Description | Specifications | Limit | ||
General | ||||
Type | In-line, DOHC |
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Number of cylinders | 4 |
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Bore | 77.2 mm (3.0394 in) |
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Stroke | 84.5 mm (3.3268 in) |
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Total displacement | 1,582 cc (96.54 cu. in) |
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Compression ratio | 17.3 : 1 |
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Firing order | 1-3-4-2 |
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Valve timing | ||||
Intake valve | Opens (ATDC) | 17° ± 4° | When valve lift is 1 mm (0.0394 in) | |
Closes (ABDC) | 14 ± 4° | |||
Exhaust valve | Opens (BBDC) | 23° ± 4° | ||
Closes (BTDC) | 20° ± 4° | |||
Cylinder head | ||||
Flatness of gasket surface | 0.05 mm (0.0020 in) for all 0.03 mm (0.0012 in) for each cylinder 0.012 mm (0.00047 in) for 50mm x 50mm |
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Flatness of manifold mounting surface | Intake | 0.025 mm (0.0010 in) for width 0.160 mm (0.0063 in) for length 0.013 mm (0.00051 in) for 50mm x 50mm |
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Exhaust | 0.025 mm (0.0010 in) for width 0.160 mm (0.0063 in) for length 0.013 mm (0.00051 in) for 50mm x 50mm |
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Camshaft | ||||
Cam height | LH camshaft | Intake | 35.452 ~ 35.652 mm (1.3957 ~ 1.4036 in) |
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Exhaust | 35.700 ~ 35.900 mm (1.4055 ~ 1.4134 in) |
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RH camshaft | Intake | 35.537 ~ 35.737 mm (1.3991 ~ 1.4070 in) |
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Exhaust | 35.452 ~ 35.652 mm (1.3957 ~ 1.4036 in) |
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Journal outer Diameter | LH camshaft | 20.944 ~ 20.960 mm (0.8246 ~ 0.8252 in) |
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RH camshaft | 20.944 ~ 20.960 mm (0.8246 ~ 0.8252 in) |
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Bearing oil clearance | 0.040 ~ 0.077 mm (0.0016 ~ 0.0030 in) |
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End play | 0.10 ~ 0.20 mm (0.0039 ~ 0.0079 in) |
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Valve | ||||
Valve length | Intake | 93.0 mm (3.6614 in) |
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Exhaust | 93.7 mm (3.6890 in) |
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Stem outer diameter | Intake | 5.455 ~ 5.470 mm (0.2148 ~ 0.2154 in) |
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Exhaust | 5.435 ~ 5.450 mm (0.2140 ~ 0.2146 in) |
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Face angle | 45.5° ~ 45.75° |
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Thickness of valve head (margin) | Intake | 1.1 mm (0.0433 in) |
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Exhaust | 1.2 mm (0.0472 in) |
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Valve stem to valve guide clearance | Intake | 0.030 ~ 0.057 mm (0.0012 ~ 0.0022 in) |
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Exhaust | 0.050 ~ 0.077 mm (0.0020 ~ 0.0030 in) |
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Valve guide | ||||
