Kia Cerato 2009 User manual

Engine Mechanical System
General Information
Engine Mechanical System

2009 > D 1.6 TCI-U >
SPECIAL SERVICE TOOLS
Tool (Number and name) Illustration Use
Torque angle adapter
(09221-4A000)
Installation of bolts & nuts needing an
angular method
Valve spring compressor
(09222-3K000)
Valve spring compressor
adapter
(09222-2A100)
Removal and installation of intake and
exhaust valves
Compression gauge
(09351-27000)
Checking engine compression pressure
Compression gauge
adapter
(09351-2A000)
Checking engine compression pressure
Valve stem oil seal
installer
(09222-2A000)
Installation of valve stem oil seals
Injector remover
(09351-4A200)
Removal of injectors

Injector remover adapter
(09351-2A100)
Removal of injectors
High pressure pump
sprocket remover
(09331-2A000)
Removal of high pressure pump sprocket
Crankshaft rear oil seal
installer
(09231-H1200)
Handle
(09231-H1100)
Installation of crankshaft rear oil seal
Front cover oil seal
installer
(09231-2A000)
Handle
(09231-H1100)
Installation of front cover oil seal
Flywheel stopper
(09231-2A100)
Removal and installation of crankshaft
pulley bolt.
Oil pan remover
(09215-3C000)
Removal of oil pan
Engine support fixture and
adapter
(09200-38001,
09200-1C000)
Engine fixing

!2009 > D 1.6 TCI-U > !
TROUBLESHOOTING
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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.
Lower engine noise,
regardless of engine
speed.
Low oil pressure. Repair or replace damaged
components as required.
Loose or damaged flywheel. Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump
screen.
Inspect the oil pan.
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 and cylinder bore.
Repair as required.
Excessive piston pin-to-bore 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.
G The connecting rod bearings.
G The connecting rods.
G The crankshaft.
GThe crankshaft journal.
Excessive crankshaft bearing clearance. Inspect the following components
and repair as required.
G The crankshaft bearings.
G The crankshaft journals.
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.
G The connecting rod bearings.
G The connecting rods.
G The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components
and repair as required.
G The crankshaft bearings.
G The crankshaft journals.
GThe cylinder block crankshaft
bearing bore.
Engine will not
crank. (crankshaft
will not rotate)
Hydraulically locked cylinder.
GCoolant/antifreeze in cylinder.
GOil in cylinder.
G Fuel in cylinder.
Remove injectors and check for fluid.
Inspect for broken head gasket.
Inspect for cracked engine block or
cylinder head.
Inspect for a sticking fuel injector
and/or leaking fuel regulator.

Broken timing chain and/or timing chain gears. Inspect timing chain and gears.
Repair as required.
Foreign material in cylinder.
;Broken valve.
;Piston material.
; Foreign material.
Inspect cylinder for damaged
components and/or foreign materials.
Repair or replace as required.
Seized crankshaft or connecting rod bearings. Inspect crankshaft and connecting
rod bearing.
Repair or replace as required.
Bent or broken connecting rod. Inspect connecting rods.
Repair or replace as required.
Broken crankshaft. Inspect crankshaft.
Repair or replace as required.

2009 > D 1.6 TCI-U >
INSPECTION
COMPESSION PRESSURE
" If the there is lack of power, excessive oil consumption or poor fuel economy, measure the
compression pressure.
"Whenever removing injectors for compression pressure inspection, replace the gaskets with new ones
and tighten them with the specified torque.
1. Warm up engine until the normal operating temperature.
2. Remove the injectors. (Refer to FL Gr.)
3. Check the cylinder compression pressure.
(1) Insert a compression gauge SST(09351-27000, 09351-2A000) into the injector hole.
(2) Fully open the throttle.
(3) While cranking the engine, measure the compression pressure.
Always use a fully charged battery to obtain engine speed of 250rpm or more.
(4) Repeat step 1) though 3) for each cylinder.

