Amanti 2007-08 User manual

2007

08 ENGINE

Mechanical - Amanti

GENERAL

SPECIFICATIONS

GENERAL SPECIFICATIONS

Description Specifications Limit

3.8L

General

Type V-type, DOHC -

Number of cylinders 6 -

Bore 96 mm (3 7795 in) -

Stroke 87 0 mm (3 4252 in) -

Total displacement 3,778 cc (230 55 cu

in )

Compression ratio 10 4 -

Firing order 1-2-3-4-5-6 -

Idle RPM 700 RPM -

alve timing

Intake Opens (ATDC) 10° -

Closes (ABDC) 62° -

Exhaust Opens (BBDC) 42° -

Closes (ATDC) 6° -

Cylinder head

Flatness of gasket surface Less than 0 05 mm

(0 0019 in )

[Less than 0 02 mm

(0 0008 in )/150 x

150]

Flatness of

manifold

mounting Intake

Less than 0 1 mm

(0 0039 in )

[Less than 0 03 mm

(0 001 in)/110 x 110]

Exhaust

Less than 0 1 mm

(0 0039 in )

[Less than 0 03 mm

(0 001 in)/110 x 110]

Camshaft

Cam height LH Camshaft Intake 46 8 mm (1 8425 in ) -

Exhaust 45 8 mm (1 8031 in ) -

RH Camshaft Intake 46 8 mm (1 8425 in ) -

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Exhaust 45 8 mm (1 8031 in ) -

Journal outer

diameter

LH, RH Camshaft Intake No 1: 27 964 ~

27 978 mm (1 1009 ~

1 1015 in )

No 2, 3, 4: 23 954 ~

23 970 mm (0 9430 ~

0 9437 in )

Exhaust No 1: 27 964 ~

27 978 mm (1 1009 ~

1 1015 in )

No 2, 3, 4: 23 954 ~

23 970 mm (0 9430 ~

0 9437 in )

Bearing oil

clearance

LH, RH camshaft Intake No 1: 0 027 ~ 0 057

mm (0 0011 ~ 0 0022

in )

No 2, 3, 4: 0 030 ~

0 067 mm (0 0012 ~

0 0026 in )

Exhaust No 1: 0 027 ~ 0 057

mm (0 0011 ~ 0 0022

in )

No 2, 3, 4: 0 030 ~

0 067 mm (0 0012 ~

0 0026 in )

End play 0 02 ~ 0 18 mm

(0 0008 ~ 0 0071 in )

alve

Valve length Intake 105 27 mm (4 1445

in )

Exhaust 105 50 mm (4 1535

in )

Stem outer

diameter

Intake 5 465 ~ 5 480 mm

(0 2151 ~ 0 2157 in )

Exhaust 5 458 ~ 5 470 mm

(0 2149 ~ 0 2153 in )

Face angle 45 25° ~ 45 75° -

Thickness of valve

head (margin)

Intake 1 56 ~ 1 86 mm

(0 06142 ~ 0 07323

in )

Exhaust 1 73 ~ 2 03 mm

(0 06811 ~ 0 07992

in )

Valve stem to

valve guide

clearance

Intake 0 020 ~ 0 047 mm

(0 00078 ~ 0 00185

in )

0 07 mm (0 00275 in )

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Exhaust 0 030 ~ 0 054 mm

(0 00118 ~ 0 00212

in )

0 09 mm (0 00354 in )

alve guide

Inner diameter Intake 5 500 ~ 5 512 mm

(0 2165 ~ 0 2170 in )

Exhaust 5 500 ~ 5 512 mm

(0 2165 ~ 0 2170 in )

Length Intake 41 8 ~ 42 2 mm

(1 6457 ~ 1 6614 in )

Exhaust 41 8 ~ 42 2 mm

(1 6457 ~ 1 6614 in )

alve seat

Width of seat

contact

Intake 1 15 ~ 1 45 mm

(0 05118 ~ 0 05709

in )

Exhaust 1 35 ~ 1 65 mm

(0 05315 ~ 0 06496

in )

Seat angle Intake 44 75° ~ 45 20° -

Exhaust 44 75° ~ 45 20° -

alve spring

Free length 43 86 mm (1 7267 in ) -

Load

19 3 ± 0 8 kg/34 0

mm (42 7 ± 1 8

lb/1 3386 in )

