 13 ~ 19N.m

(130 ~ 190kgf.cm, 10 ~ 14lb-ft) + 90° ~ 94°

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M10 : 27 ~ 33N.m

(270 ~ 330kgf.cm, 19.5 ~ 24lb-ft) + 90° ~ 94°

1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
2. Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.

Tightening torque

M8 (A) : 13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lb-ft)

M10 (B) : 27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lb-ft)

Fig. 68: Locating Bearing Cap Bolts

Courtesy of KIA MOTORS AMERICA, INC.

3. Retighten the bearing cap bolts by 90° ~ 94° in the numerical order shown.

Fig. 69: Identifying Bearing Cap Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

4. Check that the crankshaft turns smoothly.

9. Check crankshaft end play. (See Connecting rods )
10. Install piston and connecting rod assemblies.

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NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves
and cylinder bores.

1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of
the connecting rod bolts.
2. Install the ring compressor, check that the bearing is securely in place, then position the piston in
the cylinder, and tap it in using the wooden handle of a hammer.
3. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment
before pushing the piston into place.
4. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.

Tightening torque

16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15lb-ft) + 90° ~ 94°

NOTE: Maintain downward force on the ring compressor to prevent the rings
from expanding before entering the cylinder bore.

Fig. 70: Installing Piston And Connecting Rod Assemblies

Courtesy of KIA MOTORS AMERICA, INC.

11. Apply liquid gasket to the oil seal case and install the oil seal case (A).

Tightening torque

10 ~ 12N.m (100 ~ 120kgf.cm, 7.3 ~ 8.8lb-ft)

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Fig. 71: Locating Oil Seal Case And Bolt

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Use liquid gasket MS721-40A or equivalent

Check that the mating surfaces are clean and dry.

12. Install rear oil seal.

1. Apply engine oil to a new oil seal lip.
2. Using SST (09231-33000) and a hammer, tap in the oil seal until its surface is flush with the rear
oil seal retainer edge.

Fig. 72: Installing Oil Seal

Courtesy of KIA MOTORS AMERICA, INC.

13. Install front case. (See REPAIR PROCEDURES )

14. Install the upper oil pan.
1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.

NOTE: Check that the mating surfaces are clean and dry before applying
liquid gasket.

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2. Install the oil pan (A) with the 17 bolts.

Uniformly tighten the bolts in several passes.

Tightening torque

19 ~ 28N.m (190 ~ 280kgf.cm, 14 ~ 20lb-ft) : (1 ~ 15)

5 ~ 7N.m (50 ~ 70kgf.cm, 4 ~ 5lb-ft) : (16,17)

Fig. 73: Locating Oil Pan

Courtesy of KIA MOTORS AMERICA, INC.

Fig. 74: Locating Oil Pan Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: To prevent leakage of oil, apply liquid gasket to the inner

threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.

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 2010 Kia Sportage EX
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After assembly, wait at least 30 minutes before filling the engine

with oil.

15. Install oil screen.

Install a new gasket and oil screen (A) with 2 bolts (B).

Tightening torque

15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16lb-ft)

Fig. 75: Locating Oil Screen And Bolts

Courtesy of KIA MOTORS AMERICA, INC.

16. Install the lower oil pan.

1. Apply liquid gasket as an even bead, centered between the edges of the mating surface.

Use liquid gasket MS 721-40A or equivalent.

NOTE: To prevent leakage of oil, apply liquid gasket to the inner

threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.
After assembly, wait at least 30 minutes before filling the engine
with oil.

2. Install the lower oil pan 10 bolts.

Uniformly tighten the bolts several passes

Tightening torque

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 2010 Kia Sportage EX
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10 ~12N.m (100 ~ 120kgf.cm, 7.3 ~ 8.8lb-ft)

Fig. 76: Locating Lower Oil Pan Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

17. Install oil pressure sensor.

1. Apply adhesive to 2 or 3 threads.

Adhesive : THREE BOND TB2403 or equivalent.

2. Install the oil pressure sensor (A).

Tightening torque

15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16lb-ft)

Fig. 77: Locating Oil Pressure Sensor

Courtesy of KIA MOTORS AMERICA, INC.

18. Install knock sensor (A).

Tightening torque

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 2010 Kia Sportage EX
2010 ENGINE Cylinder Block (Engine Mechanical System-G2.7 DOHC) - Sportage

17 ~ 26N.m (170 ~ 260kgf.cm, 12.5 ~ 19lb-ft)

Fig. 78: Locating Knock Sensor

Courtesy of KIA MOTORS AMERICA, INC.

