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Engine Overhaul: Specifications Kia Rio II

Mechanical

SPECIFICATIONS

Description		Specifications	Limit
Description		1.6 CVVT	Limit
General
Type		In-line, DOHC
Number of cylinders		4
Bore		76.5mm (3.0118in)
Stroke		87mm (3.4252in)
Total displacement		1,599 cc (97.57 cu.in)
Compression ratio		10.0: 1
Firing order		1-3-4-2
Valve timing
Intake valve	Opens (BTDC)	8°
Intake valve	Closes (ABDC)	60°
Exhaust valve	Opens (BBDC)	46°
Exhaust valve	Closes (ATDC)	10 °
Cylinder head
Flatness of gasket surface		Less than 0.03mm (0.0012in)	0.1mm (0.0039in)
Flatness of manifold mounting surface	Intake	Less than 0.15mm (0.0059in)	0.2mm (0.0079in)
Flatness of manifold mounting surface	Exhaust	Less than 0.15mm (0.0059in)	0.2mm (0.0079in)
Valve guide hole diameter (Intake, Exhaust)	STD	11.000~11.018mm (0.4331~0.4338in)
	0.05 OS	11.050~11.068mm (0.4350~0.4357in)
	0.25 OS	11.250~11.268mm (0.4429~0.4436in)
	0.50 OS	11.500~11.518mm (0.4528~0.4535in)
Intake valve seat ring hole diameter	STD	30.400~30.421mm (1.1968~1.1977in)
	0.3 OS	30.700~30.721mm (1.2087~1.2095in)
	0.6 OS	31.000~31.021mm (1.2205~1.2213in)
Exhaust valve seat ring hole diameter	STD	27.000~27.021mm (1.0630~1.0638in)
	0.3 OS	27.300~27.321mm (1.0748~1.0756in)
	0.6 OS	27.600~27.621mm (1.0866~1.0874in)
Camshaft
Cam height	Intake	43.7492~43.9492mm (1.72241~1.73028in)
Cam height	Exhaust	44.1494~44.3494mm (1.73816~1.74604in)
Journal outer diameter (Intake, Exhaust)		26.964~26.980mm (1.0616~1.0622in)
Camshaft cap oil clearance		0.02~0.061mm (0.0008~0.0024in)	0.1mm (0.0039in)
End play		0.10~0.20mm (0.0039~0.0079in)
Valve
Valve length	Intake	91.8mm (3.6142in)
Valve length	Exhaust	92.4mm (3.6378in)
Stem outer diameter	Intake	5.965~5.980mm (0.2348~0.2354in)
Stem outer diameter	Exhaust	5.950~5.965mm (0.2343~0.2348in)
Face angle		45°~45°30'
Thickness of valve head (margin)	Intake	1.1mm (0.0433in)	0.8mm (0.0315in)
Thickness of valve head (margin)	Exhaust	1.3mm (0.0512in)	1.0mm (0.0394in)
Valve stem to valve guide clearance	Intake	0.02~0.05mm (0.0008~0.0020in)	0.10mm (0.0039in)
Valve stem to valve guide clearance	Exhaust	0.035~0.065mm (0.0014~0.0026in)	0.15mm (0.0059in)
Valve guide
Length	Intake	36.3~36.7mm (1.4291~1.4449in)
Length	Exhaust	39.3~39.7mm (1.5472~1.5630in)
Valve seat
Width of seat contact	Intake	0.8~1.2mm (0.0315~0.0472in)
Width of seat contact	Exhaust	1.3~1.7mm (0.0512~0.0669in)
Seat angle	Intake	45°~45°30*
Seat angle	Exhaust	45°~45°30'
Valve spring
Free length		44.0mm (1.7323in)
Load		21.6±1.1 kg/35mm(47.6±2.4 lb/1.3780in)
Load		45.1±2.2kg/27.2mm(99.4±4.9 lb/1.0709in)
Out of squareness		Less than 1.5°	3°
Cylinder block
Cylinder bore		76.50~76.53mm (3.0118~3.0130in)
Flatness of gasket surface		Less than 0.05mm (0.0020in)
Piston
Piston outer diameter		76.47~76.50mm (3.0106~3.0118in)