This measurement must be done in as short a time as possible.
Compression pressure :
2,157.45kPa (22.0kg/cm², 312.91psi) (200 rpm)
Minimum pressure :
1,863.25kPa (19kg/cm², 270.24psi)
Difference between each cylinder :
98.07kPa (1.0kg/cm², 14.22psi) or less
(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat step 1) through 3) for cylinders with low compression.
A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.
B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past
the gasket.
4. Reinstall the injectors. (Refer to FL Gr.)

2009 > D 1.6 TCI-U >
SPECIFICATIONS
Description Specifications (D4FB) Limit
General
Type In-line, DOHC
Number of cylinders 4
Bore 77.2mm (3.0394in)
Stroke 84.5mm (3.3268in)
Total displacement 1,582 cc (96.54 cu.in)
Compression ratio 17.3 : 1
Firing order 1-3-4-2
Valve timing
Intake valve Opens (ATDC) 17°5' ± 4°
Closes (ABDC) 14°6' ± 4°
Exhaust valve Opens (BBDC) 23°25' ± 4°
Closes (ATDC) 20° ± 4°
Cylinder head
Flatness of gasket surface 0.03mm (0.0012in) for width
0.09mm (0.0035in) for length
Flatness of
manifold
mounting
surface
Intake 0.025mm (0.0010in) for width
0.160mm (0.0063in) for length
Exhaust 0.025mm (0.0010in) for width
0.160mm (0.0063in) for length
Camshaft
Cam height
LH
camshaft
Intake 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
Exhaust 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
RH
camshaft
Intake 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
Exhaust 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
Journal outer
Diameter
LH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)
RH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)
Bearing oil clearance 0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
End play 0.10 ~ 0.20mm (0.0039-0.0079in)
Valve
Valve length Intake 93.0mm (3.6614in)
Exhaust 93.7mm (3.6890in)
Stem outer
diameter
Intake 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)
Exhaust 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
Face angle 45.5° ~ 45.75°
Thickness of Intake 1.1mm (0.0433in)

valve head
(margin) Exhaust 1.2mm (0.0472in)
Valve stem to
valve guide
clearance
Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)
Exhaust 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)
Valve guide
Inner diameter Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Length Intake 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Exhaust 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Valve seat
Width of seat
contact
Intake 0.8 ~ 1.4mm (0.0315 ~ 0.0551in)
Exhaust 1.2 ~ 1.8mm (0.0472 ~ 0.0709in)
Seat angle Intake 45° ~ 45°30'
Exhaust 45° ~ 45°30'
Valve spring
Free length 44.9mm (1.7677in)
Load 17.5±0.9kg/32.0mm(38.6±2.0 lb/1.2598in)
31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in)
Out of squareness Less than 1.5° 3°
Cylinder block
Cylinder bore 77.200 ~ 77.230mm (3.0394 ~ 3.0405in)
Flatness of gasket surface Less than 0.05mm (0.0020in)
Piston
Piston outer diameter 77.130 ~ 77.160mm (3.0366 ~ 3.0378in)
Piston to cylinder clearance 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
Ring groove
width
No. 1 ring groove 1.83 ~ 1.85mm (0.0720 ~ 0.0728in)
No. 2 ring groove 1.82 ~ 1.84mm (0.0717 ~ 0.0724in)
Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in)
Piston ring
Side clearance
No. 1 ring 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
No. 2 ring 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)
Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
End gap
No. 1 ring 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
No. 2 ring 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)
Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
Piston pin
Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
Piston pin hole inner diameter 28.004 ~ 28.010mm (1.1025 ~ 1.1028in)
Piston pin hole clearance 0.004 ~ 0.015mm (0.0002 ~ 0.0006in)

