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

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AMANTI 2007-08 User manual

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