Kia G6DB-3.3 User manual

Engine Mechanical
System
GENERAL
ENGINE AND TRANSAXLE ASSEMBLY
TIMING SYSTEM
TIMING CHAIN
CYLINDER HEAD ASSEMBLY
ENGINE BLOCK
COOLING SYSTEM
LUBRICATION SYSTEM
INTAKE AND EXHAUST SYSTEM
INTAKE MANIFOLD
EXHAUST MANIFOLD
EXHAUST PIPE
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EMA -2 ENGINE MECHANICAL SYSTEM
GENERAL
SPECIFICATION EE6CF939
Specifications
Description G6DB - 3.3 G6DA - 3.8 Limit
General
Type V-type, DOHC
Number of cylinders 6
Bore 92mm (3.6220in) 96mm (3.7795in)
Stroke 83.8mm (3.2992in) 87.0 mm(3.4252in)
Total displacement 3,342cc (203.86cu.in) 3.778cc
(230.55cu.in)
Compression ratio 10.4
Firing order 1-2-3-4-5-6
Valve timing
Opens(ATDC) 14˚10
Intake
Closes(ABDC) 66˚66
Opens(BBDC) 52˚52
Exhaust
Closes(ATDC) 0˚0
Cylinder head
Flatness of gasket surface Less than 0.05mm (0.0019in)
[Less than 0.02mm (0.0008in) / 150x150]
Intake Less than 0.1mm(0.0039in)
[Less than 0.03mm(0.001in)/110x110]
Flatness of manifold
mounting
Exhaust Less than 0.1mm(0.0039in)
[Less than 0.03mm(0.001in)/110x110]
Camshaft
Intake 46.3mm (1.8228in) 46.8mm (1.8425in)LH
Camshaft Exhaust 45.8mm (1.8031in)
Intake 46.3mm (1.8228in) 46.8mm(1.8425in)
Cam height
RH
Camshaft Exhaust 45.8mm (1.8031in)
Intake No.1: 27.964 ~ 27.978mm (1.1009 ~ 1.1015in)
No.2,3,4: 23.954 ~ 23.970mm (0.9430
~ 0.9437in)
Journal outer
diameter LH ,RH Camshaft
Exhaust No.1: 27.964 ~ 27.978mm
(1.1009 ~ 1.1015in)
No.2,3,4: 23.954 ~ 23.970mm
(0.9430 ~ 0.9437in)
Intake No.1: 0.027 ~ 0.057mm (0.0011 ~ 0.0022in)
No.2,3,4: 0.030~0.067mm(0.0012~0.0026in)
Bearing oil clearance LH ,RH
Camshaft
Exhaust No.1: 0.027 ~ 0.057mm (0.0011 ~ 0.0022in)
No.2,3,4: 0.030~0.067mm(0.0012~0.0026in)
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GENERAL EMA -3
Specifications
Description G6DB - 3.3 G6DA - 3.8 Limit
End play →0.02 ~ 0.18mm
(0.0008 ~ 0.0071in)
Valve
Intake 105.27mm(4.1445in)Valve length
Exhaust 105.50mm (4.1535in)
Intake 5.465 ~ 5.480mm (0.2151 ~ 0.2157in)Stem outer diameter
Exhaust 5.458 ~ 5.470mm (0.2149 ~ 0.2153in)
Face angle 45.25 ~ 45.75
Intake 1.56 ~ 1.86mm
(0.06142 ~ 0.07323in)
Thickness of
valvehead(margin)
Exhaust 1.73 ~ 2.03mm
(0.06811 ~ 0.07992in)
Intake 0.020 ~ 0.047mm (0.00078 ~ 0.00185in) 0.07mm
(0.00275in)
Valvestemtovalve
guide clearance
Exhaust 0.030 ~ 0.054mm (0.00118 ~ 0.00212in) 0.09mm
(0.00354in)
Valve guide
Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)Inner diameter
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
Intake 41.8 ~ 42.2mm (1.6457 ~ 1.6614in)Length
Exhaust 41.8 ~ 42.2mm (1.6457 ~ 1.6614in)
Valve seat
Intake 1.15 ~ 1.45mm (0.05118 ~ 0.05709in)Width of seat contact
Exhaust 1.35 ~ 1.65mm (0.05315 ~ 0.06496in)
Intake 44.75 ~ 45.20
Seat angle
Exhaust 44.75 ~ 45.20
Valve spring
Free length 43.86mm (1.7267in)
19.3±0.8kg/34.0mm (42.7±1.8 lb/1.3386in)
Load 42.3±1.3kg/24.2mm (93.3±2.9 lb/0.9527in)
Out of squareness Less than 1.5
MLA
Intake 34.964 ~ 34.980mm (1.3765 ~ 1.3772in)MLA outer diameter
Exhaust 34.964 ~ 34.980mm (1.3765 ~ 1.3772in)
Intake 35.000 ~ 35.025mm (1.3779 ~ 1.3789in)Cylinder head tappet
bore inner diameter Exhaust 35.000 ~ 35.025mm (1.3779 ~ 1.3789in)
Intake 0.020 ~ 0.061mm (0.0008 ~ 0.0024in) 0.07mm(0.0027in)MLA to tappet bore
clearance Exhaust 0.020 ~ 0.061mm (0.0008 ~ 0.0024in) 0.07mm(0.0027in)
Valve clearance
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EMA -4 ENGINE MECHANICAL SYSTEM
Specifications
Description G6DB - 3.3 G6DA - 3.8 Limit
Intake 0.17 ~ 0.23mm (0.0067 ~ 0.0090in) 0.10 ~ 0.30mm
(0.0039 ~ 0.0118in)
Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in) 0.20 ~ 0.40mm
(0.0078 ~ 0.0157in)
Cylinder block
Cylinder bore 92.00 ~ 92.03mm
(3.6220 ~ 3.6232in) 96.00 ~ 96.03mm (3.7795 ~ 3.7807in)
Flatness of gasket surface Less than 0.05mm (0.0019in)
[Less than 0.02mm (0.0008in) / 150x150]
Piston
Piston outer diameter 91.96 ~ 92.00mm
(3.6205 ~ 3.6220in) 95.96 ~ 95.99mm (3.7779 ~ 3.7791in)
Piston to cylinder clearance →0.03 ~ 0.05mm
(0.0012 ~ 0.0020in)
No. 1 ring groove →1.22 ~ 1.24
(0.0480 ~ 0.0488in) 1.26mm (0.0496in)
No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in) 1.26mm (0.0496in)
Ring groove width
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in) 2.05mm (0.0807in)
Piston ring
No. 1 ring →0.03 ~ 0.07mm
(0.0012 ~ 0.0027in) 0.1mm (0.004in)
No. 2 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0027in) 0.1mm (0.004in)
Side clearance
Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in) 0.2mm (0.008in)
No. 1 ring 0.17 ~ 0.32mm (0.0067 ~ 0.0126in) 0.6mm (0.0236in)
No. 2 ring 0.32 ~ 0.47mm (0.0126 ~ 0.0185in) 0.7mm (0.0275in)
End gap
Oil ring 0.20 ~ 0.70mm (0.0078 ~ 0.0275in) 0.8mm (0.0315in)
Piston pin
Piston pin outer diameter →23.001 ~ 23.006mm
(0.9055 ~ 0.9057in)
Piston pin hole inner diameter →23.016 ~ 23.021mm
(0.9061 ~ 0.9063in)
Piston pin hole clearance →0.01 ~ 0.02mm
(0.0039 ~ 0.0078in)
Connecting rod small end inner diameter 22.974 ~ 22.985mm (0.9045 ~ 0.9049in)
Connecting rod
Connecting rod big end innerdiameter 58.000 ~ 58.018mm(2.2834 ~2.2842in)
Connecting rod bearing oil clearance →0.038 ~ 0.056mm
(0.0015 ~ 0.0022in)
Side clearance 0.1 ~ 0.25mm (0.0039 ~ 0.0098in)
Crankshaft
Main journal outer diameter 68.942 ~ 68.960mm (2.7142 ~ 2.7149in)
Pin journal outer diameter 54.954 ~ 54.972mm (2.1635 ~ 2.1642in)
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GENERAL EMA -5
Specifications
Description G6DB - 3.3 G6DA - 3.8 Limit
Main bearing oil clearance 0.022 ~ 0.040mm (0.0008 ~ 0.0016in)
End play0.10 ~ 0.28mm (0.0039 ~ 0.0110in)
Oil pump
Relief valve opening pressure 450 ~ 550kPa
(4.59 ~ 5.61kgf/cm²,65.28 ~ 79.79psi)
Engine oil
Oil quantity (Oil pan) 4.5 ~ 5.5L(4.76 ~ 5.81U.S.qus, 3.96
~ 4.84lmp.qts)
Oil quantity (Oil filter) 0.4L(0.42U.S.qus,0.35lmp.qts)
Oil quantity (Drain and refill) 5.2L(5.49U.S.qus, 4.58lmp.qts)
Oil quality Above SJ or SL
Oil pressure 130kPa(1.32kgf/cm²,18.77psi)
[at 1000rpm,110 C(230 F)]
Cooling system
Cooling method Forced circulation with electrical fan
Coolant quantity 9.0L(9.40U.S.qus,7.83lmp.qts)
Type Wax pellet type
Opening temperature 82±2 C (179.6±35.6 F)
Fully opened
temperature 95 C(203F)
Thermostat
Full lift more than 10mm (0.3937in)
Main valve opening
pressure 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Radiator cap
Vacuum valve opening
pressure 0.98 ~ 4.90 kpa (0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)
Water temperature sensor
Type Thermister type
20 C(68F) 2.31 ~ 2.59kΩ
Resistance
80 C(176 F) 0.3222 kΩ
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EMA -6 ENGINE MECHANICAL SYSTEM
TIGHTENING TORQUE
Item Quantity Nm kgf.m lb.ft
Crankshaft pulley bolt 1284.2 ~ 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 49.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain cover bolt D 158.80 ~ 68.80 6.0 ~ 7.0 43.40 ~ 50.63
Timing chain cover bolt E 158.80 ~ 68.80 6.0 ~ 7.0 43.40 ~ 50.63
Timing chain cover bolt F 224.50 ~ 26.46 2.5 ~ 2.7 18.08 ~ 19.53
Timing chain cover bolt G 421.56 ~ 23.52 2.2 ~ 2.4 15.91 ~ 17.36