42 3 ± 1 3 kg/24 2

mm (93 3 ± 2 9

lb/0 9527 in )

Out of squareness Less than 1 5° -

MLA

MLA outer

diameter

Intake 34 964 ~ 34 980 mm

(1 3765 ~ 1 3772 in )

Exhaust 34 964 ~ 34 980 mm

(1 3765 ~ 1 3772 in )

Cylinder head

tappet bore inner

diameter

Intake 35 000 ~ 35 025 mm

(1 3779 ~ 1 3789 in )

Exhaust 35 000 ~ 35 025 mm

(1 3779 ~ 1 3789 in )

MLA to tappet

bore clearance

Intake 0 020 ~ 0 061 mm

(0 0008 ~ 0 0024 in )

0 07 mm (0 0027 in )

Exhaust 0 020 ~ 0 061 mm

(0 0008 ~ 0 0024 in )

0 07 mm (0 0027 in )

alve clearance

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Intake 0 17 ~ 0 23 mm

(0 0067 ~ 0 0090 in )

0 10 ~ 0 30 mm

(0 0039~0 0118 in )

Exhaust 0 27 ~ 0 33 mm

(0 0106 ~ 0 0129 in )

0 20 ~ 0 40 mm (0 0078

~ 0 0157 in )

Cylinder block

Cylinder bore 96 00 ~ 96 03 mm

(3 7795 ~ 3 7807 in )

Flatness of gasket surface

Less than 0 05 mm

(0 0019 in )

[Less than 0 02 mm

(0 0008 in )/150 x

150]

Piston

Piston outer diameter 95 96 ~ 95 99 mm

(3 7779 ~ 3 7791 in )

Piston to cylinder clearance 0 03 ~ 0 05 mm

(0 0012 ~ 0 0020 in )

Ring groove width No 1 ring groove 1 22 ~ 1 24 mm

(0 0480 ~ 0 0488 in )

1 26 mm (0 0496 in )

No 2 ring groove 1 22 ~ 1 24 mm

(0 0480 ~ 0 0488 in )

1 26 mm (0 0496 in )

Oil ring groove 2 01 ~ 2 03 mm

(0 0791 ~ 0 0799 in )

2 05 mm (0 0807 in )

Piston ring

Side clearance No 1 ring 0 03 ~ 0 07 mm

(0 0012 ~ 0 0027 in )

0 1 mm ~ 0 004 in )

No 2 ring 0 03 ~ 0 07 mm

(0 0012 ~ 0 0027 in )

0 1 mm (0 004 in )

Oil ring 0 06 ~ 0 15 mm

(0 0024 ~ 0 0059 in )

0 2 mm (0 008 in )

End gap No 1 ring 0 17 ~ 0 32 mm

(0 0067 ~ 0 0126 in )

0 6 mm (0 0236 in )

No 2 ring 0 32 ~ 0 47 mm

(0 0126 ~ 0 0185 in )

0 7 mm (0 0275 in )

Oil ring 0 20 ~ 0 70 mm

(0 0078 ~ 0 0275 in )

0 8 mm (0 0315 in )

Piston pin

Piston pin outer diameter 23 001 ~ 23 006 mm

(0 9055 ~ 0 9057 in )

Piston pin hole inner diameter 23 016 ~ 23 021 mm

(0 9061 ~ 0 9063 in )

Piston pin hole clearance 0 01 ~ 0 02 mm

(0 0004 ~ 0 0008 in )

Connecting rod small end inner diameter 22 974 ~ 22 985 mm -

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

(0 9045 ~ 0 9049 in )

Connecting rod small end hole clearance -0 032 ~ -0 016 mm (-

0 0012 ~ 0 0006 in )

Connecting rod

Connecting rod big end inner diameter 58 000 ~ 58 018 mm

(2 2834 ~ 2 2842 in )

Connecting rod bearing oil clearance 0 038 ~ 0 056 mm

(0 0015 ~ 0 0022 in )

Side clearance 0 1 ~ 0 25 mm

(0 0039 ~ 0 0098 in )

