Kia Rio: Engine Mechanical System

Specifications

Description		Specification	Limit
General
Type		In-line, DOHC
Number of cylinders		4
Bore		72.0 mm (2.8346 in.)
Hone		84.0 mm (3.3070 in)
Total Displacement		1,368 cc (83.48 cu. in.)
Compression ratio		10,5 : 1
Firing order		1-3-4-2
Valve Timing
Intake Valve	Opens	BTDC 10° - BTDC 60°
Intake Valve	Closes	74,6° ABDC - 4,6° ABDC
Exhaust Valve	Opens	BBDC 52,4° - BBDC 12,4°
Exhaust Valve	Closes	BTDC 3° - BTDC 43°
Cylinder head cover
Gasket Surface Flatness		Less than 0.05 mm (0.0025 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	36.4183 mm (1.4337 in.)
Cam Lobe Height	exhaust	36.1543 mm (1.4233 in.)
Journal Outside Diameter	Intake No. 1	36.459–36.473 mm (1.4354–1.4359 in.)
	Exhaust No. 1	36.464–36.478 mm (1.4355–1.4361 in.)
	Intake/Exhaust No. 2-5	22.964–22.978 mm (0.9040–0.9046 in.)
Valve
Valve Length	Intake	100.94 mm (3.9740 in.)
Valve Length	exhaust	101.09 mm (3.9799 in.)
Stem Outer Diameter	Intake	5.465–5.480 mm (0.2151–0.2157 in.)
Stem Outer Diameter	exhaust	5.448–5.460 mm (0.2144–0.2149 in.)
Face Angle		45,25° - 45,75°
Valve Head Margin Thickness	Intake	1.35–1.65 mm (0.0531–0.0650 in.)
Valve Head Margin Thickness	exhaust	1.60–1.90 mm (0.0630–0.0748 in.)
Valve Stem-to-Guide Clearance	Intake	0.020–0.047 mm (0.00078–0.00185 in.)
Valve Stem-to-Guide Clearance	exhaust	0.040–0.064 mm (0.00157–0.00251 in.)
Valve Guide
Inner Diameter	Intake	5.500–5.512 mm (0.21654–0.21701 in)
Inner Diameter	exhaust	5.500–5.512 mm (0.21654–0.21701 in)
Valve Seat
Valve Seat Contact Width	Intake	0.85–1.15 mm (0.0334–0.0452 in.)
Valve Seat Contact Width	exhaust	1.35–1.65 mm (0.0531–0.0649 in.)
Valve seat angle	Intake	44,75° - 45,10°
Valve seat angle	exhaust	44,75° - 45,10°
Valve Spring
Free Length		47.9 mm (1.8858 in.)
Load		16.7 ± 0.8 kg / 35.5 mm (164 ± 8 N / 1.3976 in.)
Load		29.6 ± 1.0 kg / 27.7 mm (290 ± 10 N / 1.0905 in.)
Out-of-Square		1.5° MAX.
Cylinder block
Cylinder Bore Diameter		72.00–72.03 mm (2.8346–2.8358 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		71.97–72.00 mm (2.8334–2.8346 in.)
Piston-to-Cylinder Clearance		0.02–0.04 mm (0.0008–0.0016 in.)
Ring Groove Width	No. 1 Ring Groove	1.035–1.05 mm (0.0407–0.0413 in.)
	No. 2 Ring Groove	1.23–1.25 mm (0.0484–0.0492 in.)
	Oil Ring Groove	1.995–2.010 mm (0.0785–0.0791 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	0.040–0.850 mm (0.0015–0.0335 in.)