Timing chain cover bolt H 19.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain cover bolt I 19.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain cover bolt J 19.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Cam to cam guide bolt 49.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain auto tensioner bolt 29.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain auto tensioner nut 29.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Timing chain guide bolt 419.60 ~ 24.50 2.0 ~ 2.5 14.17 ~ 18.08
Oil pump chain cover bolt 39.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Oil pump chain tensioner bolt 19.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Oil pump chain guide bolt 29.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Oil pump chain sprocket bolt 118.62 ~ 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) 181.4 ~ 85.3 8.3 ~ 8.7 60.0 ~ 62.9
Drive belt auto tensioner bolt(M8) 129.4 ~ 33.3 3.0 ~ 3.4 21.7 ~ 24.6
Drive belt idler bolt 153.90 ~ 57.82 5.5 ~ 5.9 39.78 ~ 42.67
OCV(oil control valve) bolt 29.80 ~ 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 118.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
CVVT ＆exhaust cam sprocket bolt 464.68 ~ 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) 849.00 + 90˚5.0 + 90˚36.16 + 90˚
Main bearing cap outer bolt(M8) 819.60 + 120˚2.0 + 120˚14.46 + 120˚
Main bearing cap side bolt(M8) 629.40 ~ 31.36 3.0 ~ 3.2 21.70 ~ 23.14
Oil drain cover bolt 69.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Rear oil seal case bolt 69.80 ~ 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
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GENERAL EMA -7
Item Quantity Nm kgf.m lb.ft
Knock sensor bolt 215.68 ~ 23.52 1.6 ~ 2.4 11.57 ~ 17.36
Drive plate bolt 871.54 ~ 75.46 7.3 ~ 7.7 52.80 ~ 55.69
Oil filter cap 124.50 2.5 18.08
Oil drain bolt 134.30 ~ 44.10 3.5 ~ 4.5 25.31 ~ 32.55
Oil pump bolt 319.60 ~ 23.52 2.0 ~ 2.4 14.47 ~ 17.36
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 29.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Water pump bolt(Timing chain
cover bolt L) 121.56 ~ 26.46 2.2 ~ 2.7 15.91 ~ 19.53
Water pump bolt(Timing chain
coverboltK) 49.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Water pump pulley bolt 47.84 ~ 9.80 0.8 ~ 1.0 5.78 ~ 7.23
Water temp. control nut 419.6 ~ 23.52 2.0 ~ 2.4 14.5 ~ 17.36
Water temp. control bolt 219.6 ~ 23.52 2.0 ~ 2.4 14.5 ~ 17.36
Water inlet pipe bolt 316.66 ~ 19.60 1.7 ~ 2.0 12.30 ~ 14.47
Air vent pipe bolt 29.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Intake manifold bolt 626.5 ~ 31.4 2.7 ~ 3.2 19.5 ~ 23.1
Intake manifold nut 218.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Surge tank bolt 19.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Surge tank nut 218.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Exhaust manifold stay bolt 452.0 ~ 56.9 5.3 ~ 5.8 38.3 ~ 42.0
Surge tank bolt 318.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Breather pipe bolt 29.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Surge tank bracket bolt 227.44 ~ 31.36 2.8 ~ 3.2 20.25 ~ 23.14
ETC bracket bolt 215.68 ~ 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 protector bolt 69.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Front muffler 239.20 ~ 58.80 4.0 ~ 6.0 28.93 ~ 43.40
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EMA -8 ENGINE MECHANICAL SYSTEM
INSPECTION ECE1FCC3
COMPRESSION PRESSURE
NOTE
If there is lack of power, excessive oil consumption or
poor fuel economy, measure the compression pres-
sure.