Connecting rod small end hole inner
diameter 28.022 ~ 28.034mm (1.1032 ~ 1.1037in)
Connecting rod small end hole clearance 0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
Connecting rod
Connecting rod big end inner diameter 49.000 ~ 49.018mm (1.9291 ~ 1.9298in)
Connecting rod bearing oil clearance 0.025 ~ 0.043mm (0.0010 ~ 0.0017in)
Side clearance 0.10 ~ 0.25mm (0.0039 ~ 0.0098in) 0.4mm (0.0157in)
Crankshaft
Main journal outer diameter 53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal outer diameter 45.997 ~ 46.015mm (1.8109 ~ 1.8116in)
Main bearing oil clearance 0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
End play 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Flywheel
Runout 0.1mm (0.0039in) 0.13mm (0.0051in)
Oil pump
Side clearance Inner rotor 0.040 ~ 0.085mm (0.0016 ~ 0.0033in)
Outer rotor 0.040 ~ 0.090mm (0.0016 ~ 0.0035in)
Body clearance 0.120 ~ 0.185mm (0.0047 ~ 0.0073in)
Relief valve opening pressure 490±49.0kpa (5±0.5kg/cm², 71±7.1psi)
Engine oil
Oil quantity (Total) 5.7 L (6.02 US qt, 5.01 lmp qt)
Oil quantity (Oil pan) 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil quantity (Drain and refill including oil
filter) 5.3 L (5.60 US qt, 4.66 lmp qt)
Oil quality ABOVE API CH-4 or ACEA B4 (with
CPF:C3)
Oil pressure (Idle) (Oil temperature :
80°C) 78.4kpa (0.8kg/cm², 11.3psi)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quantity 6.97 L (7.37 US qt, 6.13 lmp qt)
Thermostat
Type Wax pellet type
Opening temperature 85±1.5°C (185.0±2.7°F)
Pull opening
temperature 100°C (212°F)
Radiator cap
Main valve opening
pressure
93.16 ~ 122.58kpa
(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Vacuum valve
openingpressure
0.98 ~ 4.90 kpa
(0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)
Water temperature sensor
Type Thermister type

Resistance 20°C (68°F) 2.45±0.14 k
80°C (176°F) 0.3222 k
TIGHTENING TORQUE
Item Quantity Tightening torque
N.m kgf.m lb.ft
Cylinder block
Engine support bracket bolt 4 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Piston cooling oil jet bolt 4 8.8 ~ 12.7 0.9 ~ 1.3 6.5 ~ 9.4
Drive belt auto tensioner bolt 2 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Drive belt auto tensioner mounting
bracket bolt 318.6 ~ 27.5 1.9 ~ 2.813.7 ~ 20.3
Engine mounting
Engine mounting bracket and body fixing
bolt 349.0 ~ 63.7 5.0 ~ 6.536.2 ~ 47.0
Engine mounting insulator and engine
mounting support bracket fixing nut 168.6 ~ 93.2 7.0 ~ 9.550.6 ~ 68.7
Engine mounting support bracket and
engine support bracket fixing bolt 249.0 ~ 63.7 5.0 ~ 6.536.2 ~ 47.0
Engine mounting support bracket and
engine support bracket fixing nut 1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
Transaxle mounting bracket and body
fixing bolt 449.0 ~ 63.7 5.0 ~ 6.536.2 ~ 47.0
Transaxle mounting insulator and
transaxle support bracket fixing bolt 1 88.3 ~ 107.9 9.0 ~11.0 65.1 ~79.6
Front roll stopper bracket and sub frame
fixing bolt (10 X 45) 149.0 ~ 63.7 5.0 ~ 6.536.2 ~ 47.0
Front roll stopper bracket and sub frame
fixing bolt (10 X 25) 249.0 ~ 63.7 5.0 ~ 6.536.2 ~ 47.0
Front roll stopper insulator and front roll
stopper support bracket fixing bolt,nut 1 88.3 ~ 107.9 9.0 ~ 11.0 65.1 ~ 79.6
Rear roll stopper bracket and sub frame
fixing bolt (10 X 60) 149.0 ~ 63.7 5.0 ~ 6.536.2 ~ 47.0
Rear roll stopper bracket and sub frame
fixing bolt (10 X 40) 249.0 ~ 63.7 5.0 ~ 6.536.2 ~ 47.0
Rear roll stopper insulator and rear roll
stopper support bracket fixing bolt,nut 1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
Main moving system
Connecting rod cap bolt 8 12.7 + (87~93°) 1.3 + (87~93°) 9.4 + (87~93°)
Crankshaft main bearing cap bolt (long) 10 (22.6~26.5) +
(90~94°)
(2.3~2.7) +
(90~94°)
(16.6~19.5) +
(90~94°)
Crankshaft main bearing cap bolt (short) 10 32.4 ~ 36.3 3.3 ~ 3.7 23.9 ~ 26.8
Flywheel bolt (M/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9