End Gap	No. 1 Ring	0.13–0.18 mm (0.0051–0.0071 in.)
	No. 2 Ring	0.25–0.40 mm (0.0098–0.0157 in)
	Oil Ring	0.1–0.4 mm (0.0039–0.0157 in.)
Piston pin
Piston Pin Outer Diameter		18.000–18.003 mm (0.7086–0.7087 in.)
Piston Pin Bore Inner Diameter		18.013–18.017 mm (0.7092–0.7093 in.)
Piston Pin Bore Clearance		0.010–0.017 mm (0.00039–0.00067 in.)
Connecting Rod Small End Bore Inner Diameter		17.974–17.985 mm (0.7076–0.7080 in.)
Connecting Rod Small End Bore Clearance		0.015–0.029 mm (0.00059–0.00114 in.)
Piston Pin Press-Fit Load		150–750 kg (331–1653 lb)
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.)
Connecting Rod Bearing Oil Clearance includes big end expansion deformation		0.027–0.052 mm (0.0011–0.0020 in.)
Backlash		0.1–0.25 mm (0.0039–0.0098 in.)
Crankshaft
Main Journal Outer Diameter		47.942–47.960 mm (1.8875–1.8882 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.)
Main Bearing Oil Clearance includes big end expansion deformation		0.021–0.039 mm (0.0008–0.0015 in.)
End of Playback		0.07–0.25 mm (0.0028–0.0098 in)
Engine Oil
Oil Capacity	General	3.5 L (0.94 US gal., 3.75 US qt., 3.12 Imp. qt.)	When replacing a short engine or engine assembly
	Oil Baffle	3.3 L (0.87 US gal, 3.48 US qt, 2.90 Imp. qt)
	Drain and Refill	3.5 L (0.92 US gal, 3.70 US qt, 3.08 liters qt)	Including oil filter
Oil Grade	Recommended	For Europe, Australia, General Export, Central and South America - API SN and ACEA C2 / 0W-20 For India, Middle East, Iran, Libya, Algeria, Sudan, Morocco, Tunisia, Egypt - API SM and ILSAC GF-4 / 5W-30 - ACEA A5/B5 / 5W-30
Oil Grade	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.	May be used if the recommended engine oil is not available
Oil Pressure (at 1000 rpm)		90 kPa (0.9 kg/cm², 13.05 psi)	Engine Oil Temperature in Oil Pan: 110±2 °C
Cooling Method
Cooling System		Forced circulation with water pump
Coolant Capacity		MT: Approx. 5.1 L (1.35 US gal., 5.39 US qt., 4.49 Imp. qt.) AT: Approx. 5.5 L (1.45 US gal., 5.81 US qt., 4.84 Imp. qt.)
Thermostat	Type	Wax Pellet Type
	Opening Temperature	88 ± 1.5 °C (190.4 ± 2.7 °F)
	Fully Open Temperature	100°C (212°F)
Radiator Cap	Main Valve Opening Pressure	93.2–122.6 kPa (0.95–1.25 kg/cm², 13.51–17.78 psi)
Radiator Cap	Vacuum Valve Opening Pressure	Max. 6.86 kPa (Max. 0.07 kg/cm², 0.99 psi)
Engine coolant temperature sensor
Type		Thermistor type
Resistance	20°C (68°F)	2.45 ± 0.14 kΩ
Resistance	80°C (176°F)	0.3222 kΩ