Piston to cylinder clearance		0.020~0.040mm (0.0008~0.0016in)
Ring groove width	No. 1 ring groove	1.230~1.255mm (0.0484~0.0494in)
	No. 2 ring groove	1.230~1.255mm (0.0484~0.0494in)
	Oil ring groove	2.030~2.055mm (0.0799~0.0809in)
Piston ring
Side clearance	No.1 ring	0.04~0.085mm (0.0016~0.0033in)	0.1 mm (0.0039in)
	No.2 ring	0.04~0.085mm (0.0016~0.0033in)	0.1 mm (0.0039in)
	Oil ring	0.08~0.175mm (0.0031~0.0069in)
End gap	No. 1 ring	0.15~0.30mm (0.0059~0.0118in)	1.0mm (0.0394in)
	No. 2 ring	0.35~0.50mm (0.0138~0.0197in)	1.0mm (0.0394in)
	Oil ring	0.20~0.70mm (0.0079~0.0276in)	1.0mm (0.0394in)
Piston pin
Piston pin outer diameter		18.001~18.007mm (0.7087~0.7089in)
Piston pin hole inner diameter		18.016~18.021mm (0.7093~0.7095in)
Piston pin hole clearance		0.011~0.018mm (0.0004~0.0007in)
Connecting rod small end hole inner diameter		17.974~17.985mm (0.7076~0.7081in)
Connecting rod small end hole clearance		0.033~-0.016mm (-0.0013~-0.0006in)
Piston pin press-in load		500~1,500 kg (1,102~3,306 lb)
Connecting rod
Connecting rod big end inner diameter		48.000~48.018mm (1.8898~1.8905in)
Connecting rod bearing oil clearance		0.018~0.036mm (0.0007~0.0014in)
Side clearance		0.10~0.25mm (0.0039~0.0098in)	0.4mm (0.0157in)
Crankshaft
Main journal outer diameter		49.950~49.968mm (1.9665~1.9672in)
Pin journal outer diameter		44.954~44.972mm (1.7698~1.7705in)
Main bearing oil clearance	No. 1, 2, 4, 5	0.022~0.040mm (0.0009~0.0016in)	0.1mm (0.0039in)
Main bearing oil clearance	No. 3	0.028~0.046mm (0.0011~0.0018in)	0.1mm (0.0039in)
End play		0.05~0.175mm (0.0020~0.0069in)	0.2mm (0.0079in)
Flywheel
Runout		0.1mm (0.0039in)	0.13mm (0.0051in)
Oil pump
Side clearance	Inner rotor	0.040~0.085mm (0.0016~0.0033in)
Side clearance	Outer rotor	0.040~0.090mm (0.0016~0.0035in)
Body clearance		0.060~0.090mm (0.0024~0.0035in)
Relief valve opening pressure		500±49.0kpa (5.1±0.5kg/cm 2 , 72.5±7.1psi)
Relief spring	Free length	46.6mm (1.8346in)
Relief spring	Load	6.1±0.4kg/40.1mm (13.4±0.9 lb/1.5787in)
Engine oil
Oil quantity (Total)		3.3 L (3.49 US qt, 2.90 lmp qt)
Oil quantity (Oil pan)		3.0 L(3.17 US qt, 2.64 lmp qt)
Oil quantity (Oil filter)		0.3 L (0.32 US qt, 0.26 lmp qt)
Oil quality		Above SJ / SL
Oil pressure (Idle)		107.8kpa (1.1 kg/cm 2 , 15.6psi)
Cooling system
Cooling method		Forced circulation with cooling fan
Coolant quantity		5.5~5.8 L (5.81~6.13 US qt, 4.84~5.10 lmp qt)
Thermostat	Type	Wax pellet type
	Opening temperature	82±1.5°C (179.6±2.7°F)
	Pull opening temperature	95°C (203°F)
Radiator cap	Main valve opening pressure	93.16~122.58kpa (0.95~1.25kg/cm 2 , 13.51~17.78psi)
Radiator cap	Vacuum valve opening pressure	0.98~4.90 kpa (0.01~0.05kg/cm 2 , 0.14~0.71 psi)
Water temperature sensor
Type		Thermister type
Resistance	20°C (68°F)	2.45±0.14 kohms
Resistance	80°C (176°F)	0.3222 kohms