Crankshaft

Main journal outer diameter 68 942 ~ 68 960 mm

(2 7142 ~ 2 7149 in )

Pin journal outer diameter 54 954 ~ 54 972 mm

(2 1635 ~ 2 1642 in )

Main bearing oil clearance 0 022 ~ 0 040 mm

(0 0008 ~ 0 0016 in )

End play 0 10 ~ 0 28 mm

(0 0039 ~ 0 0110 in )

Oil pump

Relief valve opening pressure

450 ~ 550 kPa

(4 59 ~ 5 61 kgf/cm2 ,

65 28 ~ 79 79 psi)

Engine oil

Oil quantity (Total) 6 0L (6 34 U S qts,

5 28 lmp qts)

When replacing a short

engine or a block

assembly

Oil quantity (Oil pan) 5 5L (5 81 U S qts,

4 84 lmp qts)

When replacing an oil

pan only

Oil quantity (Drain and refill) 5 2L (5 49 U S qts,

4 58 lmp qts)

Oil quality Above SJ or SL -

Oil pressure

130 kPa (1 32

kgf/cm2 , 18 77 psi)

[at 1000 RPM, 110°C

(230°F)]

Cooling system

Cooling method Forced circulation

with electrical fan

Coolant quantity 8 7L (9 19 U S qts,

7 66 lmp qts)

Thermostat Type Wax pellet type -

Opening temperature 82 ± 2°C (179 6 ±

35 6°F)

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

TIGHTENING TORQUE

TIGHTENING TORQUE SPECIFICATIONS

Fully opened temperature 95°C (203°F) -

Full lift 10 mm (0 3937 in )

MIN

Radiator cap Main valve opening pressure 93 16 ~ 122 58 kPa

(0 95 ~ 1 25 kg/cm2 ,

13 51 ~ 17 78 psi)

Vacuum valve opening pressure 0 98 ~ 4 90 kPa

(0 01 ~ 0 05 kg/cm2 ,

0 14 ~ 0 71 psi)

Water temperature sensor

Type Thermistor type -

Resistance 20°C (68°F) 2 31 ~ 2 59 Kohms -

80°C (176°F) 0 3222 Kohms -

Item Quantity N.m kgf.m lb-ft

Crankshaft pulley

bolt

1 284 2 ~ 303 8 29 0 ~ 31 0 209 76 ~ 224 22

Timing chain cover

bolt B

17 18 62 ~ 21 56 1 9 ~ 2 2 13 74 ~ 15 91

Timing chain cover

bolt C

4 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Timing chain cover

bolt D

1 58 80 ~ 68 80 6 0 ~ 7 0 43 40 ~ 50 63

Timing chain cover

bolt E

1 58 80 ~ 68 80 6 0 ~ 7 0 43 40 ~ 50 63

Timing chain cover

bolt F

2 24 50 ~ 26 46 2 5 ~ 2 7 18 08 ~ 19 53

Timing chain cover

bolt G

4 21 56 ~ 23 52 2 2 ~ 2 4 15 91 ~ 17 36

Timing chain cover

bolt H

1 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Timing chain cover

bolt I

1 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Timing chain cover

bolt J

1 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Cam to cam guide

bolt

4 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Timing chain auto

tensioner bolt

2 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Timing chain auto

tensioner nut

2 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Timing chain guide

bolt

4 19 60 ~ 24 50 2 0 ~ 2 5 14 17 ~ 18 08

Oil pump chain

cover bolt

3 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Oil pump chain

tensioner bolt

1 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Oil pump chain

guide bolt

2 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Oil pump chain

sprocket bolt

1 18 62 ~ 21 56 1 9 ~ 2 2 13 74 ~ 15 91

Lower oil pan bolt 13 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Drive belt auto

tensioner bolt (M12)

1 81 4 ~ 85 3 8 3 ~ 8 7 60 0 ~ 62 9

Drive belt auto

tensioner bolt (M8)

1 17 64 ~ 21 56 1 8 ~ 2 2 13 02 ~ 15 91

Drive belt idler bolt 1 53 90 ~ 57 82 5 5 ~ 5 9 39 78 ~ 42 67

OCV (oil control

valve) bolt

2 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Cylinder head bolt 16 39 2 + 120° +90° 4 0 + 120° + 90° 28 93+ 120° + 90°