1. Warm up and stop engine.
Allow the engine to warm up to normal operating tem-
perature.
2. Remove ignition coils. (Refer to Ignition in FL Group)
3. Remove spark plugs.
Usinga16mmplugwrench,removethe6sparkplugs.
4. Check cylinder compression pressure.
a. Insert a compression gauge into the spark plug
hole.
b. Fully open the throttle.
c. After 7times of cranking the engine, measure the
compression pressure.
NOTE
Always use a fully charged battery to obtain engine
speed of 200 rpm or more.
d. Repeat steps (a) through (c) for each cylinder.
NOTE
This measurementmust be done in as short a time as
possible.
Compressionpressure:
1,225kPa (12.5kgf/cm², 177psi) - 200 ~ 250rpm
Minimum pressure :
1,078kPa (11.0kgf/cm², 156psi)
e. If the cylinder compression in 1 or morecylinders
is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat
steps (a) through (c) for cylinders with low com-
pression.
• If adding oil helps thecompression, it is likely
that the piston rings and/or cylinder bore are
worn or damaged.
• If pressure stays low, a valve may be stick-
ing or seating is improper, or there may be
leakage past the gasket.
5. Reinstall spark plugs.
6. Install ignition coils. (See EE group - ignition)
VALVE CLEARANCE INSPECTION AND
ADJUSTMENT
NOTE
Inspect and adjust the valve clearance when the en-
gine is cold (Engine coolant temperature : 20 C) and
cylinder head is installed on the cylinder block.
1. Remove the engine cover(A).
A
SBLM16001L
2. Remove the engine room resonator(A).
A
SBLM16003L
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GENERAL EMA -9
3. AfterdisconnectingtheMAFsensor connector(A)and
the breather hose(B), remove the air cleaner assem-
bly(C).
C
AB
SBLM16002L
4. Disconnect the other breather hose(A), the Purge
Control Solenoid Valve(PCSV) hose, the Positive
Crankcase Ventilation (PCV) hose(C) and the Elec-
tronic Throttle Control(ETC) cooling hoses(D) and
connector(E).
DE
C
SBLM16208L
A
SBLM16005L
5. Removethewiringoverthesurgetank.
1) Disconnect the injection harness connector(A).
2) Disconnect the camshaft position sensor(CMP)
harness connector(B).
3) Disconnect the ground line(C).
4) Disconnect the ignition coil harness connec-
tor(D).
5) Disconnect the condensor connector(E).
6) Disconnect the variable induction system(VIS)
solenoid valve connector(G).
7) Disconnect the oil control valve(OCV) harness
connector(F).
8) Disconnect the injector wiring(H) and ignition coil
wiring(I).
D
B
A
E
C
F
SBLM16006L
H
G
I
SBLM16206L
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EMA -10 ENGINE MECHANICAL SYSTEM
6. Disconnect the fuel hose tube(A).
A
SBLM16015L
7. Remove heater hose(A) and disconnect the brake
vaccume hose(B).
A
B
SBLM16017L
8. Disconnect the surge tank stay.
9. Remove the surge tank.
10. Loosenthecylinderheadcoverboltsand thenremove
the cover(A) and gasket.
A
SBLM16007L
11. Set No.1 cylinder to TDC/compression.
a. Turn the crankshaft pulley and align its groove
with the timing mark "T" of the lower timing chain
cover.
KDRF108A
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