Inner diameter | Intake | 5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in) |
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Exhaust | 5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in) |
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Length | Intake | 31.3 ~ 31.7 mm (1.2323 ~ 1.2480 in) |
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Exhaust | 31.3 ~ 31.7 mm (1.2323 ~ 1.2480 in) |
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Valve seat | ||||
Width of seat contact | Intake | 0.8 ~ 1.4 mm (0.0315 ~ 0.0551 in) |
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Exhaust | 1.2 ~ 1.8 mm (0.0472 ~ 0.0709 in) |
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Seat angle | Intake | 45° ~ 45°30' |
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Exhaust | 45° ~ 45°30' |
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Valve spring | ||||
Free length | 49.53 mm (1.9500 in) |
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Load | 16.9 ~ 18.7 kg / 32.0 mm (37.2 ~ 41.2 lb / 1.2598 in) |
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26.7 ~ 29.0 kg / 23.8 mm (58.9 ~ 63.9 lb / 0.9370 in) |
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Out of squareness | Less than 1.5° |
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Cylinder block | ||||
Cylinder bore | 77.200 ~ 77.230mm (3.0394 ~ 3.0405 in) |
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Flatness of gasket surface | Less than 0.05 mm (0.0020 in) for all Less than 0.012 mm (0.00047 in) for 50 mm (1.9685 in) X 50 mm (1.9685 in) |
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Piston | ||||
Piston outer diameter | 77.130 ~ 77.160mm (3.0366 ~ 3.0378 in) |
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Piston to cylinder clearance | 0.060 ~ 0.080 mm (0.0024 ~ 0.0031 in) |
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Ring groove width | No. 1 ring groove | 1.83 ~ 1.85 mm (0.0720 ~ 0.0728 in) |
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No. 2 ring groove | 1.82 ~ 1.84 mm (0.0717 ~ 0.0724 in) |
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Oil ring groove | 3.02 ~ 3.04 mm (0.1189 ~ 0.1197 in) |
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Piston ring | ||||
Side clearance | No. 1 ring | 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) |
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No. 2 ring | 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) |
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Oil ring | 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) |
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End gap | No. 1 ring | 0.20 ~ 0.35 mm (0.0079 ~ 0.0138 in) |
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No. 2 ring | 0.35 ~ 0.50 mm (0.0138 ~ 0.0197 in) |
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Oil ring | 0.20 ~ 0.40 mm (0.0079 ~ 0.0157 in) |
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Piston pin | ||||
Piston pin outer diameter | 27.995 ~ 28.000 mm (1.1022 ~ 1.1024 in) |
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Piston pin hole inner diameter | 28.004 ~ 28.010 mm (1.1025 ~ 1.1028 in) |
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Piston pin hole clearance | 0.004 ~ 0.015 mm (0.0002 ~ 0.0006 in) |
