Engine Mechanical: Other Kia Sorento I рестайлинг

COMPRESSION PRESSURE

Note. If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

1. Warm up and stop engine. Allow the engine to warm up to normal operating temperature.
2. Remove ignition coils. Refer to Ignition in «GENERAL (FUEL SYSTEM)»(ref-278797) .
3. Remove spark plugs. Using a 16 mm plug wrench, remove the 6 spark plugs.
4. Check cylinder compression pressure. Insert a compression gauge into the spark plug hole. Fully open the throttle. After 7 times of cranking the engine, measure the compression pressure. NOTE: Always use a fully charged battery to obtain engine speed of 200 RPM or more. Repeat steps ( a ) through ( c ) for each cylinder. NOTE: This measurement must be done in as short a time as possible. Compression pressure: 1,225 kPa (12.5 kgf/cm 2 , 177 psi) @ 200-250 RPM Minimum pressure: 1,078 kPa (11.0 kgf/cm 2 , 156 psi) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps ( a ) through ( c ) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
5. Reinstall spark plugs.
6. Install ignition coils. See «GENERAL (ENGINE ELECTRICAL SYSTEM)»(ref-278798) .

SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS Tool (Number and name) Illustration Use Crankshaft front oil seal installer (09231-3C100) Installation of the front oil seal Flywheel stopper (09231-3C300) Removal and installation of the flywheel and crankshaft pulley. Torque angle adapter (09221-4A000) Installation of bolts & nuts needing an angular method Valve stem seal remover (09222-29000) Remover of the valve stem seal Valve stem seal remover (09222-3C100) Installation of the valve stem seal Valve spring compressor & holder (09222-3K000) (09222-3C300) Removal and installation of the intake or exhaust valve 09222-3K000 09222-3C300 (holder) Crankshaft rear oil seal installer (09231-3C200) (09231-H1100) Installation of the crankshaft rear oil seal 09231-3C200 09231-H1100 Oil pan remover (09215-3C000) Removal of oil pan Oil filter wrench (09263-3C100) Removal and installation of the oil filter

Scheme 166

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Scheme 169

SPROCKETS, CHAIN TENSIONER, CHAIN GUIDE, CHAIN TENSIONER ARM

1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
3. Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.

BELT, IDLER, BELT TENSIONER, PULLEY

1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following flaws are evident, replace the belt. NOTE: Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to come into contact with oil, water and steam.
3. Inspect the idler for easy and smooth rotation and check for play or noise.

