Kia 3.5L V6 Manual
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Kia 3.5L V6 Manual

Kia 3.5L V6 Manual

2002 sedona
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2002 ENGINES
3.5L V6 - Sedona

GENERAL

SPECIFICATIONS

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Questions and answers

Jeff
April 19, 2025

Where is the oil pressure sensor/switch located on a 2002 Kid Sadona 3.5 V6 DOHC

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1 comments:
Mr. Anderson
May 10, 2025

The oil pressure sensor on a 2002 Kia Sedona 3.5L V6 DOHC is installed using a 24 mm deep socket and requires sealant on the threaded area before installation. The exact physical location is not specified in the provided information.

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Summary of Contents for Kia 3.5L V6

  • Page 1 2002 ENGINES 3.5L V6 - Sedona GENERAL SPECIFICATIONS...
  • Page 2 Fig. 1: General Specifications Courtesy of KIA MOTORS AMERICA, INC. Fig. 2: General Specifications...
  • Page 3 Courtesy of KIA MOTORS AMERICA, INC. Fig. 3: General Specifications Courtesy of KIA MOTORS AMERICA, INC.
  • Page 4 Fig. 4: General Specifications Courtesy of KIA MOTORS AMERICA, INC. TORQUE SPECIFICATIONS...
  • Page 5 TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Air Intake Surge Tank-To-Intake Manifold Bolt\Nut 11-15 (15-20) Auto Tensioner Fixing Bolt 15-20 (20-27) Camshaft Bearing Cap Bolt Inner Bolt Outer Bolt 14-15 (19-21) Camshaft Sprocket Bolt 58-72 (79-98) Catalytic Converter Nut 22-30 (30-40) Center Exhaust Pipe Nut 22-30 (30-40) Connecting Rod Nut...
  • Page 6 Starter-To-Engine Nut 15-22 (20-30) Timing Belt Cover Bolt M6 Bolt M8 Bolt 15-20 (20-27) Timing Belt Idler Pulley Bolt 37-44 (50-60) Timing Belt Tensioner Arm Fixing Bolt 26-41 (35-55) Timing Belt Tensioner Pulley Bolt 32-41 (43-55) 22-31 (30-42) Upper Oil Pan Bolt (10x38 mm) Water Outlet Fitting Bolt 13-15 (17-20) INCH Lbs.
  • Page 7 Fig. 5: Cylinder Head Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC.
  • Page 8 Fig. 6: Intake Manifold Nut Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC.
  • Page 9 Fig. 7: Upper Oil Pan Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC.
  • Page 10 Fig. 8: Cylinder Head Cover Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC.
  • Page 11 Fig. 9: Lower Oil Pan Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. FLUIDS ANTIFREEZE SERVICE STANDARD Fig. 10: Antifreeze Service Standard Chart Courtesy of KIA MOTORS AMERICA, INC.
  • Page 12 ANTIFREEZE COOLANT Fig. 11: Antifreeze Coolant Chart Courtesy of KIA MOTORS AMERICA, INC. SEALANT Fig. 12: Sealant Chart Courtesy of KIA MOTORS AMERICA, INC. SPECIAL SERVICE TOOLS Fig. 13: Special Service Tools Courtesy of KIA MOTORS AMERICA, INC.
  • Page 13 Fig. 14: Special Service Tools Courtesy of KIA MOTORS AMERICA, INC. CHECKING COMPRESSION PRESSURE 1. Before checking compression, check the engine oil level and that the starter motor and battery are all in normal operating condition. 2. Start the engine and wait until engine coolant temperature has risen to 80-95°C...
  • Page 14 Limit: 1,050 kPa (10.7 kg.cm , 149 psi) Fig. 15: Testing Compression Courtesy of KIA MOTORS AMERICA, INC. 9. Repeat steps 6 through 8 on all cylinders, making sure ensuring that the pressure difference for each of the cylinders is within the specified limit.
  • Page 15 10. If a cylinder's compression or pressure difference is below the specification, add a small amount of oil through the spark plug hole and repeat steps 6 through 9 . a. If the addition of oil causes the compression to rise, it is possible that there is wear between the piston ring and cylinder wall.
  • Page 16 Fig. 16: Recommended Oil Viscosity Chart Courtesy of KIA MOTORS AMERICA, INC. NOTE: For best performance and for maximum protection for all types of operation, select only those lubricants which: a. Confirm to the requirements of the API classification. b. Have proper SAE grade number for expected ambient temperature range.
  • Page 17 3. Remove the oil filler cap and the drain plug. Drain the engine oil. Fig. 17: Identifying Oil Drain Plug Courtesy of KIA MOTORS AMERICA, INC. 4. Tighten the drain plug to the specified torque. 26-30 ft.lbs. (35-45 N.m). CAUTION: Whenever tightening an oil drain plug, use a new drain plug gasket.
  • Page 18 9. Stop the engine and check the oil level. If not sufficient, refill engine. REPLACING OIL FILTER All Kia Motor Company engines are equipped with a quality, throw-away oil filter. This filter is recommended as a replacement filter on all vehicles. The quality of replacement filters varies considerable. Only high quality filters should be used to assure the most efficient service.
  • Page 19 Operating pressure of oil pressure switch: 19.6 - 39.2 kPa (0.2 - 0.4 kg.cm , 2.84 - 5.69 psi) Fig. 19: Illustrating Oil Pressure Switch Courtesy of KIA MOTORS AMERICA, INC. 3. Using 24 mm deep socket, tighten the switch to the specified torque. NOTE: Do not tighten the oil pressure switch to the excessive torque.
  • Page 20 Oil pressure switch and sensor assembly: 8-12 N.m (80~120 kg.cm, 5.91-8.85 lb.ft) Fig. 20: Removing & Installing Oil Pressure Switch Courtesy of KIA MOTORS AMERICA, INC. DRIVE BELT ROUTING 1. For power steering belt routing, see Fig. 21 . 2. For air conditioning compressor and alternator belt routing, see Fig. 22 .
  • Page 21 Fig. 21: Power Steering Belt Routing Courtesy of KIA MOTORS AMERICA, INC.
  • Page 22 Fig. 22: Air Conditioning Compressor & Alternator Belt Routing Courtesy of KIA MOTORS AMERICA, INC.
  • Page 23 Fig. 23: Combined Drive Belt Routing Courtesy of KIA MOTORS AMERICA, INC. DRIVE BELT ADJUSTMENT Power Steering 1. Loosen hinge bolt "A" and flange nut "B". See Fig. 24 . 2. Turn adjusting bolt "C" to set belt tension to specified deflection. See Fig. 24 and Fig. 25 . See BELT ADJUSTMENT table.
  • Page 24 4. Start engine and turn A/C on. 5. Allow vehicle to run until normal operating temperature is reached. 6. Turn engine off, recheck belt deflection after operation and readjust belt tension as necessary. See BELT ADJUSTMENT table. BELT ADJUSTMENT Application Deflection - In.
  • Page 25 Fig. 24: Adjusting Power Steering Belt Tension Courtesy of KIA MOTORS AMERICA, INC. Fig. 25: Measuring Power Steering Belt Deflection Courtesy of KIA MOTORS AMERICA, INC.
  • Page 26 Fig. 26: Adjusting Alternator & Air Conditioning Compressor Belt Courtesy of KIA MOTORS AMERICA, INC.
  • Page 27 Fig. 27: Measuring Alternator & Air Conditioning Compressor Belt Deflection Courtesy of KIA MOTORS AMERICA, INC. COOLANT LEAK CHECK 1. Loosen the radiator cap. 2. Confirm that the coolant level is up to the filler neck. 3. Install a radiator cap tester to the radiator filler neck and apply 22 lbs. of pressure. Hold for two minutes...
  • Page 28 Fig. 28: Pressure Testing Radiator Courtesy of KIA MOTORS AMERICA, INC. CAUTION: Radiator coolant may be extremely hot. Do not open the system while hot, or scalding. Engine coolant could spray out causing personal injury. Allow the vehicle to cool before servicing this system.
  • Page 29 Fig. 29: Testing Radiator Cap Courtesy of KIA MOTORS AMERICA, INC. 2. Increase the pressure until the gauge indicator stops moving. Main valve opening pressure: 14-18 psi (86-125 kPa). Main valve closing pressure: 12 psi (83 kPa) 3. Check that the pressure level is maintained at or above the limit.