Cylinder head bolt 1 18 62 ~ 23 52 1 9 ~ 2 4 13 74 ~ 17 36

CVVT & exhaust

cam sprocket bolt

4 64 68 ~ 76 44 6 6 ~ 7 8 47 74 ~ 56 42

Camshaft bearing

cap bolt

32 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Cylinder head cover

bolt

38 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Connecting rod

bearing bolt

12 19 60 + 90° 2 0 + 90° 14 46 + 90°

Main bearing cap

inner bolt (M11)

8 49 00 + 90° 5 0 + 90° 36 16 + 90°

Main bearing cap

outer bolt (M8)

8 19 60 + 120° 2 0 + 120° 14 46 + 120°

Main bearing cap

side bolt (M8)

6 29 40 ~ 31 36 3 0 ~ 3 2 21 70 ~ 23 14

Oil drain cover bolt 6 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Rear oil seal case

bolt

6 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Baffle plate bolt 12 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Upper oil pan bolt 16 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Knock sensor bolt 2 15 68 ~ 23 52 1 6 ~ 2 4 11 57 ~ 17 36

Drive plate bolt cap 8 71 54 ~ 75 46 7 3 ~ 7 7 52 80 ~ 55 69

Oil filter cap - 24 50 2 5 18 08

Oil drain bolt cap 1 34 30 ~ 44 10 3 5 ~ 4 5 25 31 ~ 32 55

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

INSPECTION

COMPRESSION PRESSURE

Oil pump bolt 3 20 6 ~ 22 6 2,1 ~ 2 3 15 2 ~ 16 6

Oil filter body bolt 10 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Oil filter body cover

bolt

11 9 80 ~ 11 76 1 0 ~ 1 2 7,23 ~ 8 68

Water vent hose bolt

(Timing chain cover

bolt L)

2 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Water pump bolt

(Timing chain cover

bolt K)

1 21 56 ~ 26 46 2 2 ~ 2 7 15 91 ~ 19 53

Water pump bolt 4 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Water pump pulley

bolt

4 7 84 ~ 9 80 0 8 ~ 1 0 5 78 ~ 7 23

Water temp, control

nut

4 19 6 ~ 23 52 2 0 ~ 2 4 14 5 ~ 17 36

Water temp, control

bolt

2 19 6 ~ 23 52 2 0 ~ 2 4 14 5 ~ 17 36

Water inlet pipe bolt 3 16 66 ~ 19 60 1 7 ~ 2 0 12 30 ~ 14 47

Air vent pipe bolt 2 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Intake manifold bolt 6 26 5 ~ 31 4 2 7 ~ 3 2 19 5 ~ 23 1

Intake manifold nut 2 18 62 ~ 23 52 1 9 ~ 2 4 13 74 ~ 17 36

Surge tank bolt (M8

x 25)

3 18 62 ~ 23 52 1 9 ~ 2 4 13 74 ~ 17 36

Surge tank bolt (M6

x 106)

2 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Surge tank nut 1 18 62 ~ 23 52 1 9 ~ 2 4 13 74 ~ 17 36

Breather pipe bolt 2 9 80 ~ 11 76 1 0 ~ 1 2 7 23 ~ 8 68

Surge tank bracket

bolt rear (M10 x 18)

2 27 44 ~ 31 36 2 8 ~ 3 2 20 25 ~ 23 14

Surge tank bracket

bolt front (M8 x 16)

2 18 62 ~ 23 52 1 9 ~ 2 4 13,74 ~ 17 36

ETC bracket bolt 2 15 68 ~ 25 48 1 6 ~ 2 6 11 57 ~ 18 80

Exhaust manifold

nut

16 39 20 ~ 44 10 4 0 ~ 4 5 28 93 ~ 32 55

Heat proctor bolt 8 16 66 ~ 21 56 1 7 ~ 2 2 12 30 ~ 15 91

Front muffler 2 39 20 ~ 58 80 4 0 ~ 6 0 28 93 ~ 43 40

NOTE: If the there Is lack f p wer, excessive il c nsumpti n r p r fuel ec n my,

measure the c mpressi n pressure.