GENERAL SPECIFICATIONS

TIGHTENING TORQUE

Item	Quantity	Tightening torque
Item	Quantity	N.m	Kgf.m	Lb-ft
Cylinder block
Engine support bracket bolt	2	44.1~53.9	4.5~5.5	32.5~39.8
Engine support bracket nut	1	44.1~53.9	4.5~5.5	32.5~39.8
Engine support bracket stay bolt	2	44.1~53.9	4.5~5.5	32.5~39.8
Rear plate bolt	1	9.8~11.8	1.0~1.2	7.2~8.7
Engine mounting
Engine mounting bracket and body fixing bolt	3	49.0~63.7	5.0~6.5	36.2~47.0
Engine mounting insulator and engine mounting support bracket fixing nut	1	68.6~93.2	7.0~9.5	50.6~68.7
Engine mounting support bracket and engine support bracket fixing bolt	2	49.0~63.7	5.0~6.5	36.2~47.0
Engine mounting support bracket and engine support bracket fixing nut	1	49.0~63.7	5.0~6.5	36.2~47.0
Transaxle mounting bracket and body fixing bolt	3	49.0~63.7	5.0~6.5	36.2~47.0
Transaxle mounting insulator and transaxle support bracket fixing bolt	2	68.6~93.2	7.0~9.5	50.6~68.7
Front roll stopper bracket and sub frame fixing bolt	3	49.0~63.7	5.0~6.5	36.2~47.0
Front roll stopper insulator and front roll stopper support bracket fixing bolt, nut	1	49.0~63.7	5.0~6.5	36.2~47.0
Rear roll stopper bracket and sub frame fixing bolt	3	49.0~63.7	5.0~6.5	36.2~47.0
Rear roll stopper insulator and rear roll stopper support bracket fixing bolt, nut	1	49.0~63.7	5.0~6.5	36.2~47.0
Main moving system
Connecting rod cap nut	8	31.4~34.3	3.2~3.5	23.1~25.3
Crankshaft main bearing cap bolt	10	53.9~58.8	5.5~6.0	39.8~43.4
Flywheel bolt (M/T)	5	117.7~127.5	12.0~13.0	86.8~94.0
Drive plate bolt (A/T)	5	117.7~127.5	12.0~13.0	86.8~94.0
Timing belt
Timing belt front upper cover bolt	4	7.8~9.8	0.8~1.0	5.8~7.2
Timing belt front lower cover bolt	5	7.8~9.8	0.8~1.0	5.8~7.2
Timing belt rear lower LH cover bolt	3	9.8~11.8	1.0~1.2	7.2~8.7
Timing belt rear upper LH cover bolt	1	9.8~11.8	1.0~1.2	7.2~8.7
Timing belt rear upper RH cover bolt	2	9.8~11.8	1.0~1.2	7.2~8.7
Crankshaft pulley bolt	1	137.3~147.1	14.0~15.0	101.3~108.5
Camshaft sprocket bolt	1	78.5~98.1	8.0~10.0	57.9~72.3
Timing belt tensioner bolt	1	19.6~26.5	2.0~2.7	14.5~19.5
Timing belt idler bolt	1	42.2~53.9	4.3~5.5	31.1~39.8
Cylinder head
Engine cover bolt	4	3.9~5.9	0.4~0.6	2.9~4.3
Cylinder head cover bolt	12	7.8~9.8	0.8~1.0	5.8~7.2
Camshaft bearing cap bolt	24	11.8~13.7	1.2~1.4	8.7~10.1
Intake camshaft and CMP sensor target wheel fixing bolt	1	14.7~19.6	1.5~2.0	10.8~14.5