  • Page 30: Engine Mounting

    NOTE: Recommended coolant concentration is 40-50 percent, using only ethylene glycol for aluminum type coolant. Fig. 30: Testing Coolant Concentration & Specific Gravity Courtesy of KIA MOTORS AMERICA, INC. ENGINE MOUNTING ENGINE MOUNTS...
  • Page 31 Fig. 31: Identifying Engine Mounts Courtesy of KIA MOTORS AMERICA, INC. SUB FRAME MOUNTS...
  • Page 32 Fig. 32: Identifying Subframe Mounts Courtesy of KIA MOTORS AMERICA, INC. ENGINE AND TRANSAXLE ASSEMBLY REMOVAL 1. Remove the battery and engine cover.
  • Page 33 2. Detach the air cleaner. 3. Disconnect the connectors for the engine harness. 4. Disconnect the connectors for the alternator harness, the oil pressure switch and the oil pressure sensor. 5. Disconnect the connector of starter motor harness. 6. Drain the engine coolant. 7.
  • Page 34 Fig. 33: Disconnecting The Speed Sensor Connector Courtesy of KIA MOTORS AMERICA, INC. 19. Remove the power steering oil pump hose. 20. Raise the vehicle. 21. Remove the oil pan shield. 22. Drain the transaxle oil.
  • Page 35 Fig. 34: Drain The Transaxle Oil Courtesy of KIA MOTORS AMERICA, INC. 23. Disconnect the front exhaust pipe from the manifold. NOTE: Use a wire to suspend the exhaust pipe from the bottom of the vehicle. 24. Remove the tie rod end from steering knuckles.
  • Page 36 Fig. 35: Removing Pinch Bolt From Knuckle Courtesy of KIA MOTORS AMERICA, INC. 27. Remove the drive shaft from the transaxle housing. CAUTION: Plug up the holes of the transaxle case to prevent entry of foreign material. The circlips on the drive shafts should be replaced whenever...
  • Page 37 Fig. 36: Removing The Drive Shaft From The Transaxle Housing Courtesy of KIA MOTORS AMERICA, INC. 28. Remove intermediate shaft bolt. See REMOVAL . 29. Remove No. 3, No. 4 engine mounting. 30. Support auto transaxle, engine and subframe with a suitable floor jack.