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

1 Warm up and stop engine

Allow the engine to warm up to normal operating temperature

2 Remove the surge tank

3 Remove the ignition coil connectors (A) and ignition coils (B)

Fig. 1: Identifying Ignition Coil Connectors And Ignition Coils

Courtesy of KIA MOTORS AMERICA, INC.

4 Remove the spark plugs

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

5 Check cylinder compression pressure

1 Insert a compression gauge into the spark plug hole

2 Fully open the throttle

3 After 7 times of cranking the engine, measure the compression pressure

4 Repeat steps 1) through 3) for each cylinder

Compression pressure :

1,225 kPa (12 5 kgf/cm2 , 177 psi)

Minimum pressure :

NOTE: Always use a fully charged battery t btain engine speed f 250

RPM r m re.

NOTE: This measurement must be d ne in as sh rt a time as p ssible.

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

1,078 kPa (11 0 kgf/cm2 , 156 psi)

5 If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the

cylinder through the spark plug hole and repeat steps (1) through (3) 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

6 Reinstall the spark plugs

7 Install the ignition coil and ignition coil connectors

8 Install the surge tank

AL E CLEARANCE INSPECTION AND ADJUSTMENT

1 Remove the engine cover

2 Remove air cleaner assembly

3 Remove the surge tank

4 Remove the cylinder head cover

1 Disconnect the ignition coil connector and remove the ignition coil

2 Disconnect the breather pipe assembly (A) from the cylinder head cover

Fig. 2: Locating Breather Pipe Assembly

Courtesy of KIA MOTORS AMERICA, INC.

Loosen the cylinder head cover bolts and then remove the cover (A) and gasket

NOTE: Inspect and adjust the valve clearance when the engine is c ld (Engine c lant

temperature: 20°C) and cylinder head is installed n the cylinder bl ck.

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Fig. 3: Locating Cylinder Head Cover

Courtesy of KIA MOTORS AMERICA, INC.

5 Set No 1 cylinder to TDC/compression

1 Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain

cover

Fig. 4: Aligning Crankshaft Pulley With Timing Mark "T" Of Lower Timing Chain Cover

Courtesy of KIA MOTORS AMERICA, INC.

2 Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head

surface as shown in the illustration

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

NOTE: D n t r tate engine c untercl ckwise

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Fig. 5: Locating Mark Of Camshaft Timing Sprockets

Courtesy of KIA MOTORS AMERICA, INC.

6 Inspect the valve clearance

1 Check only the valve indicated as shown in illustration [No 1 cylinder: TDC/Compression]

measure the valve clearance

Fig. 6: Identifying Timing Mark

Courtesy of KIA MOTORS AMERICA, INC.

Measurement method

 Using a thickness gauge, measure the clearance between the tappet and the base circle of

camshaft

 Record the out-of-specification valve clearance measurements They will be used later to

determine the required replacement adjusting tappet

Valve clearance

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Specification

Engine coolant temperature: 20°C [68°F]

Limit

Intake: 0 17 ~ 0 23 mm (0 0067 ~ 0 0090 in )

Exhaust: 0 27 ~ 0 33 mm (0 0106 ~ 0 0129 in )

2 Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the

lower timing chain cover

3 Check only valves indicated as shown in illustration [NO 4 cylinder: TDC/compression] Measure

the valve clearance (Refer to procedure step 1)

Fig. 7: Identifying Timing Mark

Courtesy of KIA MOTORS AMERICA, INC.

7 Adjust the intake and exhaust valve clearance

1 Set the No 1 cylinder to the TDC/compression

2 Remove the timing chain

Remove the camshaft bearing caps (A)

NOTE: D n t r tate engine c untercl ckwise

NOTE: Bef re rem ving the timing chain, mark the RH/LH timing chain with

an identificati n based n the l cati n f the spr cket because the

identificati n mark n the chain f r TDC (T p Dead Center) can be

erased.

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Fig. 8: Locating Camshaft Bearing Caps

Courtesy of KIA MOTORS AMERICA, INC.

4 Remove the camshaft assembly (A)

Fig. 9: Identifying Camshaft Assembly

Courtesy of KIA MOTORS AMERICA, INC.