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Scheme 179

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Scheme 182

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Scheme 185

Scheme 186

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Scheme 189

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Scheme 191

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Scheme 193

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Scheme 195

1. The key(A) of crankshaft should be aligned with the timing mark(B) of timing chain cover. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke. see scheme 69: Identifying Key And Timing Mark On Timing Chain Cover
2. Install tensioner adapter assembly(A). see scheme 70: Identifying Tensioner Adapter Assembly
3. Install crankshaft sprocket(A)(LH camshaft drive). see scheme 71: Identifying Crankshaft Sprocket (LH Camshaft Drive)
4. Install LH timing chain guide(A). Tightening torque 19.60 ~ 24.50Nm(2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft) see scheme 72: Identifying LH Timing Chain Guide
5. Install LH timing chain. To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure. Crankshaft sprocket(A) --> Timing chain guide(B) --> Exhaust camshaft sprocket(C) --> Intake camshaft sprocket (D). The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain. (Scheme 170): Identifying Timing Mark On Exhaust Camshaft Sprocket And Intake Camshaft Sprocket
6. Install LH timing chain tensioner arm(B). Tightening torque 18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
7. Install chain tensioner(A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 171): Identifying LH Timing Chain Tensioner Arm And Chain Tensioner
8. Install LH cam-to-cam guide(A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 172): Identifying LH Cam-To-Cam Guide
9. Install crankshaft sprocket(A)(O/P&RH camshaft drive). (Scheme 173): Identifying Crankshaft Sprocket (O/P And RH Camshaft Drive)
10. Install oil pump chain(B) and oil pump sprocket(A). Tightening torque 18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft) (Scheme 174): Identifying Oil Pump Chain And Oil Pump Sprocket With Mounting Bolt
11. Install RH timing chain guide(A). Tightening torque 19.60 ~ 24.50Nm(2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft) (Scheme 175): Identifying RH Timing Chain Guide
12. Install RH timing chain. To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure. Crankshaft sprocket(A) --> Intake camshaft sprocket(B) --> Exhaust camshaft sprocket(C). The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain. (Scheme 176): Identifying Timing Mark On Crankshaft Sprocket (Scheme 177): Identifying Timing Mark On Intake Camshaft Sprocket And Exhaust Camshaft Sprocket
13. Install RH timing chain tensioner arm(B).
14. Install RH timing chain auto tensioner(A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 178): Identifying RH Timing Chain Auto Tensioner And RH Timing Chain Tensioner Arm
15. Install RH cam-to-cam guide(A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 179): Identifying RH Cam-To-Cam Guide
16. Install oil pump chain guide(A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 180): Identifying Oil Pump Chain Guide
17. Install oil pump chain tensioner assembly(A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 181): Identifying Oil Pump Chain Tensioner Assembly
18. Pull out the pins of hydraulic tensioner (LH&RH).
19. Install oil pump chain cover(A). Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 182): Identifying Oil Pump Chain Cover With Mounting Bolts
20. After rotating crankshaft 2 revolutions in regular direction(clockwise viewed from front), confirm the timing mark. NOTE: Always turn the crankshaft clockwise.
21. Install timing chain cover. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and ETC. Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between cylinder head and cylinder block The part must be assembled within 5 minutes after sealant was applied. Bead width: 2.5mm(0.1in.) (Scheme 183): Identifying Timing Chain Cover After applying liquid sealant TB1217H on timing chain cover. The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied without discontinuity. Sealant should also be applied all around the two holes of the dowel pins. Bead width: 2.5mm(0.1in.) (Scheme 184): Identifying Timing Chain Cover Liquid Sealant TB1217H Applying Dimensions Install the new gasket(A) to the timing chain cover. (Scheme 185): Identifying Timing Chain Cover Gasket The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position. Tightening torque B(17): 18.62 ~ 21.56Nm(1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft) C(4): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) D(1): 58.80 ~ 68.80Nm(6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft) E(1): 58.80 ~ 68.80Nm(6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft) F(2): 24.50 ~ 26.46Nm(2.5 ~ 2.7kgf.m, 18.08 ~ 19.53lb-ft) G(4): 21.56 ~ 23.52Nm(2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft) H(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) I(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) J(1): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) K(4): 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) L(1): 21.56 ~ 26.46Nm(2.2 ~ 2.7kgf.m, 15.91 ~ 19.53lb-ft) - New bolt (Scheme 186): Identifying Cylinder Block Mounting Dowel Pins Tightening Sequence The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
22. Using SST(09231-3C100), install timing chain cover oil seal. (Scheme 187): Installing Timing Chain Cover Oil Seal Using SST (09231-3C100)
23. Install lower oil pan. Using a gasket scraper, remove all the old packing material from the gasket surfaces. Before assebling the oil pan, the liquid sealant TB1217H should be applied on oil pan. The part must be assembled within 5 minutes after the sealant was applied. Bead width: 2.5mm(0.1in.). (Scheme 188): Identifying Lower Oil Pan Sealant Applying Area CAUTION: Make clean the sealing face before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant. When applying sealant gasket, sealant must not be protruded into the inside of oil pan. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. Install oil pan(A). Uniformly tighten the bolts in several passes. Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 189): Identifying Oil Pan Mounting Bolts
24. Using SST(09231-3C300) install crankshaft damper pulley(A). Tightening torque 284.2 ~ 303.8Nm(29.0 ~ 31.0kgf.m, 209.76 ~ 224.22lb-ft) (Scheme 190): Identifying Crankshaft Damper Pulley (Scheme 191): Installing Crankshaft Damper Pulley Using SST (09231-3C300)
25. Install cylinder head cover.

Scheme 196

Scheme 197

Scheme 198

1. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
2. After applying sealant(TB1217H), it should be assembled within 5 minutes. Bead width: 2.5mm(0.1in.) (Scheme 192): Identifying Cylinder Head Cover Sealant Applying Area
3. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
4. Install the cylinder head cover bolts as following method. Tightening torque 9.80 ~ 11.76Nm(1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft) (Scheme 193): Identifying Cylinder Head Cover Bolts Tightening Sequence CAUTION: Do not reuse cylinder head cover gasket.
5. Install ignition coil
6. Connect RH ignition coil connector(A), condenser connector(B) and install wiring bracket(C). (Scheme 194): Identifying RH Ignition Coil Connector, Condenser Connector And Wiring Bracket
7. Install connector bracket from LH cylinder head cover.