Exhaust camshaft and CVVT assembly fixing bolt	1	64.7~76.5	6.6~7.8	47.7~56.4
Timing chain auto tensioner bolt	2	7.8~9.8	0.8~1.0	5.8~7.2
OCV(oil control valve) bolt	1	9.8~11.8	1.0~1.2	7.2~8.7
OCV(oil control valve) filter	1	40.2~50.0	4.1~5.1	29.7~36.9
Cylinder head bolt	10	29.4+90° --> Release all bolts --> 29.4+90°	3.0+90° --> Release all bolts --> 3.0+90°	21.7+90° --> Release all bolts --> 21.7+90°
Cooling system
Water pump pulley bolt	4	7.8~9.8	0.8~1.0	5.8~7.2
Water pump bolt (8 X 28)	3	11.8~14.7	1.2~1.5	8.7~10.8
Water pump and alternator brace fixing bolt (8 X 45)	1	19.6~26.5	2.0~2.7	14.5~19.5
Water pump and alternator brace fixing bolt (8 X 65)	1	19.6~26.5	2.0~2.7	14.5~19.5
Thermostat housing nut	2	14.7~19.6	1.5~2.0	10.8~14.5
Water outlet fitting nut	2	14.7~19.6	1.5~2.0	10.8~14.5
Water inlet fitting bolt	3	16.7~19.6	1.7~2.0	12.3~14.5
Water temperature sensor	1	19.6~39.2	2.0~4.0	14.5~28.9
Water pipe fixing bolt	1	9.8~14.7	1.0~1.5	7.2~10.8
Lubrication system
Oil filter	1	11.8~15.7	1.2~1.6	8.7~11.6
Front case bolt (8 X 22)	1	18.6~23.5	1.9~2.4	13.7~17.4
Front case bolt (8 X 30)	3	18.6~23.5	1.9~2.4	13.7~17.4
Front case bolt (8 X 45)	1	18.6~23.5	1.9-2.4	13.7~17.4
Front case bolt (8 X 60)	1	18.6~23.5	1.9~2.4	13.7~17.4
Oil pan bolt	18	9.8~11.8	1.0~1.2	7.2~8.7
Oil pan drain plug	1	39.2~44.1	4.0~4.5	28.9~32.5
Oil screen bolt	2	14.7~21.6	1.5~2.2	10.8~15.9
Oil pressure switch	1	14.7~21.6	1.5~2.2	10.8~15.9
Rear oil seal case	5	9.8~11.8	1.0~1.2	7.2~8.7
Intake and exhaust system
Intake manifold and cylinder head fixing nut	6	14.7~19.6	1.5~2.0	10.8~14.5
Intake manifold and cylinder head fixing bolt(8X45)	2	14.7~19.6	1.5~2.0	10.8~14.5
Intake manifold and cylinder head fixing bolt(8X22)	1	14.7~19.6	1.5~2.0	10.8~14.5
Intake manifold stay bolt	4	17.7~24.5	1.8~2.5	13.0~18.1
Exhaust manifold and cylinder head fixing nut	9	29.4~34.3	3.0~3.5	21.7~25.3
O2 sensor to exhaust manifold	1	49.0~58.8	5.0~6.0	36.2~43.4
Exhaust manifold heat cover and exhaust manifold fixing bolt	3	16.7~21.6	1.7~2.2	12.3~15.9
Air cleaner lower cover fixing bolt	3	7.8~9.8	0.8~1.0	5.8~7.2
Throttle body and surge tank fixing bolt and nut	4	14.7~19.6	1.5~2.0	10.8~14.5
Exhaust manifold and front muffler fixing nut	2	29.4~39.2	3.0~4.0	21.7~28.9
Front muffler and center muffler fixing nut	2	29.4~39.2	3.0~4.0	21.7~28.9
Center muffler and main muffler fixing nut	2	29.4~39.2	3.0~4.0	21.7~28.9

TIGHTENING TORQUE SPECIFICATIONS