Drive plate bolt (A/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Timing chain
Timing chain cover bolt (8 X 70) 7 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain cover bolt (8 X 60) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain cover bolt (8 X 35) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Timing chain cover bolt (6 X 35) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain cover bolt (6 X 28) 7 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain case bolt (8 X 22) 4 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Timing chain case bolt (8 X 32) 1 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Timing chain case bolt (6 X 35) 1 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Engine hanger (front) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Crankshaft pulley bolt 1 225.6 ~ 245.2 23.0 ~ 25.0 166.4 ~ 180.8
Camshaft chain sprocket bolt 1 68.6 ~ 73.5 7.0 ~ 7.5 50.6 ~ 54.2
High pressure pump chain sprocket bolt 1 64.7 ~ 74.5 6.6 ~ 7.6 47.7 ~ 55.0
Timing chain guide (1) bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain guide (2) bolt 1 9.8 ~ 13.7 1.0 ~ 1.4 7.2 ~ 10.1
Timing chain "A" auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain "C" auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cylinder head
Engine cover bolt 5 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3
Cylinder head cover bolt 13 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Camshaft bearing cap bolt (mark 10) 16 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1
Camshaft bearing cap bolt (mark 9) 6 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1
Engine hanger bolt 2 28.4 ~ 32.4 2.9 ~ 3.3 21.0 ~ 23.9
Cylinder head bolt
10
(47.1~51.0) +
(88~92°) +
(118~122°)
(4.8~5.2) +
(88~92°) +
(118~122°)
(34.7~37.6) +
(88~92°) +
(118~122°)
Cooling system
Water pump pulley bolt 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt (8 X 50) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Water pump bolt (8 X 70) 1 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Thermostat housing bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Thermostat housing nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water return pipe assembly bolt 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Water temperature sensor 1 19.6 ~ 39.2 2.0 ~ 4.0 14.5 ~ 28.9
Water inlet fitting nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
Lubrication system
Oil filter assembly bolt 4 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil cooler assembly bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Oil filter upper cap 1 24.5 2.5 18.1
Oil level gauge bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil pan bolt (6 X 20) 16 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 65) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan bolt (6 X 85) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan and transaxle fixing bolt 3 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
Oil pan drain bolt 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Oil screen nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pressure switch 1 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Intake and exhaust system
Intake manifold and cylinder head fixing
nut 214.7 ~ 19.6 1.5 ~ 2.010.8 ~ 14.5
Intake manifold and cylinder head fixing
bolt 714.7 ~ 19.6 1.5 ~ 2.010.8 ~ 14.5
Exhaust manifold and cylinder head fixing
nut 829.4 ~ 34.3 3.0 ~ 3.521.7 ~ 25.3
Exhaust manifold heat protector bolt 3 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
WCC assembly fixing nut 3 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3
Air cleaner lower cover fixing bolt 3 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Throttle body and surge tank fixing bolt 4 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3
Exhaust manifold and front muffler fixing
bolt 239.2 ~ 58.8 4.0 ~ 6.028.9 ~ 43.4
Front muffler fixing clip bolt 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9
Front muffler and center muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Center muffler and main muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Engine Mechanical System
Timing System - Timing *OHPU
Engine Mechanical System

2009 > D 1.6 TCI-U >
COMPONENTS

2009 > D 1.6 TCI-U >
REMOVAL
Engine removal is not required for this procedure.
1. Remove the drive belt.
2. Remove the injector(A). (Refer to FL Gr.)
3. Remove the cylinder head cover(A).
4. Remove the engine mounting support bracket.
(1) Set the jack to the engine oil pan

(2) Remove the engine mounting support bracket(A).
5. Remove the alternator(A).
6. Remove the water pump pulley(A).
7. Remove the engine support bracket(A).

8. Remove the drive belt auto tensioner(A).
9. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. (No.1 cylinder
compression TDC position)
10. Remove the crankshaft pulley bolt(B) and crankshaft pulley(A).