19. Install water pump. (See REPAIR PROCEDURES )

20. Install the power steering pump bracket (A).

Tightening torque

35 ~ 55N.m (350 ~ 550kgf.cm, 25.8 ~ 40.6 lb-ft)

Fig. 79: Locating Power Steering Pump Bracket

Courtesy of KIA MOTORS AMERICA, INC.

21. Install the air compressor. (See COMPRESSOR )

22. Install the alternator. (See ALTERNATOR )
23. Install oil level gauge assembly.
1. Install a new O-ring on the oil level gauge.
2. Apply engine oil on the O-ring.
3. Install the oil level gauge assembly (A) with the bolt.

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Tightening torque

12 ~ 15N.m (120 ~ 150 kgf.cm, 9 ~ 11 lb-ft)

24. Install cylinder head. (See INSTALLATION )

25. Install timing belt. (See INSTALLATION )
26. Remove engine stand.
27. Install drive plate.

Tightening torque

73 ~ 77N.m (730 ~ 770kgf.cm, 53 ~ 56lb-ft)

REASSEMBLY

NOTE: Thoroughly clean all parts to assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating
surfaces.
Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble piston and connecting rod.

1. Use a hydraulic press for installation.
2. The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of
the engine.

Fig. 80: Locating Piston Front Mark And Connecting Rod Front Mark
Courtesy of KIA MOTORS AMERICA, INC.

2. Install piston rings.

1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.

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3. Position the piston rings so that the ring ends are as shown.

Fig. 81: Identifying Piston Rings End Positions

Courtesy of KIA MOTORS AMERICA, INC.

3. Install connecting rod bearings.

1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
2. Install the bearings in the connecting rod and connecting rod cap.

Fig. 82: Locating Bearings And Connecting Rod Cap

Courtesy of KIA MOTORS AMERICA, INC.

4. Install main bearings.

NOTE: Upper 1, 2, 3, 4 bearings have an oil groove of oil holes; Lower bearings do
not.

1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings
(A).

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Fig. 83: Locating Upper Bearings

Courtesy of KIA MOTORS AMERICA, INC.

2. Align the bearing claw with the claw groove of the main bearing cap (A), and push in the 4 lower
bearings (B).

Fig. 84: Locating Main Bearing Cap And Lower Bearings

Courtesy of KIA MOTORS AMERICA, INC.

5. Install thrust bearings.

Install the 2 thrust bearings (A) under the No. 3 journal position of the cylinder block with the oil grooves
facing outward.

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Fig. 85: Locating Thrust Bearings

Courtesy of KIA MOTORS AMERICA, INC.

6. Place crankshaft (A) on the cylinder block.

Fig. 86: Locating Crankshaft

Courtesy of KIA MOTORS AMERICA, INC.

7. Place main bearing caps on cylinder block.

8. Install main bearing cap bolts.

NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
If any of the bearing cap bolts in broken or deformed, replace it.

Tightening torque

Main bearing cap bolt

M8

13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lbf.ft) + 90° ~ 94°

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M10

27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft) + 90° ~ 94°

1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
2. Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.

Tightening torque

M8 (A) : 13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lbf.ft)

M10 (B) : 27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lbf.ft)

Fig. 87: Identifying Bearing Cap Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

3. Retighten the bearing cap bolts by 90° ~ 94° in the numerical order shown.

Fig. 88: Identifying Bearing Cap Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

4. Check that the crankshaft turns smoothly.

9. Check crankshaft end play. (See Connecting rods )
10. Install piston and connecting rod assemblies.

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 2010 Kia Sportage EX
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NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves
and cylinder bores.

1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of
the connecting rod bolts.
2. Install the ring compressor, check that the bearing is securely in place, then position the piston in
the cylinder, and tap it in using the wooden handle of a hammer.
3. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment
before pushing the piston into place.
4. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.

Tightening torque

16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15lbf.ft) + 90° ~ 94°

NOTE: Maintain downward force on the ring compressor to prevent the rings
from expanding before entering the cylinder bore.

Fig. 89: Installing Piston And Connecting Rod Assemblies

Courtesy of KIA MOTORS AMERICA, INC.