Tightening torque

Item	N·m	kgf·m	lbf·ft
Engine Mounting
Engine mount bracket and body mount insulator	49,0 - 63,7	5,0 - 6,5	36,2 - 47,0
Engine Mounting Bracket and Body Mounting Nut	49,0 - 63,7	5,0 - 6,5	36,2 - 47,0
Engine Mount Insulator to Engine Mount Bracket Nut	88,3 - 107,9	9,0 - 11,0	65,1 - 79,6
Engine mount bracket and engine mount bracket bolt	58,8 - 73,5	6,0 - 7,5	43,4 - 54,2
Engine mount bracket and engine mount bracket nuts	58,8 - 73,5	6,0 - 7,5	43,4 - 54,2
Transaxle mount bracket and body mount bolts	49,0 - 63,7	5,0 - 6,5	36,2 - 47,0
Transaxle Mounting Bracket and Body Mounting Nut	49,0 - 63,7	5,0 - 6,5	36,2 - 47,0
Transaxle mount insulator and transaxle mount bracket support bolts	88,3 - 107,9	9,0 - 11,0	65,1 - 79,6
Steering tie rod bracket and subframe mounting bolts	49,0 - 63,7	5,0 - 6,5	36,1 - 47,0
Link Bracket to Link Support Bracket Mounting Bolt	107,9 - 127,5	11,0 - 13,0	79,6 - 94,0
Cylinder block
Ladder Frame Bolts	28,4 - 32,4	2,9 - 3,3	21,0 - 23,9
Piston Cooling Jet Bolts	8,8 - 12,7	0,9 - 1,3	6,5 - 9,4
Connecting Rod Bearing Cap Bolts	[10,8–14,7] + [88–92°]	[1,1–1,5] + [88–92°]	[8,0–10,8] + [88–92°]
Crankshaft Main Bearing Cap Bolts	[17,7–21,6] + [90°]	[1,8–2,2] + [90°]	[13,0–15,9] + [90°]
Flywheel Bolts (M/T)	68,6 - 78,5	7,0–8,0	50,6 - 57,9
Drive Plate Bolts (Transaxle)	68,6 - 78,5	7,0–8,0	50,6 - 57,9
Drive Belt System
Drive Belt Tensioner Bolts	19,6 - 26,5	2,0 - 2,7	14,5 - 19,5
Crankshaft Damper Pulley Bolt	65,7 - 71,6 + 59 - 61°	6,7 - 7,3 + 59 - 61°	48,5 - 52,8 + 59 - 61°
SYNC System
Timing Chain Cover Bolts (A)	18,6 - 23,5	1,9 - 2,4	13,7 - 17,4
Timing Chain Cover Bolts (B)	44,1 - 53,9	4,5 - 5,5	32,5 - 39,8
Timing Chain Cover Bolts (C)	9,8 - 11,8	1,0 - 1,2	7,2 - 8,7
Timing Chain Cover Bolt (D)	18,6 - 23,5	1,9 - 2,4	13,7 - 17,4
Timing Chain Tensioner Bolts	9,8 - 11,8	1,0 - 1,2	7,2 - 8,7
Timing Chain Camshaft Guide Bolts	9,8 - 11,8	1,0 - 1,2	7,2 - 8,7
Timing Chain Crankshaft Guide Bolts	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 Bolts	[3,9–5,9] + [7,8–9,8]	[0,4–0,6] + [0,8–1,0]	[2,9–4,3] + [5,8–7,2]
Camshaft Bearing Cap Bolts	11,8 - 13,7	1,2 - 1,4	8,7 - 10,1
Front Camshaft Bearing Cap Mounting Bolts	18,6 - 22,6	1,9 - 2,3	13,7 - 16,6
Cylinder Head Bolts	[12,7–16,7] + [90–95°] + [120–125°]	[1,3–1,7] + [90–95°] + [120–125°]	[9,4–12,3] + [90–95°] + [120–125°]
CVVT OCV Inlet Bolt	85,3 - 95,1	8,7 - 9,7	62,9 - 70,2
CVVT Exhaust Bolt	63,7 - 73,5	6,5 - 7,5	47,0 - 54,2
Cooling System
Water Pump Pulley Bolts	12,7 - 14,7	1,3 - 1,5	9,4 - 10,8
Water Pump Bolts	9,8 - 11,8	1,0 - 1,2	7,2 - 8,7
Heater Pipe Bolt and Nut	19,6 - 26,5	2,0 - 2,7	14,5 - 19,5
Thermostat Housing Bolts and Nuts	9,8 - 11,8	1,0 - 1,2	7,2 - 8,7
Water Inlet Pipe Bolt and Nut	18,6 - 23,5	1,9 - 2,4	13,7 - 17,3
Water Temperature Control Assembly Bolts and Nuts	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 Pump Bolts	9,8 - 11,8	1,0 - 1,2	7,2 - 8,7
Oil Pan Bolts	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 Screen Bolts	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 Bolts and Nuts	18,6 - 23,5	1,9 - 2,4	13,7 - 17,4
Exhaust Manifold Mounting Bolts	39,2 - 49,0	4,0–5,0	28,9 - 36,2
Exhaust Manifold Heat Protector Mounting Bolts	8,8 - 10,8	0,9 - 1,1	6,5 - 7,9
Exhaust Manifold Nuts	29,4 - 34,3	3,0 - 3,5	21,7 - 25,3
Exhaust Manifold and Front Muffler Nuts	39,2 - 58,8	4,0–6,0	28,9 - 43,4
Front Muffler, Catalytic Converter and Center Muffler Nuts	39,2 - 58,8	4,0–6,0	28,9 - 43,4
Catalytic Converter and Center Muffler and Rear Muffler Nuts	39,2 - 58,8	4,0–6,0	28,9 - 43,4