5 Remove MLAs

Measure the thickness of the removed tappet using a micrometer

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Fig. 10: Measuring Thickness Of Tappet Using Micrometer

Courtesy of KIA MOTORS AMERICA, INC.

7 Calculate the thickness of a new tappet so that the valve clearance comes within the specified

value

Valve clearance (Engine coolant temperature: 20°C [68°F])

T: Thickness of removed tappet

A: Measured valve clearance

N: Thickness of new tappet

Intake: N = T + [A - 0 20 mm (0 0079 in )]

Exhaust: N = T + [A - 0 30 mm (0 0118 in )]

8 Select a new tappet with a thickness as close as possible to the calculated value

9 Place a new tappet on the cylinder head

10 Install the intake and exhaust camshaft

11 Install the bearing caps (Refer to CYLINDER HEAD ASSEMBLY)

12 Install the timing chain (Refer to TIMING SYSTEM)

13 Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket

and camshaft sprocket timing marks (A)

NOTE: Shims are available in 41 size increments f 0.015 mm (0.0006 in.)

fr m 3.00 mm (0.118 in.) t 3.600 mm (0.1417 in.)

NOTE: Apply engine il at the selected tappet n the periphery and t p

surface.

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Fig. 11: Locating Mark Of Camshaft Timing Sprockets

Courtesy of KIA MOTORS AMERICA, INC.

14 Recheck the valve clearance

Valve clearance (Engine coolant temperature: 20°C [68°F])

[Specification]

Intake: 0 17 ~ 0 23 mm (0 0067 ~ 0 0090 in )

Exhaust: 0 27 ~ 0 33 mm (0 0106 ~ 0 0129 in )

TROUBLESHOOTING

TROUBLESHOOTING CHART

Symptom Suspect area Remedy

Engine misfire with abnormal

internal lower engine noises

Worn crankshaft bearings

Loose or damaged engine drive plate

Replace the crankshaft and

bearings as required

Repair or replace the drive plate

as required

Worn piston rings

(Oil consumption may or may not

cause the engine to misfire )

Inspect the cylinder for a loss of

compression

Repair or replace as required

Worn crankshaft thrust bearings Replace the crankshaft and

bearings as required

Engine misfire with abnormal

valve train noise

Stuck valves

(Carbon buildup on the valve stem)

Repair or replace as required

Excessive worn or misaligned timing

chain

Replace the timing chain and

sprocket as required

Worn camshaft lobes Replace the camshaft and valve

lifters

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Engine misfire with coolant

consumption

Faulty cylinder head gasket

and/or cranking or other damage

to the cylinder head and engine

block cooling system

Coolant consumption may or

may not cause the engine to

overheat

Inspect the cylinder head

and engine block for

damage to the coolant

passages and/or a faulty

head gasket

Repair or replace as

required

Engine misfire with excessive

oil consumption

Worn valves, guides and/or valve stem

oil seals

Repair or replace as required

Worn piston rings

(Oil consumption may or may not

cause the engine to misfire)