1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following flaws are evident, replace the belt. NOTE: Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to come into contact with oil, water and steam.
3. Inspect the idler for easy and smooth rotation and check for play or noise.

Scheme 199

Scheme 200

Scheme 201

1. Install drive belt auto tensioner (A). Tightening torque 81.4-85.3 N.m (8.3-8.7 kgf.m, 60.0-62.9 lb-ft) 29.4-33.3 N.m (3.0-3.4 kgf.m, 21.7-24.6 lb-ft)
2. Install drive belt idler (A). Tightening torque 52.92-57.82 N.m (5.4-5.9 kgf.m, 39.06-42.67 lb-ft)
3. Install drive belt (A). Crankshaft pulley --> A/C pulley --> idler pulley --> alternator pulley --> water pump pulley --> P/S pump pulley --> tensioner pulley. Rotate auto tensioner arm in the counter-clockwise moving auto tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

Scheme 202

Scheme 203

MLA

1. Inspect MLA. Using a micrometer, measure the MLA outside diameter. MLA O.D. Intake/Exhaust: 34.964-34.980 mm (1.3765-1.3771 in.)
2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head. Tappet bore I.D. Intake/Exhaust: 35.000-35.025 mm (1.3779-1.3789 in.)
3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement. MLA to tappet bore clearance [Standard] Intake/Exhaust: 0.020-0.061 mm (0.0008-0.0024 in.) [Limit] Intake/Exhaust: 0.07 mm (0.0027 in.)

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Scheme 206

1. Inspect cam lobes. Using a micrometer, measure the cam lobe height. Cam height [Standard value] Intake: 46.3 mm (1.8228 in.) (3.3L engine) 46.8 mm (1.8425 in.) (3.8L engine) Exhaust: 45.8 mm (1.8031 in.) If the cam lobe height is less than standard, replace the camshaft.
2. Inspect camshaft journal clearance. Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of plastigage across each of the camshaft journal. Install the bearing caps. CAUTION: Do not turn the camshaft. Remove the bearing caps. Measure the plastigage at its widest point. Bearing oil clearance [Standard value] Intake No.1 journal: 0.020-0.057 mm (0.0008-0.0022 in.) No. 2, 3, 4 journal: 0.030-0.067 mm (0.0012-0.0026 in.) Exhaust No.1 journal: 0.020-0.057 mm (0.0008-0.0022 in.) No. 2, 3, 4 journal: 0.030-0.067 mm (0.0012-0.0026 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head. Completely remove the plastigage. Remove the camshafts.
3. Inspect camshaft end play. Install the camshafts. Using a dial indicator, measure the end play while moving the camshaft back and forth. Camshaft end play [Standard value] 0.056-0.064 mm (0.0022-0.0025in) - 3.3L engine 0.02-0.18 mm (0.0008-0.0071in) - 3.8L engine If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head. Remove the camshafts.

Scheme 207

Scheme 208

1. Inspect CVVT assembly. Check that the CVVT assembly will not turn. Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration. Wind tape around the tip of the air gun and apply air of approx. 150 kPa (1.5 kgf/cm 2 , 21 psi) to the port of the camshaft. (Perform this order to release the lock pin for the maximum delay angle locking.) NOTE: When the oil splashes, wipe it off with a shop rag. Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your hand. Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released. Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back and forth and check the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 22.5° Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (clockwise).

THERMOSTAT

Note. Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat.

Scheme 209

1. Drain engine coolant so its level is below thermostat.
2. Remove water inlet (A) and thermostat (B).

WATER PUMP

1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump assembly. NOTE: A small amount of "weeping" from the bleed hole is normal.

Scheme 210

1. Immerse the thermostat in water and gradually heat the water.
2. Check the valve opening temperature. Valve opening temperature: 82°C (177°F) Full opening temperature: 95°C (205°F) If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift. Valve lift: M in. 10 mm (0.4 in.) at 95°C (205°F) If the valve lift is not as specified, replace the thermostat.

Scheme 211

1. Install the water pump (A) and a new gasket(1, 2) with 12 bolts. Tightening torque 21.56-23.52 N.m (2.2-2.4 kgf.m, 15.91-17.36 lb-ft) 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) NOTE: Make clean the contact face before assembly. When replacing a water pump, always use new gasket (1, 2). When reassembling a water pump, replace the bolt (B) with a new one.
2. Install the 4 bolts and pump pulley (A). Tightening torque 7.84-9.80 N.m (0.8-1.0 kgf.m, 5.78-7.23 lb-ft)
3. Install drive belt (A).
4. Fill with engine coolant.
5. Start engine and check for leaks.
6. Recheck engine coolant level.