  • Page 38: Timing System

    Fig. 37: Support Auto Transaxle, Engine & Subframe With A Suitable Floor Jack Courtesy of KIA MOTORS AMERICA, INC. 31. Remove nuts and blots of impact bar and subframe. 32. Slowly lower engine, auto transaxle and subframe. 33. Remove No. 1, No. 2 engine mounting from subframe.
  • Page 39 TIMING BELT COMPONENTS Fig. 38: Identifying Timing System Components Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Remove the engine cover. 2. Remove the drive belt. 3. Remove the idler pulley, crankshaft pulley, power steering pulley and tensioner pulley.
  • Page 40 Fig. 39: Identifying Belt Routing Courtesy of KIA MOTORS AMERICA, INC. 4. Remove the upper and lower timing belt cover.
  • Page 41 Fig. 40: Removing The Upper & Lower Timing Belt Cover Courtesy of KIA MOTORS AMERICA, INC. 5. Support the engine with garage jack or special tool, and then remove the engine mounting insulator. CAUTION: Take care not to deform the engine oil pan.
  • Page 42 Fig. 41: Removing The Auto Tensioner Courtesy of KIA MOTORS AMERICA, INC. NOTE: Rotate the crankshaft clockwise and align the timing mark to get the No. 1 cylinder's piston be in TDC position (compression stroke). At this time, the timing marks of the camshaft sprocket and cylinder head cover should coincide with each other.
  • Page 43 Fig. 42: Remove The Timing Belt Courtesy of KIA MOTORS AMERICA, INC. NOTE: When re-using timing belt, make sure of marking the rotating direction on the belt so as to install correctly. INSPECTION TIMING BELT Check the belt carefully and if any damage is found, exchange it with a new one.
  • Page 44 Fig. 43: Testing Timing Belt For Vulcanization Courtesy of KIA MOTORS AMERICA, INC. 2. Crack on the rubber belt surface.
  • Page 45 Fig. 44: Testing Timing Belt For Cracks Courtesy of KIA MOTORS AMERICA, INC. 3. Abnormal wearing of side face of belt. CAUTION: Belts in good condition seem to be cut by a sharp knife.
  • Page 46 Fig. 45: Testing Timing Belt For Side Face Wear Courtesy of KIA MOTORS AMERICA, INC. 4. Abnormal tooth wearing...
  • Page 47 Fig. 46: Testing Timing Belt For Abnormal Tooth Wear Courtesy of KIA MOTORS AMERICA, INC. Initial stage Wearing of side face of load exerting tooth (Fabric puff up, rubber material peel off with color changing to white and fabric become uneven and rough).
  • Page 48 Fig. 47: Testing Timing Belt Tensioner Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION...
  • Page 49 Fig. 48: Identifying Timing Belt Positions Courtesy of KIA MOTORS AMERICA, INC. TIMING BELT AND AUTO TENSIONER 1. Install the idler pulley to the engine support lower bracket.
  • Page 50 Fig. 49: Installing The Idler Pulley To The Engine Support Lower Bracket Courtesy of KIA MOTORS AMERICA, INC. 2. Install the tensioner arm, shaft and plain washer to the cylinder block. Tightening torque: 35-55 N.m (350-550 kg.cm, 25.82-40.57 lb.ft)
  • Page 51 Fig. 50: Installing The Tensioner Arm, Shaft And Plain Washer To The Cylinder Block Courtesy of KIA MOTORS AMERICA, INC. 3. Install the crankshaft sprocket. NOTE: Confirm if timing marks coincide with.
  • Page 52 Fig. 51: Installing The Crankshaft Sprocket Courtesy of KIA MOTORS AMERICA, INC. CAUTION: Align the spacer with a pin, and assemble it exerting even force not to deform the crankshaft sensing blade.
  • Page 53 Fig. 52: Align The Spacer & Pin Courtesy of KIA MOTORS AMERICA, INC. 4. Install the camshaft sprocket.
  • Page 54 Fig. 53: Installing & Aligning Camshaft Sprockets Courtesy of KIA MOTORS AMERICA, INC. 5. Install the auto tensioner to the oil pump case. CAUTION: At this time the auto tensioner's set pin should be assembled...
  • Page 55 Fig. 54: Installing The Auto Tensioner To The Oil Pump Case Courtesy of KIA MOTORS AMERICA, INC. 6. Align the timing marks of each sprocket and install the timing belt, maintaining the proper belt tension between each shaft in this order.
  • Page 56 Fig. 55: Identifying Timing Belt Routing Courtesy of KIA MOTORS AMERICA, INC. CAUTION: As a result of this, position of No. 1 cylinder comes to compression TDC. As each camshaft sprocket tends to rotate by itself, pay attention not to injure fingers or other bodily part. Especially be careful with the right bank.
  • Page 57 8. With tensioner pulley slightly pushing the belt down, tighten the center bolts lightly. Fig. 56: Exerting The Reverse-Directed Force To The Right Bank Exhaust Camshaft Sprocket Courtesy of KIA MOTORS AMERICA, INC. 9. Pull out the auto tensioner set pin.
  • Page 58 While maintaining this state, tighten the center bolt to the standard torque. Center bolt standard torque: 43-55 N.m (430-550 kg.cm, 31.72-40.57 lb.ft) Fig. 57: Tensioning Timing Belt Courtesy of KIA MOTORS AMERICA, INC. 2. Pull out the auto tensioner fixing pin.
  • Page 59 Fig. 58: Removing Auto Tensioner Fixing Pin Courtesy of KIA MOTORS AMERICA, INC. 2. How to check tension (While auto tensioner is operating: and fixing pin being uninstalled.) a. After rotating crankshaft 2 revolutions clockwise to position No. 1 cylinder at TDC, wait for about 5 minutes, and measure the amount of protruding of the auto tensioner rod.
  • Page 60 Fig. 59: Measuring The Amount Of Rod Protruding From Auto Tensioner Courtesy of KIA MOTORS AMERICA, INC. c. Recheck if each sprocket is within the specified range. NOTE: If it is not within the specified range, repeat from TIMING BELT AND AUTO TENSIONER .
  • Page 61 Fig. 60: Exploded View Of Camshaft Components Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Remove the cylinder head cover.
  • Page 62 Fig. 61: Removing Cylinder Head Cover...
  • Page 63 Courtesy of KIA MOTORS AMERICA, INC. 2. Remove the front bearing cap. Fig. 62: Removing Front Bearing Cover Courtesy of KIA MOTORS AMERICA, INC. 3. Remove the rear bearing cap. 4. Remove the bearing cap. 5. Remove the camshaft oil seal.
  • Page 64 Fig. 63: Identifying Camshaft Components Courtesy of KIA MOTORS AMERICA, INC. INSPECTION CAMSHAFT 1. If there is excessive wear or damage on the camshaft journal or/and cam lobe after checking, replace it with a new one. Measure the height of cam and if the readings are beyond the specification, replace it.
  • Page 65 Fig. 64: Measuring Camshaft Wear Courtesy of KIA MOTORS AMERICA, INC. ROCKER ARM 1. Inspect the roller visually, if any damage or crack is found, replace it. 2. Check that the roller rotates smoothly. If there is excessive clearance, replace it.
  • Page 66 Fig. 65: Releasing Air From Lash Adjuster Courtesy of KIA MOTORS AMERICA, INC. CAUTION: As the ball weight is very small (just a few grams), pushing the special tool excessively can damage the lash adjuster. Push it with care and appropriate force.
  • Page 67 1mm. Replace it if the time is out of standard range. Standard dropping down rate: 2~16.5sec/mm (Light oil, oil temperature 20~30°C) Fig. 66: Measuring Lash Adjuster Drop Courtesy of KIA MOTORS AMERICA, INC. ADJUSTMENT OF ROCKER ARM CLEARANCE 1. Replace the rocker arm with the one specially made for measurement.
  • Page 68 Clearance between camshaft (Basic circle) and rocker arm (roller): 0.7+/-0.25 mm (0.0276+/-0.0098 in) Fig. 67: Measuring Rocker Arm Clearance Courtesy of KIA MOTORS AMERICA, INC. CAUTION: As the ball weight is very small (just a few grams), pushing the special tool excessively can damage the lash adjuster. Push it with care and appropriate force.
  • Page 69 1. Rotate the crankshaft and No. 1 cylinder is in TDC. (Compression stroke) 2. Check the position of the rocker arm whether it is exactly installed on the lash adjuster and valve or not. 3. Install the camshaft dowel pin as shown.
  • Page 70 Fig. 68: Installing Camshaft Dowel Pin Courtesy of KIA MOTORS AMERICA, INC. 4. The left and right banks of the camshafts are different and you should be careful not to confuse them. For camshaft identification, see identification signal below. CAMSHAFT IDENTIFICATION SIGNAL...
  • Page 71 Fig. 70: Illustrating Bearing Caps Identification Mark Chart Courtesy of KIA MOTORS AMERICA, INC. Fig. 71: Illustrating Bearing Caps Identification Marks Courtesy of KIA MOTORS AMERICA, INC. 6. Tighten the bearing cap in two or three steps. Tighten it to the standard torque at the last stage.