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Connecting rod small end hole inner diameter | 28.022 ~ 28.034 mm (1.1032 ~ 1.1037 in) |
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Connecting rod small end hole clearance | 0.022 ~ 0.039 mm (0.0009 ~ 0.0015 in) |
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Connecting rod | ||||
Connecting rod big end inner diameter | 49.000 ~ 49.018 mm (1.9291 ~ 1.9298 in) |
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Connecting rod bearing oil clearance | 0.025 ~ 0.043 mm (0.0010 ~ 0.0017 in) |
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Side clearance | 0.050 ~ 0.302 mm (0.0020 ~ 0.0119 in) | 0.4 mm (0.0157 in) | ||
Crankshaft | ||||
Main journal outer diameter | 53.972 ~ 53.990 mm (2.1249 ~ 2.1256 in) |
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Pin journal outer diameter | 45.997 ~ 46.015 mm (1.8109 ~ 1.8116 in) |
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Main bearing oil clearance | 0.024 ~ 0.042 mm (0.0009 ~ 0.0017 in) |
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End play | 0.08 ~ 0.28 mm (0.0031 ~ 0.110 in) |
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Oil pump | ||||
Side clearance | Inner rotor | 0.040 ~ 0.085 mm (0.0016 ~ 0.0033 in) |
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Outer rotor | 0.040 ~ 0.090 mm (0.0016 ~ 0.0035 in) |
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Body clearance | 0.255 ~ 0.350 mm (0.0100 ~ 0.0138 in) |
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Relief valve opening pressure | 490 ± 49.0 kPa (5 ± 0.5 kg/cm², 71 ± 7.1 psi) |
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Engine oil | ||||
Oil quantity | Total | 5.7 L (1.51 U.S.gal., 6.02 U.S.qt., 5.01 lmp.qt.) | When replacing a short engine or a block assembly | |
Oil pan | 4.8 L (1.27 U.S.gal., 5.07 U.S.qt., 4.22 lmp.qt.) |
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Drain and refill | 5.3 L (1.40 U.S.gal., 5.60 U.S.qt., 4.66 lmp.qt.) | Including oil filter | ||
Oil grade | Recommended | - With DPF : ACEA C2 or C3 - Without DPF : ACEA B4 For information on SAE viscosity grades based on ambient temperatures, refer to the “Lubrication System”. |
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Approved | ACEA C2 | Chevron : KIXX D1 C2 5W30 TOTAL : QUARTZ INEO HKS D 5W30 |
List of engine oil approved by KIA | |
ACEA C3 | SK : ZIC LS 5W30 Chevron : KIXX D1 5W30 TOTAL : QUARTZ INEO MC3 5W30 | |||
Oil pressure (at idle) | 78.45kPa (0.8kg/cm², 11.38psi) or above | Oil temperature in oil pan : 80℃ (176°F) | ||
Cooling system | ||||
Cooling method | Forced circulation with cooling fan |
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Coolant quantity | MT : Approx. 6.8 L (1.80 US gal., 7.19 US qt., 5.98 lmp qt.) AT : Approx. 7.0 L (1.85 US gal., 7.40 US qt., 6.16 lmp qt.) |
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Thermostat | Type | Wax pellet type |
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Opening temperature | 90±1.5 °C (194±34.7 °F) |
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Pull opening temperature | 100°C (212°F) |
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Radiator cap | Main valve opening pressure | 93.16 ~ 122.58 kPa (0.95 ~ 1.25 kg/cm², 13.51 ~ 17.78 psi) |