Inspect the cylinder for a

loss of compression

Repair or replace as

required

Engine noise on start-up, but

only lasting a few seconds

Incorrect oil viscosity Drain the oil

Install the correct

viscosity oil

Worn crankshaft thrust bearing Inspect the thrust bearing

and crankshaft

Repair or replace as

required

Upper engine noise, regardless

of engine speed

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 damaged sprocket teeth

Replace the timing chain and

sprockets

Worn timing chain tensioner, if

applicable

Replace the timing chain

tensioner as required

Worn camshaft lobes Inspect the camshaft

lobes

Replace the timing

camshaft and valve lifters

as required

Worn valve guides or valve stems Inspect the valves and valve

guides, then repair as required

Stuck valves Carbon on the valve

stem or valve seat may cause the valve

to stay open

Inspect the valves and valve

guides, then repair as required

Worn drive belt, idler, tensioner and

bearing

Replace as required

Lower engine noise, regardless

of engine speed

Low oil pressure Repair as required

Loose or damaged drive plate Repair or replace the drive plate

Damaged oil pan, contacting the oil Inspect the oil pan

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

pump screen Inspect the oil pump

screen

Repair or replace as

required

Oil pump screen loose, damaged or

restricted

Inspect the oil pump

screen

Repair or replace as

required

Excessive piston-to-cylinder bore

clearance

Inspect the piston, piston

pin and cylinder bore

Repair as required

Excessive piston pin-to-piston

clearance

Inspect the piston, piston

pin and the connecting

rod

Repair or replace as

required

Excessive connecting rod bearing

clearance

Inspect the following

components and repair as

required

The connecting rod

bearings

The connecting rods

The crankshaft pin

journals

Excessive crankshaft bearing

clearance

Inspect the following

components, and repair as

required

The crankshaft bearings

The crankshaft main

journals

The cylinder block

Incorrect piston, piston pin and

connecting rod installation

Verify the piston pins and

connecting rods are

installed correctly

Repair as required

Engine noise under load Low oil pressure Repair or replace as required

Excessive connecting rod bearing

clearance

Inspect the following

components and repair as

required :

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

SPECIAL SER ICE TOOLS

The connecting rod

bearings

The connecting rods

The crankshaft

Excessive crankshaft bearing

clearance

Inspect the following

components, and repair as

required

The crankshaft bearings

The crankshaft main

journals

The cylinder block

Engine will not crank-crankshaft

will not rotate

Hydraulically locked cylinder

Coolant/antifreeze in cylinder

Oil in cylinder

Fuel in cylinder

1 Remove spark plugs and

check for fluid

2 Inspect for broken head

gasket

3 Inspect for cracked engine

block or cylinder head

4 Inspect for a sticking fuel

injector and/or leaking

fuel regulator

Broken timing chain and/or timing

chain and/or timing chain gears 1 Inspect timing chain and

gears

2 Repair as required

Material in cylinder

Broken valve

Piston material

Foreign material

1 Inspect cylinder for

damaged components

and/or foreign materials

2 Repair or replace as

required

Seized crankshaft or connecting rod

bearings 1 Inspect crankshaft and

connecting rod bearing

2 Repair as required

Bent or broken connecting rod 1 Inspect connecting rods

2 Repair as required

Broken crankshaft 1 Inspect crankshaft

2 Repair as required

Tool (Number and name) Illustration Use

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Crankshaft front oil seal installer

(09231-3C100)

Installation of the front oil seal

Flywheel stopper (09231-3C300) Removal and installation of the

flywheel and crankshaft pulley

Torque angle adapter (09221-

4A000)

Installation of bolts & nuts

needing an angular method

Valve stem seal remover (09222-

29000)

Removal of the valve stem seal

Valve stem seal installer (09222-

3C100)

Installation of the valve stem seal

Valve spring compressor & holder

(09222-3K000)

(09222-3C300)

Removal and installation of the

intake or exhaust valves

a 09222-3K000

b 09222-3C300 (holder)

Crankshaft rear oil seal installer

(09231-3C200)

(09231-H1100)

Installation of the crankshaft rear

oil seal

a 09231-3C200

b 09231-H1100

Oil pan remover

(09215-3C000)

Removal of oil pan

2008 Kia Amanti

2007-08 ENGINE Mechanical - Amanti

Table of contents

Popular Engine manuals by other brands

Lenze

Lenze g500-S Mounting and switch-on instructions

FTI

FTI M Series Operation and parts manual

Lenze

Lenze m550-H-P63 80 Series Mounting and switch-on instructions

MTU

MTU 8V2000Mx4x operating instructions

Mitsubishi

Mitsubishi S4Q user manual

Briggs & Stratton

Briggs & Stratton 90000 series Operator's manual

PTM Engines

PTM Engines 120F owner's manual

Weber

Weber MPE 750 NA ATV Service manual

MTU

MTU 12 V 4000 T94 operating instructions

Texas

Texas TG595 user manual

Kohler

Kohler KT715 Service manual

Novarossi

Novarossi MEPHISTO.21 GT5 instructions

Dynamite

Dynamite Mach 15R owner's manual

DANA

DANA 4360-61 parts list

Toshiba

Toshiba EQP III 300 Series Brochure & specs

Wilesco

Wilesco D 22 quick start guide

Jamara

Jamara High End Micro instructions

DAF

DAF DF 615 M Operator's manual

AMANTI 2007-08 User manual

Popular Engine manuals by other brands