  • Page 72: Cylinder Head Assembly

    Fig. 72: Locating Bearing Cap Positions Courtesy of KIA MOTORS AMERICA, INC. CYLINDER HEAD ASSEMBLY COMPONENTS...
  • Page 73 Fig. 73: Exploded View Of Cylinder Head Assemblies Courtesy of KIA MOTORS AMERICA, INC. DISASSEMBLY Arrange removal parts according to cylinder numbers, intake and exhaust valves. REMOVING CYLINDER HEAD BOLT Remove the cylinder head bolts using the hexagonal wrench.
  • Page 74 REMOVING RETAINING LOCK 1. Compress the valve spring using Service Tool (09222-28000, 09222-28100). Fig. 74: Compressing Valve Springs Courtesy of KIA MOTORS AMERICA, INC. 2. Remove the retainer lock. REMOVING VALVE STEM SEAL Do not reuse the valve stem seal.
  • Page 75 Fig. 75: Removing Valve Stem Seals Courtesy of KIA MOTORS AMERICA, INC. INSPECTION & SERVICING CYLINDER HEAD (Bare) 1. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged.
  • Page 76 Fig. 76: Measuring Cylinder Head Flatness Courtesy of KIA MOTORS AMERICA, INC. VALVES 1. Clean the valve with wire brush.
  • Page 77 Fig. 77: Illustrating Cleaning Valves Courtesy of KIA MOTORS AMERICA, INC. 2. Inspect wear and damage of each valve. Check for bending at the valve head and stem if there is wear, replace the valve. If margin is smaller than service standard, replace the valve.
  • Page 78 Fig. 78: Illustrating Valve Margin Courtesy of KIA MOTORS AMERICA, INC.
  • Page 79 VALVE SPRINGS 1. Check free height of each valve spring and replace if necessary. 2. Using a square, test squareness of each valve spring. If spring is excessively out of square, replace it. VALVE SPRING HEIGHT MEASUREMENTS Application Margin Standard In. (mm) Margin Limit In.
  • Page 80 Courtesy of KIA MOTORS AMERICA, INC. VALVE GUIDE Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with a new oversize guide. VALVE GUIDE MEASUREMENTS Application Margin Standard In. (mm) Service Limit In. (mm) Intake 0.0009-0.00020 (.02-.05)
  • Page 81 Fig. 81: Grinding Valve Seat Courtesy of KIA MOTORS AMERICA, INC.
  • Page 82 Fig. 82: Valve Seat Angle Chart Courtesy of KIA MOTORS AMERICA, INC. VALVE SEAT REPLACEMENT PROCEDURE 1. If the valve seat insert is excessively worn, cut out the insert wall using valve seat cover at normal temperature. See figure "A" in figure 83.
  • Page 83 Fig. 83: Insert Wall Removal Diagram Courtesy of KIA MOTORS AMERICA, INC. 2. After removing the seat insert, match the seat insert bore using a reamer or cutter to the indicated size in the table below. 3. Heat the cylinder head up to 250°C and press in an oversize seat insert. At this time, the temperature of oversize seat insert must be the same as the room temperature.
  • Page 84 Fig. 85: Illustrating Valve Guide Installation Tool Courtesy of KIA MOTORS AMERICA, INC. 4. Valve guide is to be installed from the upside of the cylinder head. As length of the intake valve guide is different from that of the exhaust valve guide, be careful. (The lengths of guide for intake valve and exhaust valve are 45.5mm and 50.5mm respectively.)
  • Page 85 Fig. 86: Measuring Valve Guide Length Courtesy of KIA MOTORS AMERICA, INC. 5. When the valve guide is replaced, inspect for valve contact state. If necessary, adjust the valve seat. VALVE GUIDE INSERT OVERSIZES...
  • Page 86 Fig. 87: Valve Guide Oversize Chart Courtesy of KIA MOTORS AMERICA, INC. REASSEMBLY VALVE STEM SEAL 1. Install the valve spring seat. 2. Install a new stem seal on valve guide using the special tool (09222-28200).
  • Page 87 Fig. 88: Identifying Valve Stem Seal Position Courtesy of KIA MOTORS AMERICA, INC. CAUTION: Valve stem seal should never be reused. Incorrect seal installation can cause oil leakage through lower part of the valve guide. When the valve stem seal is removed due to missing of valve spring seat,...
  • Page 88 Fig. 89: Installing Valve Stem Seal Courtesy of KIA MOTORS AMERICA, INC. VALVE SPRING Install the valve spring so that the end part with identification mark is paced at the end of the spring retainer.
  • Page 89 Fig. 90: Positioning Valve Spring Courtesy of KIA MOTORS AMERICA, INC. RETAINER LOCK Insert the retainer lock by pressing down the valve spring with special tool (09222-28000).
  • Page 90 Fig. 91: Installing Valve Retainer Lock Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION CYLINDER HEAD GASKET 1. All mating faces for the gasket on the cylinder block and the cylinder head should be cleaned. 2. Install new cylinder head gasket on the cylinder head assembly. Do not smear the sealant on the gasket...
  • Page 91 Fig. 92: Illustrating Cylinder Head Gasket Courtesy of KIA MOTORS AMERICA, INC. CYLINDER HEAD BOLT 1. Tighten the cylinder head bolts as shown in illustration below using the appropriate tool. Tightening torque: 105-115 N.m (1050-1150 kg.cm, 75.9-83.2 lb.ft)