11. Apply liquid gasket to the oil seal case and install the oil seal case (A).

Tightening torque

10 ~ 12N.m (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)

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 2010 Kia Sportage EX
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Fig. 90: Locating Oil Seal Case And Bolts

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Use liquid gasket MS721-40A or equivalent

Check that the mating surfaces are clean and dry.

12. Install rear oil seal.

1. Apply engine oil to a new oil seal lip.
2. Using SST (09231-33000) and a hammer, tap in the oil seal until its surface is flush with the rear
oil seal retainer edge.

Fig. 91: Installing Oil Seal

Courtesy of KIA MOTORS AMERICA, INC.

13. Install front case. (See INSTALLATION )

14. Install the upper oil pan.
1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.

NOTE: Check that the mating surfaces are clean and dry before applying
liquid gasket.

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 2010 Kia Sportage EX
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2. Install the oil pan (A) with the 17 bolts.

Uniformly tighten the bolts in several passes.

Tightening torque

19 ~ 28N.m (190 ~ 280kgf.cm, 14 ~ 20lbf.ft) : (1 ~ 15)

5 ~ 7N.m (50 ~ 70kgf.cm, 4 ~ 5lbf.ft) : (16,17)

Fig. 92: Locating Oil Pan

Courtesy of KIA MOTORS AMERICA, INC.

Fig. 93: Identifying Oil Pan Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: To prevent leakage of oil, apply liquid gasket to the inner

threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.

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 2010 Kia Sportage EX
2010 ENGINE Cylinder Block (Engine Mechanical System-G2.7 DOHC) - Sportage

After assembly, wait at least 30 minutes before filling the engine

with oil.

15. Install oil screen.

Install a new gasket and oil screen (A) with 2 bolts (B).

Tightening torque

15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16 lbf.ft)

Fig. 94: Locating Oil Screen And Bolts

Courtesy of KIA MOTORS AMERICA, INC.

16. Install the lower oil pan.

1. Apply liquid gasket as an even bead, centered between the edges of the mating surface.

Use liquid gasket MS 721-40A or equivalent.

NOTE: To prevent leakage of oil, apply liquid gasket to the inner

threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.
After assembly, wait at least 30 minutes before filling the engine
with oil.

2. Install the lower oil pan 10 bolts.

Uniformly tighten the bolts several passes

Tightening torque

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 2010 Kia Sportage EX
2010 ENGINE Cylinder Block (Engine Mechanical System-G2.7 DOHC) - Sportage

10 ~12N.m (100 ~ 120kgf.cm, 7.3 ~ 8.8 lbf.ft)

Fig. 95: Identifying Lower Oil Pan Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

17. Install oil pressure sensor.

1. Apply adhesive to 2 or 3 threads.

Adhesive : THREE BOND TB2403 or equivalent.

2. Install the oil pressure sensor (A).

Tightening torque

15 ~ 22N.m (150 ~ 220kgf.cm, 11 ~ 16 lbf.ft)

Fig. 96: Locating Oil Pressure Sensor

Courtesy of KIA MOTORS AMERICA, INC.

18. Install knock sensor (A).

Tightening torque

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2010 ENGINE Cylinder Block (Engine Mechanical System-G2.7 DOHC) - Sportage

17 ~ 26N.m (170 ~ 260kgf.cm, 12.5 ~ 19 lbf.ft)

Fig. 97: Locating Knock Sensor

Courtesy of KIA MOTORS AMERICA, INC.

19. Install water pump. (See INSTALLATION )

20. Install the power steering pump bracket (A).

Tightening torque

35 ~ 55N.m (350 ~ 550kgf.cm, 25.8 ~ 40.6 lbf.ft)

Fig. 98: Locating Power Steering Pump Bracket

Courtesy of KIA MOTORS AMERICA, INC.

21. Install the air compressor. (See COMPRESSOR )

22. Install the alternator. (See ALTERNATOR )
23. Install oil level gauge assembly.
1. Install a new O-ring on the oil level gauge.
2. Apply engine oil on the O-ring.
3. Install the oil level gauge assembly (A) with the bolt.

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Tightening torque

12 ~ 15N.m (120 ~ 150kgf.cm, 9 ~ 11 lbf.ft)

24. Install cylinder head. (See INSTALLATION )

25. Install timing belt. (See INSTALLATION )
26. Remove engine stand.
27. Install drive plate.

Tightening torque

73 ~ 77N.m (730 ~ 770 kgf.cm, 53 ~ 56 lbf.ft)

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