Kia Stinger: Engine Mechanical System

Repair Procedures

Compression Pressure Test

1
Warm up and stop the engine.

Allow the engine to warm up to normal operating temperature.
2
Disconnect the ignition coil extension connector (A).
3
Remove the spark plugs.

(Refer to Engine Electrical System - Spark Plug)
4
Check the compression pressure in the cylinder.
1. Insert the compression gauge into the spark plug hole.
2. Fully open the throttle valve.
3. While cranking the engine, measure the compression pressure.
  
  NOTE
  Always use a fully charged battery to obtain engine speed of 200 rpm and above.
4. Repeat steps (1) through (3) for each cylinder.
  
  NOTE
  This measurement must be done as quickly as possible.
  
  Compression pressure:
  
  1078 kPa (11.0 kgf/cm², 156 psi) / 200–250 rpm
  
  Minimum pressure:
  
  931 kPa (9.5 kgf/cm², 135 psi)
  
  Difference between each cylinder:
  
  100 kPa (1.0 kgf/cm², 15 psi) or less
5. If compression in one or more cylinders is low, add a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (1) through (3) for the cylinders with low compression.
  - If adding oil improves compression, the piston rings and/or cylinder bore are likely worn or damaged.
  - If the pressure remains low, a valve may be stuck or improperly seated, or there may be a leak past the cylinder head gasket.
5
Reinstall the spark plugs.
6
Install the ignition coils.
7
Connect the injector extension connector and the ignition coil connectors.
8
Some DTCs may remain after the inspection test and may need to be cleared manually using the KDS/GDS.

Troubleshooting

Symptoms	Suspected Area	Remedy
Engine misfire with abnormal internal low engine noise.	Worn crankshaft bearings Engine flywheel loose or out of specification	If necessary, replace the crankshaft and bearings. If necessary, repair or replace the flywheel.
	Worn piston rings (Oil consumption may or may not cause engine misfire.)	Inspect the cylinder for loss of compression. Repair or replace if necessary.
	Worn crankshaft thrust bearings	Replace the crankshaft and bearings as necessary.
Engine misfire with abnormal valve train noise.	Sticking valves. (Carbon on valve stem)	Repair or replace as necessary
	Excessively worn or displaced timing chain Valve clearances not within specification	Replace the timing chain and sprocket if necessary.
	Worn camshaft lobes.	Replace the camshaft and valve lifters.
Engine misfire with coolant consumption	Faulty cylinder head gasket or other cylinder head and cylinder block cooling system damage. Coolant consumption may or may not cause engine overheating.	Inspect the cylinder head and cylinder block for damage to coolant passages and/or defective cylinder head gasket. Repair or replace if necessary.
Engine misfire with excessive oil consumption	Wear of valves, valve guides and/or valve stem seals.	Repair or replace if necessary.
Engine misfire with excessive oil consumption	Worn piston rings. (Oil consumption may or may not cause engine misfire.)	Inspect the cylinder for loss of compression. Repair or replace if necessary.
Engine noise at startup that lasts only a few seconds. (Check and compare with a known good vehicle to determine normal condition.)	Incorrect engine oil viscosity	Drain the oil. Fill with engine oil of the correct viscosity.
	Worn crankshaft thrust bearing.	Inspect the thrust bearing and crankshaft. Repair or replace if necessary.
Excessive engine noise regardless of engine speed.	Low oil pressure	Repair or replace if necessary.
	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 equipped.	Replace the timing chain tensioner if necessary.
	Worn camshaft lobes.	Inspect the camshaft lobes. Replace the camshaft and valve lifters if necessary.
	Valve clearances not within specification Worn valve guides or valve stems.	Inspect the valves and valve guides, then repair or replace as necessary.
	Stuck valves. (Carbon deposits on the valve stem or valve seat may cause the valve to remain open.)	Inspect the valves and valve guides, then repair or replace as necessary.
	Worn drive belt, tensioner, idler and bearing.	Replace as necessary
Low engine noise regardless of crankshaft speed.	Low oil pressure	Repair or replace as necessary
	Flywheel loose or damaged.	Repair or replace the flywheel.
	Damage to oil pan, contact with oil pump strainer.	Inspect the oil pan. Inspect the oil pump strainer. Repair or replace if necessary.
	Oil pump strainer is loose, damaged, or clogged.	Inspect the oil pump strainer. Repair or replace if necessary.
	Excessive piston-to-cylinder clearance.	Inspect the piston, piston pin, and cylinder bore. Repair or replace if necessary.
	Excessive piston pin-to-piston clearance	Inspect the piston, piston pin, and connecting rod. Repair or replace if necessary.
	Excessive connecting rod bearing clearance	Inspect the following components and repair or replace if necessary. Connecting rod bearings. Connecting rods. Crankshaft thrust washers.
	Excessive crankshaft bearing clearance	Inspect the following components and repair or replace if necessary. Crankshaft bearings. Crankshaft main journals. Cylinder block
	Incorrect installation of piston, piston pin, and connecting rod	Make sure the piston pins and connecting rods are installed correctly. Repair as necessary.
Engine noise under load	Low oil pressure	Repair or replace if necessary.
	Excessive connecting rod bearing clearance	Inspect the following components and repair or replace if necessary: Connecting rod bearings. Connecting rods. Crankshaft
	Excessive crankshaft bearing clearance	Inspect the following components and repair or replace if necessary. Crankshaft bearings. Crankshaft main journals. Cylinder block.
Engine does not crank, crankshaft does not rotate	Hydraulic lock of cylinder Coolant/antifreeze in cylinder. Oil in cylinder. Fuel in cylinder	1 Remove the spark plugs and check for liquid. 2 Inspect for a broken head gasket. 3 Inspect the cylinder block or cylinder head for cracks. 4 Inspect the fuel injector and/or fuel pressure regulator for sticking.
	Timing chain breakage and/or timing chain and/or timing chain sprocket.	1 Inspect the timing chain and sprockets. 2 Repair as necessary.
	Material in cylinder Broken valve Piston material Foreign material	1 Inspect the cylinder for damaged components and/or foreign material. 2 Repair or replace if necessary.
	Seized crankshaft or connecting rod bearings.	1 Inspect the crankshaft and connecting rod bearings. 2 Repair as necessary.
	Bent or broken connecting rod.	1 Inspect the connecting rods. 2 Repair as necessary.
	Broken crankshaft	1 Inspect the crankshaft. 2 Repair as necessary.

Special Service Tools

Tool Name/Number	Illustration	Description
Crankshaft Damper Pulley Holding Tool 0K231-2C100 Crankshaft Damper Pulley Adapter Holder 09231-2J210 Crankshaft Damper Pulley Fixing Adapter Washer 09231-D2100		Used to prevent rotation of the crankshaft damper pulley when removing/installing the crankshaft damper pulley bolt.
Front Crankshaft Oil Seal Installer 0K231-2K200
Valve Stem Oil Seal Installer 09222-4A000
Valve Spring Compressor 09222-3K000 Holder 09222-3K100		Used to remove/install the intake or exhaust valve.
Rear Crankshaft Oil Seal Installer 09214-2W200 Handle 09231-H1100
Oil Pan Remover 09215-3C000
Oil Filter Wrench 09263-2E000		Used to remove/install the oil filter.
E-CVVT Plug Installer (A) E-CVVT Cover Installer (B) Handle (C) 09243-2C200
Water Pump Belt Removal and Installation 09252-C1000		Used to remove/install the water pump belt.
Engine mount bracket (beam) 09200-3N000
Engine Support Bracket (Stand) 09200-2C000 09200-2C100 09200-2C200