  • Page 92: Lubrication System

    Fig. 93: Illustrating Cylinder Head Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. LUBRICATION SYSTEM COMPONENTS...
  • Page 93 Fig. 94: Exploded View Of Oil Pump & Oil Pan Courtesy of KIA MOTORS AMERICA, INC. DISASSEMBLY 1. Remove the oil pressure switch, using 24 mm deep socket.
  • Page 94 Fig. 95: Removing Oil Pressure Switch Courtesy of KIA MOTORS AMERICA, INC. NOTE: Since a sealant is used on the threaded area, be careful not to damage the oil pressure switch. 2. Remove the oil filter and the oil pan.
  • Page 95 OIL PUMP 1. Visually check the parts of the oil pump case for cracks and damage. 2. Assemble the rotor on the oil pump and then check the clearance with a thickness gauge. OIL PUMP CLEARANCE Application Standard In. (mm) Body Clearance 0.0039-0.0071 (0.100-0.181) Side Clearance...
  • Page 96 Courtesy of KIA MOTORS AMERICA, INC. Fig. 97: Measuring Side & Body Clearance Courtesy of KIA MOTORS AMERICA, INC. RELIEF PLUNGER AND SPRING 1. Check the relief plunger for smooth operation. 2. Check the relief spring for the deformed or broken condition.
  • Page 97 If there is continuity, replace the oil pressure switch. Fig. 98: Testing Oil Pressure Switch Continuity Courtesy of KIA MOTORS AMERICA, INC. 2. Check the continuity between the terminal and the body when the fine wedge is pushed. If there is...
  • Page 98 Fig. 99: Testing Oil Pressure Switch Continuity When Activated Courtesy of KIA MOTORS AMERICA, INC. 3. Or, if there is no continuity when a 50kPa (0.5 kg/cm , 7psi) vacuum is applied through the oil hole, the switch is operating properly. Check that air doesn't leak. If air leaks, the diaphragm is broken, replace it.
  • Page 99 Oil pump cover screw: 8-12 N.m (80-120 kg.cm, 5.91-8.85 lb.ft) Fig. 100: Positioning Oil Pump Case & Gasket Courtesy of KIA MOTORS AMERICA, INC. 2. Install the oil seal in the oil pump case, using special tool (09214-33000).
  • Page 100 Fig. 101: Installing Oil Pump Seal Courtesy of KIA MOTORS AMERICA, INC. 3. Install the relief plunger and spring, and tighten the oil relief valve plug to the specified torque. Tightening torque: Oil relief valve plug: 40-50 N.m (400-500 kg.cm, 29.5-36.88 lb.ft)
  • Page 101 Fig. 102: Installing Relief Plunger & Spring Courtesy of KIA MOTORS AMERICA, INC. 4. Install the oil screen with a new gasket.
  • Page 102 Tightening torque Oil screen bolt: 15-22 N.m (150-220 kg.cm, 11.06-16.23 lb.ft) 5. Clean the gasket surfaces of the cylinder block and the oil pan. 6. Apply sealant into the groove of the oil pan flange. NOTE: Make the first cut from the end of the nozzle furnished with the sealant approx.
  • Page 103 Courtesy of KIA MOTORS AMERICA, INC. 8. Install the lower oil pan and tighten the bolts to specified torque. Tightening torque: Lower oil pan bolt: 9.8-11.8 N.m (100-120 kg.cm, 7.2-8.7 lb.ft) Fig. 104: Lower Oil Pan Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC.
  • Page 104 Do not tighten the oil pressure switch to the excessive torque. Oil pressure switch tightening torque: 8-12 N.m (80-120 kg.cm, 5.91-8.85 lb.ft) Fig. 105: Tightening Oil Pressure Switch Courtesy of KIA MOTORS AMERICA, INC. MAIN MOVING SYSTEM CONNECTING ROD & PISTON ASSEMBLY...
  • Page 105 COMPONENTS Fig. 106: Exploded View Of Connecting Rod & Piston Assembly Courtesy of KIA MOTORS AMERICA, INC. DISASSEMBLY CONNECTING ROD CAP...
  • Page 106 CAUTION: Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for proper reassembly. 1. Remove the connecting rod cap bolts, then remove the caps and the big end lower bearing mark for reassembly. 2. Push each piston connecting rod assembly toward the top of the cylinder.
  • Page 108 Fig. 107: Marking Connecting Rod Assemblies Courtesy of KIA MOTORS AMERICA, INC. PISTON PIN REMOVAL & INSTALLATION 1. Use the appropriate tool to disassemble piston and connecting rod. Fig. 108: Illustrating Removal & Installation Tools Courtesy of KIA MOTORS AMERICA, INC.
  • Page 109 Fig. 109: Piston Pin Removal Fixture Courtesy of KIA MOTORS AMERICA, INC. 4. Press the piston pin out of the connecting rod. 5. Install proper pin guide through piston into connecting rod. Hand tap pin guide into piston for proper...
  • Page 110 Fig. 110: Piston Pin Installation Fixture Courtesy of KIA MOTORS AMERICA, INC. CAUTION: The pin guide centers on the connecting rod in the piston. When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork tool, the guide pin will also center on the tool assembly.
  • Page 111 Fig. 111: Illustrating Fixture Set-Up Courtesy of KIA MOTORS AMERICA, INC. 7. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the specified alphanumeric is obtained. 8. Insert the installing tool through the hole in the arch of the tool. Press the piston pin into the connecting...