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Vacuum valve opening pressure | MAX. 6.86 kPa (0.07kg/cm², 1.00 psi) |
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Water temperature sensor | ||||
Type | Thermister type |
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Resistance | 20°C (68°F) | 2.45±0.14 kΩ |
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80°C (176°F) | 0.3222 kΩ |
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Location | Product |
Mating surface of timing chain cover | LOCTITE 5900, LOCTITE 5900H, THREE BOND 1217H |
Front area of mating surface between timing chain cover and timing chain case | |
Front area of mating surface between timing chain case and cylinder head | |
Mating surface of camshaft bearing rear cap | |
Mating surface of oil pan | |
Mating surface of bed plate | Loctite 5205, Hylomar 3000 , Dreibond 5105 |
Mating surface of oil pressure switch | THREE BOND 2403 |
Item | Quantity | N.m | kgf.m | lb-ft |
Engine mounting | ||||
Engine mounting bracket and body fixing bolt | 2 | 49.0 ~ 63.7 | 5.0 ~ 6.5 | 36.2 ~ 47.0 |
Engine mounting bracket and body fixing nut | 2 | 49.0 ~ 63.7 | 5.0 ~ 6.5 | 36.2 ~ 47.0 |
Engine mounting insulator and engine mounting support bracket fixing nut | 1 | 78.5~ 98.1 | 8.0 ~ 10.0 | 57.9 ~ 72.3 |
Engine mounting support bracket and engine support bracket fixing bolt | 1 | 58.8 ~ 73.5 | 6.0 ~ 7.5 | 43.4 ~ 54.2 |
Engine mounting support bracket and engine support bracket fixing nut | 2 | 58.8 ~ 73.5 | 6.0 ~ 7.5 | 43.4 ~ 54.2 |
Transaxle mounting bracket and body fixing bolt | 3 | 49.0 ~ 63.7 | 5.0 ~ 6.5 | 36.2 ~ 47.0 |
Transaxle mounting bracket and body fixing nut | 1 | 49.0 ~ 63.7 | 5.0 ~ 6.5 | 36.2 ~ 47.0 |
Transaxle mounting bracket and transaxle mounting support bracket fixing bolt | 2 | 88.2 ~ 107.9 | 9.0 ~ 11.0 | 65.1 ~ 79.6 |
Rear roll rod bracket and sub frame fixing bolt | 2 | 49.0 ~ 63.7 | 5.0 ~ 6.5 | 36.2 ~ 47.0 |
Rear roll rod bracket and roll rod mounting support bracket fixing nut | 1 | 107.9 ~ 127.5 | 11.0 ~ 13.0 | 79.6 ~ 94.0 |
Timing chain | ||||
Timing chain cover bolt (10 X 90) | 4 | 42.2 ~ 53.9 | 4.3 ~ 5.5 | 31.1 ~ 39.8 |
Timing chain cover bolt (8 X 70) | 5 | 19.6 ~ 26.5 | 2.0 ~ 2.7 | 14.5 ~ 19.5 |
Timing chain cover bolt (8 X 70) - Washer seal | 2 | 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 (6 X 65) | 1 | 9.8 ~ 11.8 | 1.0 ~ 1.2 | 7.2 ~ 8.7 |
Timing chain cover bolt (6 X 30) | 5 | 9.8 ~ 11.8 | 1.0 ~ 1.2 | 7.2 ~ 8.7 |
Timing chain case bolt (8 X 23.5) | 4 | 24.5 ~ 30.4 | 2.5 ~ 3.1 | 18.1 ~ 22.4 |
Timing chain case bolt (8 X 32) | 1 | 18.6 ~ 27.5 | 1.9 ~ 2.8 | 13.7 ~ 20.3 |
Timing chain case guide bolt | 1 | 25.5 ~ 34.3 | 2.6 ~ 3.5 | 18.8 ~ 25.3 |
Engine hanger (front) | 2 | 19.6 ~ 24.5 | 2.0 ~ 2.5 | 14.5 ~ 18.1 |
Crankshaft pulley bolt | 1 | 98.0 + 35˚ | 10.0 + 35˚ | 72.3 + 35˚ |
Camshaft chain sprocket bolt | 2 | 68.6 ~ 73.5 | 7.0 ~ 7.5 | 50.6 ~ 54.2 |
High pressure pump chain sprocket nut | 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 | 2 | 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 | ||||
Cylinder head cover bolt | 13 | [3.9~5.9]+ [8.8~10.8] | [0.4~0.6] + [0.9~1.1] | [2.9~4.3] + [6.5~8.0] |
Camshaft bearing cap bolt (mark 10) | 16 | 12.7 ~ 14.7 | 1.3 ~ 1.5 | 9.4 ~ 10.8 |
Camshaft bearing cap bolt (mark 9) | 6 | 12.7 ~ 14.7 | 1.3 ~ 1.5 | 9.4 ~ 10.8 |