1. Place thermostat in thermostat housing. Install the thermostat with the jiggle valve upward. Install a new thermostat (B).
2. Install water inlet (A). Tightening torque 16.66-19.60 N.m (1.7-2.0 kgf.m, 12.30-14.47 lb-ft)
3. Fill with engine coolant.
4. Start engine and check for leaks.

Scheme 212

1. Install the radiator assembly.
2. Install the cooling fan shroud (A) by connecting cooling fan harness connector (B) and tightening the mounting bolts (C).
3. Install the radiator with the condenser by tightening bolts. Refer to Condenser in «HEATING, VENTILATION AND AIR CONDITIONING»(ref-278799) .
4. Connect the radiator upper hose (A) and lower hose (B) and the automatic transaxle fluid cooler hoses (C).
5. Install the radiator grille upper cover (A).
6. Install the under cover (A).
7. Install the engine cover (A).
8. Refill engine coolant.

Scheme 213

OIL AND FILTER

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Scheme 215

1. Park the car on level ground. Start the engine and let it warm up.
2. Turn the engine off and open the hood. Remove the engine cover.
3. Wait for 5minutes after loosening the oil filter cap by turning it counterclockwise with SST(09263-3C100) to drain well the oil in the oil filter.
4. Drain the engine oil. Remove the oil filler cap. After lifting the car, remove the oil drain plug and drain the oil into a container.
5. Replace oil filter. Disconnect the oil filter cap from oil filter body. Remove the oil filter element. Check and clean the oil filter installation surface. Check the part number of the new oil filter is as same as old one. Install new oil filter element (A) and two new O-rings (B). Apply clean engine oil to the new O-rings. Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat. Finally tighten it again by specified tightening torque. Tightening torque 24.50 N.m (2.5 kgf.m, 18.08 lb-ft) CAUTION: When replacing a oil filter, the water temperature control (WTC) assembly should not be stained with oil.
6. Refill with engine oil. Install the oil drain plug with a new gasket. Tightening torque 34.3-44.1 N.m (3.5-4.5 kgf.m, 25.3-32.5 lb-ft) Fill with fresh engine oil, after remove the engine oil level gauge. Capacity Oil filter: 0.4L (0.42 U.S. qts, 0.35 Imp. qts) Drain and refill: 5.2L (5.49 U.S. qts, 4.58 Imp. qts) Install the oil filler cap and oil level gauge.
7. Start the engine and check to be sure no oil is leaking from the drain plug or oil filter.
8. Recheck engine oil level.

ENGINE OIL

1. Check engine oil quality. Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil.
2. Check engine oil level. After warming up the engine and then 5 minutes after the engine stop, oil level should be between the "L" and "F" marks on the dipstick. If low, check for leakage and add oil up to the "F" mark. NOTE: Do not fill with engine oil above the "F" mark.

SELECTION OF ENGINE OIL

Recommended API classification: Above SJ or SL Recommended SAE viscosity grades: 5W-20

If 5W-20 engine oil is not available, 5W-30 or secondary recommended engine oil for corresponding temperature range can be used.

Scheme 216

Note. For best performance and maximum protection of all types of operation, select only those lubricants which: Satisfy the requirement of the API classification. Have proper SAE grade number for expected ambient temperature range.

Note. Lubricants that do not have both an SAE grade number and API service classification on the container should not be used.

Scheme 217

1. Install oil pump (A). Tightening torque 19.60-23.52 N.m (2.0-2.4 kgf.m, 14.47-17.36 lb-ft) NOTE: Always use a new O-ring.
2. Install oil pump sprocket (A) and oil pump chain on the oil pump. Tightening torque 18.62-21.56 N.m (1.9-2.2 kgf.m, 13.74-15.91 lb-ft)
3. Install oil pump chain cover (A). Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
4. Install upper oil pan. Using a gasket scraper, remove all the old packing material from the gasket surfaces. Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan. The part must be assembled within 5 minutes after the sealant was applied. Bead width: 2.5 mm (0.1 in.) CAUTION: Make clean the sealing face before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant When applying sealant gasket, sealant must not be protruded into the inside of oil pan. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. e. Install upper oil pan. Uniformly tighten the bolts in several passes. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) f. Install the front suspension member. g. After assembly, wait at least 30 minutes before filling the engine with oil.