Kia Picanto JA Quiz

Engine Mechanical System

In this manual: Engine Mechanical System
General Information — 8Maintenance — 30Engine Mechanical System — 46Engine Electrical System — 14Emission Control System — 11Engine Control System/Fuel System — 46Clutch System — 12Manual Transmission — 10Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 17Brake System — 22Body (Interior and Exterior) — 104Body Electrical System — 80Heating, Ventilation, and Air Conditioning — 17
11steps
~96min
5/5difficulty
6special tools
Done 0 of 11

Specifications

Specifications

Description Specification Limit
General
Type Inline, DOHC
Number of cylinders 3
Bore 71.0 mm (2.7952 in)
Hone 84.0 mm (3.3070 in)
Total Displacement 998 cc (60.9 cu in)
Compression ratio 10,5 : 1
Firing order 1-2-3
Valve Timing
Intake Valve Opens BTDC 40° - BTDC 10°
Closes ABDC 20,7° - ABDC 70,7°
Exhaust Valve Opens BBDC 61,27° - BBDC 21,27°
Closes BTDC 10° - BTDC 50°
Valve Clearance (at 20 °C [68°F])
Intake 0.20–0.26 mm (0.0079–0.0102 in.)
exhaust 0.39–0.45 mm (0.0154–0.0177 in.)
Cylinder head cover
Gasket Surface Flatness Less than 0.05 mm (0.0020 in.)
Less than 0.02 mm (0.0008 in.) / 100 x 100
Manifold Flatness Intake Less than 0.1 mm (0.0039 in)
Mounting surface exhaust Less than 0.1 mm (0.0039 in)
Camshaft
Cam Lobe Height Intake 41.79824 mm (1.6456 in)
exhaust 41.57000 mm (1.6366 in)
Journal Outside Diameter Intake/Exhaust No. 1 36.464–36.478 mm (1.4355–1.4361 in.)
Intake/Exhaust No. 2–5 20.964–20.978 mm (0.8254–0.8259 in.)
End of Playback 0.1–0.2 mm (0.0039–0.0078 in.)
Valve
Valve Length Intake 92.85 mm (3.6555 in)
exhaust 93.37 mm (3.6759 in)
Stem Outer Diameter Intake 5.465–5.480 mm (0.2151–0.2157 in.)
exhaust 5.448–5.460 mm (0.2144–0.2149 in.)
Face Angle
Valve Head Margin Thickness Intake 1.50 mm (0.0590 in)
exhaust 1.75 mm (0.0688 in)
Valve Stem-to-Guide Clearance Intake 0.020–0.047 mm (0.00078–0.00185 in.)
exhaust 0.040–0.064 mm (0.00157–0.00251 in.)
MLA Outer Diameter 27.964–27.980 mm (1.1010–1.1016 in.)
Tappet Bore Inside Diameter 28.000–28.025 mm (1.1024–1.1033 in.)
MLA to Tappet Bore Clearance 0.020–0.061 mm (0.0008–0.0024 in.)
Valve 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.)
Valve Seat
Seat Contact Width Intake 0.85–1.15 mm (0.0334–0.0452 in.)
exhaust 1.35–1.65 mm (0.0531–0.0649 in.)
Seat Angle Intake 44,75° - 45,10°
exhaust 44,75° - 45,10°
Valve Spring
Free Length 47.9 mm (1.8858 in.)
Load 15.29 ± 0.82 kgf/34.2 mm
(150 ± 8.1 N / 1.3465 in.)
26.51 ± 0.95 kgf/25.7 mm
(260 ± 9.4 N / 1.0118 in.)
Out-of-Square 1.5° MAX.
Cylinder block
Cylinder Bore Diameter 71.00–71.03 mm (2.7952–2.7964 in.)
Gasket Surface Flatness Less than 0.05 mm (0.0020 in.)
Less than 0.02 mm (0.0008 in.) / 100 x 100
Piston
Piston Outer Diameter 70.965–71.995 mm (2.7939–2.7951 in.)
Piston-to-Cylinder Clearance 0.02–0.04 mm (0.0008–0.0016 in.)
Ring Groove Width No. 1 Ring Groove 1.235–1.250 mm (0.0486–0.0492 in.)
No. 2 Ring Groove 1.23–1.25 mm (0.0484–0.0492 in.)
Oil Ring Groove 2.010–2.025 mm (0.0791–0.0797 in.)
Piston Ring
Backlash No. 1 Ring 0.05–0.08 mm (0.0020–0.0031 in.)
No. 2 Ring 0.04–0.08 mm (0.0015–0.0031 in.)
Oil Ring 0.050–0.125 mm (0.0020–0.0049 in.)
End Gap No. 1 Ring 0.13–0.25 mm (0.0051–0.0098 in.)
No. 2 Ring 0.25–0.40 mm (0.0098–0.0157 in)
Oil Ring 0.2–0.7 mm (0.0079–0.0276 in.)
Piston pin
Piston Pin Outer Diameter 17.997–18.000 mm (0.7085–0.7086 in.)
Piston Pin Bore Clearance 0.005–0.012 mm (0.0002–0.0005 in.)
Connecting Rod Small End Bore Clearance 0.005–0.014 mm (0.0002–0.0006 in.)
Connecting Rod
Connecting Rod Big End Inner Diameter 42.000–42.018 mm (1.6535–1.6542 in.)
Connecting Rod Bearing Oil Clearance 0.018–0.036 mm (0.0007–0.0014 in.)
Backlash 0.10–0.25 mm (0.0039–0.0098 in.)
Crankshaft
Main Journal Outer Diameter 47.942–47.960 mm (1.8874–1.8880 in.)
Crankpin Outer Diameter 38.954–38.972 mm (1.5336–1.5343 in.)
Main Bearing Oil Clearance 0.006–0.024 mm (0.0002–0.0009 in.)
End of Playback 0.07–0.25 mm (0.0028–0.0098 in)
Engine Oil
Oil Capacity General 3.9 L (1.03 US gal, 4.12 US qt, 3.43 Imp qt) When replacing a short engine or engine assembly
Oil Baffle 3.3 L (0.87 US gal, 3.49 US qt, 2.90 Imp qt)
Drain and Refill 3.6 L (0.95 US gal, 3.80 US qt, 3.17 Imp qt) Including oil filter
Oil Grade Recommended For India, Middle East, Iran, Libya, Algeria, Sudan, Morocco, Tunisia, Egypt
- API SM and ILSAC GF-4 or higher / 5W-30
- ACEA A5/B5 / 5W-30
For Australia general export
- ACEA A5/B5 / 5W-30
For Europe
- API SN and ACEA C2 / 0W-30
Allowable - API SL or higher
- ILSAC GF-3 or higher
- ACEA A3/B3 or A3/B4