  • Page 112 the connecting rod as the piston pin is pressed in. CAUTION: Do not exceed 5000 pounds of force when stopping the installation arbor sleeve against the arch. INSPECTION PISTONS AND PISTON PINS 1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective. 2.
  • Page 113 Fig. 112: Exploded View Of Piston Rings Courtesy of KIA MOTORS AMERICA, INC.
  • Page 114 2. 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.
  • Page 115 Fig. 113: Positioning Connecting Rod Bearing Courtesy of KIA MOTORS AMERICA, INC. REASSEMBLY 1. Install the expander.
  • Page 116 Fig. 114: Positioning Oil Ring Courtesy of KIA MOTORS AMERICA, INC. 2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring groove and spacer, hold it firmly, and press down with finger on the portion to be inserted into the groove.
  • Page 117 Fig. 115: Installing Oil Ring Side Rail Courtesy of KIA MOTORS AMERICA, INC. 4. Apply engine oil around the piston and piston grooves. 5. Using a piston ring expander, install the No. 2 piston ring. 6. Install the No. 1 piston ring.
  • Page 118 Fig. 117: Positioning Piston Rings Courtesy of KIA MOTORS AMERICA, INC. 8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder. 9. Install the upper connecting rod bearings into the connecting rod.
  • Page 119 Fig. 118: Positioning Connecting Rod Bearing Cap Courtesy of KIA MOTORS AMERICA, INC. 14. When assembling, bolts should be fastened using the following technique. a. Apply oil to the threads and matching areas. b. Tighten the connecting rod bolt. Connecting rod bolt, tightening torque: 35 N.m + 92° (350 kg.cm + 92°, 26 lb.ft + 92°)
  • Page 120 Remove the cap, measure at the widest part by using the scale printed on the plastigauge package. Connecting rod cap bearing clearance, standard value :0.022-0.040 mm (0.0009-0.0016 in). Limit: 0.1 mm (0.0039 in) Fig. 119: Measuring Bearing Clearance Courtesy of KIA MOTORS AMERICA, INC.
  • Page 121 16. Check the connecting rod side clearance. Connecting rod side clearance, standard: 0.10-0.25 mm (0.0039-0.0098 in.) Limit: 0.4 mm (0.0157 in.) Fig. 120: Measuring Bearing Side Clearance Courtesy of KIA MOTORS AMERICA, INC. CRANK SHAFT COMPONENTS...
  • Page 122 Fig. 121: Exploded View Of Crankshaft Components Courtesy of KIA MOTORS AMERICA, INC. DISASSEMBLY 1. Remove the timing belt, cylinder head assembly, drive plate, transaxle mounting plate oil pan. See TIMING SYSTEM . 2. Remove the oil seal case and the rear oil seal.
  • Page 123 1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check the oil holes for restrictions. Repair or replace any defective part. 2. Inspect for out-of-roundness and taper of the crankshaft journal and pin. Fig. 122: Crankshaft Specification Courtesy of KIA MOTORS AMERICA, INC.
  • Page 124 Fig. 123: Measuring Crankshaft Journal Courtesy of KIA MOTORS AMERICA, INC. MAIN BEARING AND CONNECTING ROD BEARING Visually inspect each bearing for peeling, melt, seizure and improper contact. Replace any defective bearings. OIL CLEARANCE MEASUREMENT Check for oil clearance by measuring the outside diameter of the crankshaft journal and the inside diameter of the bearing.
  • Page 125 Connecting rod bearing: 0.022 - 0.040 mm (0.0009 - 0.0016 in) Fig. 124: Measuring Oil Clearance Courtesy of KIA MOTORS AMERICA, INC. PLASTIGAUGE METHOD Plastigauge may be used to measure the clearance. 1. Remove oil and grease and any other dirt from the bearings and journals.
  • Page 126 Fig. 125: Measuring Oil Clearance Using Plastigauge Courtesy of KIA MOTORS AMERICA, INC. 3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation, do not turn the crankshaft. Remove the caps. Measure the width of the widest part by using the scale printed on the gauge package.
  • Page 127 1. Install the grooved main bearing (upper bearing) on the cylinder block side. Fig. 126: Identifying Main Bearings Courtesy of KIA MOTORS AMERICA, INC. 2. Install the grooveless main bearing (lower bearing) on the main bearing cap side. 3. Install the crankshaft. Apply engine oil to the journal and pin.
  • Page 128 Fig. 127: Crankshaft Bearing Cap Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 6. Cap bolt should be tightened to specified torque in 4~5 steps before being tightened to the specified torque. 7. Make certain that the crankshaft turns freely and has the proper crankshaft end play.
  • Page 129 Fig. 128: Measuring Crankshaft End Play Courtesy of KIA MOTORS AMERICA, INC. 8. Assemble the rear oil seal to oil case using the special tool (09231-33000).
  • Page 130 Fig. 129: Positioning Rear Oil Seal Onto Special Tool Courtesy of KIA MOTORS AMERICA, INC. 9. Install the drive plate and the adapter plate. Tightening torque Drive bolt: 73 - 77 N.m (730 - 770 kg.cm, 53.85 - 56.80 lb.ft)