Engine hanger bolt (rear) | 1 | 47.1 ~ 51.0 | 4.8 ~ 5.2 | 34.7 ~ 37.6 |
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°] |
Cylinder block | ||||
Piston cooling oil jet bolt | 4 | 8.8 ~ 12.7 | 0.9 ~ 1.3 | 6.5 ~ 9.4 |
Drive belt auto tensioner bolt | 2 | 25.5 ~ 30.4 | 2.6 ~ 3.1 | 18.8 ~ 22.4 |
Drive belt auto tensioner mounting bracket bolt | 3 | 18.6 ~ 27.5 | 1.9 ~ 2.8 | 13.7 ~ 20.3 |
Main moving system | ||||
Connecting rod cap bolt | 8 | [12.7] + [88 ~ 92˚] | [1.3] + [88 ~ 92˚] | [9.4] + [88 ~ 92˚] |
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 |
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) | 3 | 19.6 ~ 24.5 | 2.0 ~ 2.5 | 14.5 ~ 18.1 |
Water pump bolt (8 X 28) | 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 |
Engine coolant temperature sensor | 1 | 24.5 ~ 34.3 | 2.5 ~ 3.5 | 18.1 ~ 25.3 |
Thermostat cover bolt | 2 | 19.6 ~ 24.5 | 2.0 ~ 2.5 | 14.5 ~ 18.1 |
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 | 31.5 ~ 38.5 | 3.2 ~ 3.9 | 28.2 ~ 28.4 |
Oil level gauge guide 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 transmission fixing bolt | 3 | 34.3 ~ 49.1 | 3.5 ~ 5.0 | 25.3 ~ 36.2 |
Oil drain plug | 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 | 1 | 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 |
Baffle plate bolt | 4 | 9.8 ~ 11.8 | 1.0 ~ 1.2 | 7.2 ~ 8.7 |
Intake and exhaust system | ||||
Intake manifold and cylinder head fixing nut | 2 | 19.6 ~ 23.5 | 2.0 ~ 2.4 | 14.5 ~ 17.4 |
Intake manifold and cylinder head fixing bolt | 7 | 19.6 ~ 23.5 | 2.0 ~ 2.4 | 14.5 ~ 17.4 |
Exhaust manifold and cylinder head fixing nut | 8 | 29.4 ~ 34.3 | 3.0 ~ 3.5 | 21.7 ~ 25.3 |
Exhaust manifold heat protector bolt | 3 | 14.7 ~ 19.6 | 1.5 ~ 2.0 | 10.8 ~ 14.5 |
DPF (or WCC) converter bracket fixing bolt | 6 | 49.0 ~ 63.7 | 5.0 ~ 6.0 | 36.2 ~ 47.0 |
DPF (or WCC) converter assembly fixing nut | 1 | 49.1 ~ 63.7 | 5.0 ~ 6.5 | 36.2 ~ 47.0 |
DPF (or WCC) converter assembly fixing bolt | 2 | 49.1 ~ 63.7 | 5.0 ~ 6.5 | 36.2 ~ 47.0 |
EGR cooler outlet pipe fixing bolt [Euro 4/5] | 2 | 19.6 ~ 23.5 | 2.0 ~ 2.4 | 14.5 ~ 17.4 |
EGR valve & cooler assembly fixing bolt [Euro 4/5] | 3 | 21.6 ~ 27.5 | 2.2 ~ 2.8 | 15.9 ~ 20.3 |
EGR Cooler and EGR valve fixing bolt [Euro 4/5] | 2 | 21.6 ~ 27.5 | 2.2 ~ 2.8 | 15.9 ~ 20.3 |
EGR pipe and EGR cooler fixing bolt [Euro 4/5] | 2 | 21.6 ~ 27.5 | 2.2 ~ 2.8 | 15.9 ~ 20.3 |
EGR valve pipe and intake manifold fixing nut [Euro 3] | 2 | 19.6 ~ 23.5 | 2.0 ~ 2.4 | 14.5 ~ 17.4 |
EGR valve pipe and EGR valve assembly fixing bolt [Euro 3] | 2 | 21.6 ~ 27.5 | 2.2 ~ 2.8 | 15.9 ~ 20.3 |
EGR valve assembly and cylinder head fixing bolt [Euro 3] | 2 | 21.6 ~ 27.5 | 2.2 ~ 2.8 | 15.9 ~ 20.3 |
EGR pipe and EGR valve fixing bolt [Euro 3] | 2 | 21.6 ~ 27.5 | 2.2 ~ 2.8 | 15.9 ~ 20.3 |
EGR pipe and exhaust manifold fixing bolt | 2 | 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 |
DPF (or WCC) converter and front muffler fixing nut | 2 | 39.2 ~ 58.8 | 4.0 ~ 6.0 | 28.9 ~ 43.4 |
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 ~ 58.9 | 4.0 ~ 6.0 | 28.9 ~ 43.5 |
Torque-to-yield cylinder head, connecting rod cap and crankshaft main bearing cap bolts must be replaced once removed because the bolts are designed to be permanently elongated beyond the state of elasticity when torqued.
If the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