- For SAE viscosity grades according to ambient temperature, refer to "Lubrication System."		 Use if the recommended engine oil is not available
Oil Pressure (at 1000 rpm) 130 kPa (1.3 kgf/cm², 18.9 psi) or higher Oil Pan Oil Temperature: 110 ± 2 °C
Cooling Method
Cooling System Forced circulation with water pump
Coolant Capacity Approx. 5.3 L (1.40 US gal, 5.60 US qt, 4.66 Imp qt)
Main Thermostat Type Wax Pellet Type
Opening temperature 88 ± 1,5 °C
Full Open Temperature More than 8 mm (0.3150 in.) / 100 °C
Block Thermostat (for split cooling) Type Wax Pellet Type
Opening temperature 105 ± 1,5 °C
Full Open Temperature More than 8 mm (0.3150 in.) / 120 °C
Radiator Cap Main Valve Opening Pressure 93.16–122.58 kPa (0.95–1.25 kgf/cm, 13.51–17.78 psi)
Vacuum Valve Opening Pressure Max. 6.8 kPa
(Max. 0.07 kgf/cm, 0.99 psi)
Engine coolant temperature sensor
Type Thermistor type
Resistance 20°C (68°F) 2.45 ± 0.14 kΩ
80°C (176°F) 0.3222 kΩ