Special Service Tools

Tool Name/Number	Illustration	Description
Ring Gear Stopper 09231-3H100 09231-2B100		Used to prevent the flywheel from rotating when removing/installing the crankshaft pulley bolt.
Oil Seal Cap Installer 09222-03100		Used to install the valve stem oil seal.
Valve Spring Compressor and Retainer 09222-3K000 (Compressor) 09222-3K100 (Handle)		Used to remove/install intake or exhaust valve
Front Crankshaft Oil Seal Installer 09214-1R000 (Installer) 09231-H1100 (Handle)		Used to install the front crankshaft oil seal.
Rear Crankshaft Oil Seal Installer 09214-03100 (Installer) 09231-H1100 (Handle)		Used to install the rear crankshaft oil seal.
Oil Pan Remover 09215-3C000		Used to remove the oil pan.
Oil Filter Wrench 09263-02000		Used to remove/install the oil filter.

Repair Procedures

Compression Pressure Test

1
Start the engine and warm it up to normal operating temperature (about 5 minutes).

Stop the engine.
2
Remove the ignition coil.

(See Engine Electrical System - Ignition Coil)
3
Remove the spark plugs.

(Refer to Engine Electrical System - Spark Plug)
4
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.
  
  NOTE
  Always use a fully charged battery to obtain an engine speed of 250 rpm or higher.
4. Repeat steps (1) through (3) for each cylinder.
  
  NOTE
  This measurement must be performed as quickly as possible.
  
  Compression pressure:
  
  1373 kPa (14.0 kg/cm², 199.0 psi)
  
  Minimum pressure:
  
  1226 kPa (12.5 kg/cm², 178.0 psi)
  
  Difference between each cylinder:
  
  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 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.

Tightening torque: 14.7–24 N·m
6
Connect the injector connectors.
7
Install the ignition coil.

Tightening Torque: 9.8–11.8 N·m
8
Connect the ignition coil connectors.
9
Some DTCs may remain after the inspection test and may need to be cleared manually using GDS.

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 2500–3000 rpm for 15 minutes. If the problem does not go away, 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 cylinder block cooling system. 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 on start-up that lasts only a few seconds.	Incorrect oil viscosity.	Drain the oil. Fill with engine oil of the correct viscosity.
Engine noise on start-up that lasts only a few seconds.	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.
	Valve sticking. Carbon deposits on the valve stem or valve seat can cause the valve to stick 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.

Engine Mechanical System

Specifications

Specifications

Special Service Tools

Special Service Tools

Repair Procedures

Compression Pressure Test

Tightening torque: 14.7–24 N·m

Tightening Torque: 9.8–11.8 N·m

Troubleshooting

Troubleshooting

Test yourself