  • Page 131: Engine Block

    Fig. 130: Installing Drive & Adapter Plates Courtesy of KIA MOTORS AMERICA, INC. ENGINE BLOCK COMPONENTS...
  • Page 132 Fig. 131: Identifying Cylinder Block Components Courtesy of KIA MOTORS AMERICA, INC. DISASSEMBLY Remove the timing belt, cylinder head assembly, drive plate, transaxle mounting plate, oil pan and the oil pump case. INSPECTING CYLINDER BLOCK 1. Visually check the cylinder block for scores, rust and corrosion.
  • Page 133 Level 3: Bottom of cylinder Fig. 132: Measuring Cylinder Bore Courtesy of KIA MOTORS AMERICA, INC. 3. If the cylinder bores show more than the specified out-of round or taper, or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed. New oversize pistons and rings should be installed.
  • Page 134 Cylinder bore: 93.00-93.03 mm (3.66-3.663 in) Deviation of concentricity and taper of cylinder bore : 0.02 mm (0.00079 in) or less 4. If a ridge exists at the top of the cylinder, cut it way with a ridge reamer. 5. Oversize pistons are available in four sizes. Oversize piston size.
  • Page 135 Fig. 133: Measuring Cylinder Block Flatness Courtesy of KIA MOTORS AMERICA, INC. Standard value: Flatness of the gasket mating surface: less than 0.05 mm (0.002 in) Limit Flatness of the gasket mating surface: 0.1 mm (0.0039 in) CAUTION: When the cylinder head is assembled, grinding less than 0.2 mm is permissible.
  • Page 136 2. Measure the outside diameter of the piston to be used. Fig. 134: Measuring Piston Diameter Courtesy of KIA MOTORS AMERICA, INC. 3. Based on the measured O.D., calculate the boring finish dimension. Boring finish dimension = piston outer diameter + 0.02~0.04 mm (The clearance between piston outer diameter and cylinder) - 0.01 mm (Honing margin)

  • Page 137: Cooling System

    Standard value: 0.03-0.05 mm (0.0012 - 0.0020 in) NOTE: All cylinders should be bored to the same oversize. Never bore only one cylinder to an oversize. COOLING SYSTEM GENERAL INLET CONTROL Fig. 135: Illustrating Coolant Inlet Flow Courtesy of KIA MOTORS AMERICA, INC. FLOW CHART...
  • Page 138 Fig. 136: Illustrating Coolant Flow Chart Courtesy of KIA MOTORS AMERICA, INC. RADIATOR COMPONENTS...
  • Page 139 Fig. 137: Locating Radiator Components Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Remove the air duct. 2. Remove the hood locker. 3. Disconnect the horn connector. 4. Remove the shroud upper member. 5. Disconnect the radiator fan motor connector and the condenser fan motor connector.
  • Page 140 4. Check if there are any leakage from radiator, hose and connecting part. RADIATOR CAP COMPONENTS Fig. 138: Illustrating Radiator Cap Components Courtesy of KIA MOTORS AMERICA, INC. INSPECTION 1. Inspect the radiator cap for damage, crack and weakening.
  • Page 141 Fig. 139: Inspecting Radiator Cap Courtesy of KIA MOTORS AMERICA, INC. 2. Connect the radiator cap tester to the radiator cap. 3. Apply the pressure to the tester untill the needle is fixed.
  • Page 142 Fig. 140: Testing Radiator Cap Courtesy of KIA MOTORS AMERICA, INC. 4. If the needle stays at the same position for 10 seconds, the radiator cap is in good condition. RADIATOR FAN MOTOR COMPONENTS...
  • Page 143 Fig. 141: Exploded View Of Fan Motor Assembly Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Remove the air duct. 2. Remove the hood locker. 3. Disconnect the horn connector. 4. Remove the shroud upper member. 5. Disconnect the radiator fan motor connector.
  • Page 144 Fig. 142: Testing Radiator Fan Motor Courtesy of KIA MOTORS AMERICA, INC. b. Check if there is abnormal noise while motor is rotating. INSTALLATION 1. Installation is done in the reverse order of disassembly procedure. CAUTION: When assembling the shroud, be cautions not to touch the cooling fan.
  • Page 145 Fig. 143: Exploded View Of Water Pump Assembly Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION 1. Clean the gasket mating surface of the water pump body and cylinder block. 2. After installing new O-ring in the groove at front of the water pipe, soak it with water. At this time, do not soak it with oil or grease.
  • Page 146 Fig. 144: Water Pump Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 4. Install the timing belt tensioner and timing belt. After adjusting the timing belt tension, install the timing belt cover. 5. After installing the water pump pulley and driving belt, adjust the belt tension.
  • Page 147 COMPONENTS Fig. 145: Exploded View Of Thermostat Components Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Drain the coolant to the bottom level of thermostat. 2. Remove the water outlet fitting. 3. Remove the thermostat. INSPECTION 1. Heat the thermostat and check if the valve operates properly.
  • Page 148 2. Check to determine the temperature at which the value begins to open and is completely opened. Valve opening temperature: 80.0-84.0°C (176-183.2°F) The temperature when the valve is completely opened: 95°C (203°F) Fig. 146: Testing Thermostat Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION 1. Align the arrangement mark of thermostat housing with the jiggle valve.
  • Page 149 Fig. 147: Positioning Thermostat Courtesy of KIA MOTORS AMERICA, INC.
  • Page 150 2. Check to ensure that the flange of the thermostat at is correctly seated in the socket of the thermost at housing. If the thermostat is installed in the wrong direction, the bottom of the thermostat will touch the rib inside the intake manifold, making it impossible to seat flange in position. 3.
  • Page 151 Fig. 148: Exploded View Of Water Hoses Courtesy of KIA MOTORS AMERICA, INC. REMOVAL WATER TEMPERATURE GAUGE UNIT AND SENSOR 1. Drain the coolant to the bottom level of the gauge unit. 2. After disconnecting the battery ground cable, disconnect engine harness.
  • Page 152 Fig. 149: Locating Water Temp Gauge Unit Courtesy of KIA MOTORS AMERICA, INC. INSPECTION ENGINE COOLANT HOSE/PIPES Check for cracks, damage, or blockage on the water hose and pipe, and replace if necessary. WATER TEMPERATURE GAUGE UNIT AND SENSOR 1. Water temperature gauge unit a.
  • Page 153 Fig. 150: Temperature Gauge Resistance Chart Courtesy of KIA MOTORS AMERICA, INC. 2. Water temperature sensor a. Immerse the sensor in hot water. b. Check if the resistance is within the specified range. Fig. 151: Temperature Sender Resistance Chart Courtesy of KIA MOTORS AMERICA, INC.
  • Page 154 Fig. 152: Testing Sending Unit Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION ENGINE COOLANT HOSE/PIPES After inserting O-ring into a groove at the lower part of water inlet pipe, soak O-ring in water and insert it into the water inlet pipe.
  • Page 155 Fig. 153: Positioning Water Pipe O-Ring...