Tightening Torque
Item N·m kgf·m lbf·ft
Engine Mounting
Engine Mounting Bracket and Body Mounting Bolt 49,0 - 63,7 5,0 - 6,5 36,1 - 47,0
Engine Mounting Bracket and Engine Mounting Bracket Support Bolt 49,0 - 63,7 5,0 - 6,5 36,1 - 47,0
Engine Mounting Bracket and Engine Mounting Bracket Support Nut 49,0 - 63,7 5,0 - 6,5 36,1 - 47,0
Transaxle Mounting Bracket and Body Mounting Bolt 49,0 - 63,7 5,0 - 6,5 36,1 - 47,0
Transaxle Mounting Bracket and Body Mounting Nut 49,0 - 63,7 5,0 - 6,5 36,1 - 47,0
Transaxle Mounting Bracket Support to Transaxle Mounting Bracket Mounting Bolt 88,3 - 107,9 9,0 - 11,0 65,1 - 79,6
Steering Rod Bracket and Subframe Mounting Bolt 49,0 - 63,7 5,0 - 6,5 36,1 - 47,0
Link Bracket and Link Bracket Support Bolt 127,5 - 147,1 13,0 - 15,0 79,6 ~ 94,0
Drive Belt System
Drive belt tensioner bolt 19,6 - 26,5 2,0 - 2,7 14,5 - 19,5
Crankshaft Damper Pulley Bolt [55,9 - 61,8] + [38 - 42°] [5,7–6,3] + [38–42°] [41,2 - 45,6] + [38 - 42°]
SYNC System
Timing Chain Cover and Oil Pump Bolt (A) 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Timing Chain Cover and Oil Pump Bolt (B) 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Timing Chain Cover and Oil Pump Bolt (C) 44,1 - 53,9 4,5 - 5,5 32,5 - 39,8
Timing Chain Tensioner Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Timing Chain Tensioner Arm Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Timing Chain Guide Bolt 18,6 - 21,6 1,9 - 2,2 13,7 - 15,9
Cylinder head cover
Cylinder Head Cover Bolt [3,9–5,9] → [7,8–9,8] [0,4–0,6] → [0,8–1,0] [2,9–4,3] → [5,8–7,2]
CVVT Sprocket Bolt 63,7 - 73,5 6,5 - 7,5 47,0 - 54,2
Camshaft Bearing Cap Bolt (M6) [5,9] → [11,8–13,7] [0,6] → [1,2–1,4] [4.3] → [8.7 - 10.1]
Front Camshaft Bearing Cap Bolt (M8) [9,8] → [18,6 - 22,6] [1,0] → [1,9–2,3] [7,2] → [13,7–16,6]
Cylinder head bolt [12,7–16,7] + [90–95°] + [120–125°] [1,3–1,7] + [90–95°] + [120–125°] [9,4–12,3] + [90–95°] + [120–125°]
Cylinder block
Ladder frame bolt 28,4 - 32,4 2,9 - 3,3 21,0 - 23,9
Connecting Rod Bearing Cap Bolt [10,8–14,7] + [88–92°] [1,1–1,5] + [88–92°] [8,0–10,8] + [88–92°]
Main Bearing Cap Bolt [17,7–21,6] + [88–92°] [1,8–2,2] + [88–92°] [13,0–15,9] + [88–92°]
Piston Cooling Jet Bolt 8,8 - 12,7 0,9 - 1,3 6,5 - 9,4
Flywheel Bolt 68,6 - 78,5 7,0–8,0 50,6 - 57,9
Cooling System
Water Pump Pulley Bolt 12,7 - 14,7 1,3 - 1,5 9,4 - 10,8
Water pump bolt 19,6 - 26,5 2,0 - 2,7 14,5 - 19,5
Heater hose bolt 19,6 - 26,5 2,0 - 2,7 14,5 - 19,5
Water temperature control assembly bolt 19,6 - 26,5 2,0 - 2,7 14,5 - 19,5
Water Inlet Pipe Bolt and Nut 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Lubrication System
Oil Filter 11,8 - 15,7 1,2 - 1,6 8,7 - 11,6
Oil Level Gauge Guide Bolt 8,8 - 13,7 0,9 - 1,4 6,5 - 10,1
Oil Pan Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Oil Pan Drain Plug 34,3 - 44,1 3,5 - 4,5 25,2 - 32,4
Oil Filter Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Oil pressure sensor 7,8 - 11,8 0,8 - 1,2 5,8 - 8,7
Intake and Exhaust System
Intake Manifold Bolt and Nut 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Intake Manifold Mounting Bolt 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Warm-Up Catalytic Converter (WCC) Heat Shield Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Warm-Up Catalytic Converter (WCC) Upper Stud Bolt 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Warm-Up Catalytic Converter (WCC) Lower Mounting Bolt 39,2 - 44,1 4,0 - 4,5 28,9 - 32,5
Warm-Up Catalytic Converter (WCC) Nut 49,0 - 53,9 5,0 - 5,5 36,1 - 39,7
Water Drain Pipe Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Water Drain Pipe Bolt with Eyelet 26,4 - 32,3 2,7 - 3,3 19,5 - 32,3
Water Supply Hose and Eyelet Bolt 26,4 - 32,3 2,7 - 3,3 19,5 - 32,3
Oil Drain Tube Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Oil Supply Tube Bolt 11,8 - 17,7 1,2 - 1,8 8,7 - 13,0
Turbocharger Manifold Module Heat Shield 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Turbocharger Manifold Module Nut 35,3 - 41,2 3,6 - 4,2 26,0 - 30,4
Muffler Nut 39,2 - 58,8 4,0–6,0 28,9 - 43,4
Center Muffler Pipe and Main Muffler Mounting Nut 17,0 - 27,0 1,7 - 2,8 12,5 - 19,9

Special Service Tools

Special Service Tools

Tool Name/Number Illustration Description
Crankshaft Damper Pulley Adapter
09231-2M100
Crankshaft Damper Pulley Adapter Holder
09231-2J210
Used for removing/installing the crankshaft damper pulley.
Front Crankshaft Oil Seal Installer
09214-1R000
Handle
09231-H1100
Valve Stem Oil Seal Installer
09222-1C100
Valve Spring Compressor
09222-3K000
Valve Spring Compressor Adapter
09222-3K100
Used to remove/install intake or exhaust valve
Rear Crankshaft Oil Seal Installer
09214-03100
Handle
09231-H1100
Oil Pan Remover
09215-3C000
Oil Filter Wrench
09263-02000
Used to remove/install the oil filter.
Radiator Cap Pressure Tester
0K253-G5100
Used to check the radiator cap sealing pressure and coolant leakage.

Repair Procedures

Compression Test

Compression Pressure Test
  1. Start the engine and warm it up to normal operating temperature (about five minutes). Stop the engine.
  2. Remove the air cleaner assembly. (Refer to Air Intake and Exhaust System - "Air Cleaner").
  3. Disconnect the injector connectors (A) and the ignition coil connectors (B).
  4. Remove the ignition coils. (Refer to Engine Electrical System - "Ignition Coil")
  5. Remove the three spark plugs using a 16 mm spark plug socket. (Refer to Engine Electrical System - Spark Plug)
  6. Inspect 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.
    4. Repeat steps (1) through (3) for each cylinder.Compression pressure: 1128 kPa (11.5 kgf/cm², 163.6 psi) Minimum pressure: 1030 kPa (10.5 kgf/cm², 149.3 psi) Difference between cylinders: 98 kPa (1.0 kgf/cm², 14 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 pressure remains low, a valve may be sticking or seating improperly, or there may be leakage past the head gasket.
  7. Reinstall the spark plugs. (Refer to Engine Electrical System - "Spark Plug")
  8. Install the ignition coils. (Refer to Engine Electrical System - "Ignition Coil")
  9. Connect the injector connectors and the ignition coil connectors.
  10. Install the air cleaner assembly. (Refer to Air Intake and Exhaust System - "Air Cleaner").
  11. Some DTCs may remain after the inspection test and may need to be cleared manually using the KDS.