  • Page 156: Air Cleaner

    Courtesy of KIA MOTORS AMERICA, INC. WATER TEMPERATURE GAUGE UNIT AND SENSOR 1. Apply the sealant on thread and then tighten it to the specified torque. Fig. 154: Sealant & Tightening Chart Courtesy of KIA MOTORS AMERICA, INC. 2. Connect the harness to water temperature gauge unit and cable.
  • Page 157 Fig. 155: Identifying Air Cleaner Components Courtesy of KIA MOTORS AMERICA, INC.
  • Page 158 REMOVAL 1. Disconnect the AFS connector. Fig. 156: Locating AFS Connector Courtesy of KIA MOTORS AMERICA, INC. 2. Pull out air duct which is connected to the air inlet hose and air cleaner. 3. Detach the air cleaner. INSPECTION 1. Inspect the body, cover and packing of air cleaner for distortion, corrosion and damage.
  • Page 159 Fig. 157: Cleaning Air Cleaner Courtesy of KIA MOTORS AMERICA, INC. 4. Inspect the air cleaner housing for dirt, contamination and damage. 5. If the inside of air cleaner housing is contaminated, eliminates the contaminated material. SURGE TANK & INTAKE MANIFOLD...
  • Page 160 Fig. 158: Exploded View Of Surge Tank & Intake Manifold Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Detach the P.C.V. hose and brake booster vacuum hose. 2. Disconnect the connecting part of vacuum hose.
  • Page 161 Fig. 159: Disconnecting PCV Hose Courtesy of KIA MOTORS AMERICA, INC. 3. Remove the surge tank stay.
  • Page 162 Fig. 160: Removing The Surge Tank Stay Courtesy of KIA MOTORS AMERICA, INC. 4. After reducing the pressure of fuel pipe line to prevent fuel overflow, disconnect the connecting part of the high pressure hose.
  • Page 163 Fig. 161: Disconnecting High Pressure Fuel Hose Courtesy of KIA MOTORS AMERICA, INC. 5. Remove the surge tank.
  • Page 164 Fig. 162: Removing The Surge Tank Courtesy of KIA MOTORS AMERICA, INC. 6. After removing the surge tank, remove the gasket.
  • Page 165 Fig. 163: Removing Surge Tank Gasket Courtesy of KIA MOTORS AMERICA, INC. 7. Disconnect the fuel injector harness connector.
  • Page 166 Fig. 164: Disconnecting Fuel Injector Harness Connector Courtesy of KIA MOTORS AMERICA, INC. 8. Remove the delivery pipe with fuel injector and pressure regulator attached. CAUTION: When removing the delivery pipe, be cautions not to drop the injectors.
  • Page 167 Fig. 165: Removing Fuel Delivery Pipe Courtesy of KIA MOTORS AMERICA, INC. 9. Disconnect the wiring harness connector which is connected to the water temperature gauge unit and water temperature sensor assembly.
  • Page 168 Fig. 166: Disconnecting Wiring Harness Courtesy of KIA MOTORS AMERICA, INC. 10. Remove the water outlet fitting and gasket. 11. Remove the thermostat. INSPECTION 1. Surge tank a. Inspect the surge tank for damage and crack, if necessary, replace it.
  • Page 169 Fig. 167: Measuring Surge Tank Flatness Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION 1. After replacing the intake manifold gasket, install the surge tank and tighten to the specified torque. Tightening torque: 19.6-22.6 N.m (200-230 kg.cm, 14.5-16.6 lb.ft.)
  • Page 170 Fig. 168: Illustrating Intake Manifold Courtesy of KIA MOTORS AMERICA, INC. 2. Install the delivery pipe and injector assembly to the intake manifold. CAUTION: Check the interference between the injector and injector hole in intake manifold. 3. Install the surge tank stay.
  • Page 171 Fig. 169: Installing Surge Tank Stay Courtesy of KIA MOTORS AMERICA, INC. 4. Install the fuel injector connector and wiring harness. 5. Connect the high pressure fuel hose. 6. Connect the various vacuum hose. 7. Connect the PCV valve hose and brake booster hose.

  • Page 172: Exhaust System

    EXHAUST SYSTEM EXHAUST MANIFOLD COMPONENTS Fig. 170: Exploded View Of Exhaust Manifold Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Remove the heat protector.
  • Page 173 Fig. 171: Removing Heat Protector Courtesy of KIA MOTORS AMERICA, INC. 2. Remove the exhaust manifold.
  • Page 174 Fig. 172: Removing Exhaust Manifold Courtesy of KIA MOTORS AMERICA, INC. INSPECTION 1. Exhaust manifold a. Check for cracks, replace if necessary. b. Check the distortion in mating surface with a straight edge and filler gauge...
  • Page 175 Fig. 173: Exhaust Manifold Flatness Specifications Courtesy of KIA MOTORS AMERICA, INC. Fig. 174: Measuring Exhaust Manifold Flatness Courtesy of KIA MOTORS AMERICA, INC. 2. Heat protector, gasket Check for damages and cracks in all parts, replace if necessary. INSTALLATION 1.
  • Page 176 Fig. 175: Installing Exhaust Manifold Courtesy of KIA MOTORS AMERICA, INC. CAUTION: Use only new exhaust manifold gaskets and nuts. 2. Install the heat protector.
  • Page 177 Fig. 176: Installing Heat Protector Courtesy of KIA MOTORS AMERICA, INC. MUFFLER COMPONENTS...
  • Page 178 Fig. 177: Identifying Muffler Components Courtesy of KIA MOTORS AMERICA, INC.

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