Troubleshooting

Troubleshooting

Symptom Suspected Area Remedy
Engine misfire with abnormal internal low engine noise. Worn crankshaft bearings.
Loose or damaged drive plate.		 Replace the crankshaft and bearings if necessary.
Repair or replace the drive plate if necessary.
Worn piston rings.
(Oil consumption may or may not cause engine misfire.)		 Inspect the cylinder for loss of compression. Repair or replace as necessary.
Worn crankshaft thrust bearings Replace the crankshaft and bearings if necessary.
Engine misfire with abnormal valve train noise. Sticking valves.
(Carbon on valve stem)		 Repair or replace if necessary.
Excessively worn or displaced timing chain. Replace the timing chain and sprocket if necessary.
Worn camshaft lobes. Replace the camshaft and valve lifters.
HLA sponge Run the engine at 2,500–3,000 rpm for 15 minutes.
If the condition does not disappear, refer to Cylinder Head Assembly in this group.
Engine misfire with coolant consumption.
  • Faulty cylinder head gasket and/or crankshaft rotation or other damage to the cylinder head and engine block cooling system.
  • Coolant consumption may or may not cause engine overheating.
  • Inspect the cylinder head and cylinder block for damage to the coolant passages and/or a defective 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.
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 on start-up that lasts only a few seconds. Incorrect 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.
Worn valve guides or valve stems. Inspect the valves and valve guides, then repair if necessary.
Sticking valves. Carbon on the valve stem or seat may cause the valve to remain open. Inspect the valves and valve guides, then repair if necessary.
Worn drive belt, tensioner, idler and bearing. Replace as necessary.
Low engine noise regardless of engine speed. Low oil pressure. Repair as necessary.
Loose or damaged drive plate. Repair or replace the drive plate.
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 as necessary.
Excessive piston pin 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 if necessary.
  • Connecting rod bearings.
  • Connecting rods.
  • Crankshaft thrust washers.
Excessive crankshaft bearing clearance. Inspect the following components and repair 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 if necessary:
  • Connecting rod bearings.
  • Connecting rods.
  • Crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components and repair if necessary.
  • Crankshaft bearings.
  • Crankshaft main journals.
  • Cylinder block.
Engine does not crank, crankshaft does not rotate. Hydraulic lock cylinder.
  • Coolant/antifreeze in cylinder.
  • Oil in cylinder.
  • Fuel in cylinder.
  • Remove the spark plugs and check for liquid.
  • Inspect for a broken head gasket.
  • Inspect the cylinder block or cylinder head for cracks.
  • Inspect the fuel injector and/or fuel pressure regulator for sticking.
Timing chain breakage and/or timing chain and/or timing chain sprocket.
  • Inspect the timing chain and sprockets.
  • Repair as necessary.
Foreign material in cylinder.
  • Broken valve
  • Piston material
  • Foreign material
  • Inspect the cylinder for damaged components and/or foreign material.
  • Repair or replace if necessary.
Seized crankshaft or connecting rod bearings.
  • Inspect the crankshaft and connecting rod bearings.
  • Repair as necessary.
Bent or broken connecting rod.
  • Inspect the connecting rods.
  • Repair as necessary.
Broken crankshaft.
  • Inspect the crankshaft.
  • Repair as necessary.

Test yourself

A quick Kia Picanto JA quiz: every answer comes with an explanation and a link to the manual page.