Home/Kia/Sportage/Kia Sportage II (2004-2008)/Repair manual/Mechanical/General - 2.0L Engine: Specifications

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Wiring diagrams Section: Mechanical

Engine and Transaxle Assembly - 2.7L

Intake System and Exhaust System - 2.7L

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General - 2.0L Engine: Specifications Kia Sportage II

Mechanical

SPECIFICATIONS

Description		Specifications (2.0 CVVT)	Limit
General
Type		In-line, DOHC
Number of cylinders		4
Bore		82mm (3.2283in)
Stroke		93.5mm (8.6811 in)
Total displacement		1,975 cc (120.5 cu.in)
Compression ratio		10.1: 1
Firing order		1-3-4-2
Valve timing
Intake valve	Opens (ATDC)	11°
Intake valve	Closes (ABDC)	59°
Exhaust valve	Opens (BBDC)	42°
Exhaust valve	Closes (ATDC)	6°
Cylinder head
Flatness of gasket surface		Less than 0.03mm (0.0012in)	0.06mm (0.0024in)
Flatness of manifold mounting surface	Intake	Less than 0.15mm (0.0059in)	0.30mm (0.0118in)
Flatness of manifold mounting surface	Exhaust	Less than 0.15mm (0.0059in)	0.30mm (0.0118in)
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	33.000 ~ 33.025mm (1.2992 ~ 1.3002in)
	0.3 OS	33.300 ~ 33.325mm (1.3110 ~ 1.3120in)
	0.6 OS	33.600 ~ 33.625mm (1.3228 ~ 1.3238in)
Exhaust valve seat ring hole diameter	STD	28.500 ~ 28.521mm (1.1220 ~ 1.1229in)
	0.3 OS	28.800 ~ 28.821mm (1.1339 ~ 1.1347in)
	0.6 OS	29.100 ~ 29.121mm (1.1457 ~ 1.1465in)

GENERAL SPECIFICATIONS

Description		Specifications (2.0 CVVT)	Limit
Camshaft
Cam height	Intake	44.518 ~ 44.718mm (1.7527 ~ 1.7605in)
Cam height	Exhaust	44.418 ~ 44.618mm (1.7487 ~ 1.7566in)
Journal outer Diameter (Intake, Exhaust)		27.964 ~ 27.980mm (1.1009 ~ 1.1016in)
Bearing 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	114.34mm (4.5016in)
Valve length	Exhaust	116.8mm (4.5984in)
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	1.15mm (0.0453in)	0.8mm (0.0315in)
Thickness of Valve head (margin)	Exhaust	1.35mm (0.0531 in)	1.0mm (0.0394in)
Valve stem to Valve guide clearance	Intake	0.020 ~ 0.050mm (0.0008 ~ 0.0020in)	0.10mm (0.0039in)
Valve stem to Valve guide clearance	Exhaust	0.035 ~ 0.065mm (0.0014 ~ 0.0026in)	0.13mm (0.0051 in)
Valve guide
Length	Intake	45.8 ~ 46.2mm (1.8031 ~ 1.8189in)
Length	Exhaust	54.3 ~ 54.6mm (2.1378 ~ 2.1496in)
Valve seat
Width of seat contact	Intake	1.1 ~ 1.5mm (0.0433 ~ 0.0591 in)
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		48.86mm (1.9236in)
Load		18.8+/-0.9kg/39.0mm (41.4+/-2.0 lb/1.5354in)
Load		41.0+/-1.5kg/30.5mm (90.4+/-3.3 lb/1.2008in)
Out of squareness		Less than 1.5°	3°
Valve clearance
Cold (20°C +/- 5°C) (68°F +/- 9°F)	Intake	0.20mm (0.0079in)	0.12~0.28mm (0.0047~0.0110in)
Cold (20°C +/- 5°C) (68°F +/- 9°F)	Exhaust	0.28mm (0.0110in)	0.20~0.38mm (0.0079~0.0150in)
Cylinder block
Cylinder bore		82.00 ~ 82.03mm (3.2283 ~ 3.2295in)
Flatness of gasket surface		Total: Less than 0.05mm (0.0020in) Bore to bore: Less than 0.03mm (0.0012in)
Piston
Piston outer diameter		81.970 ~ 82.000mm (3.2272 ~ 3.2283in)
Piston to cylinder clearance		0.020 ~ 0.040mm (0.0008 ~ 0.0016in)
Ring groove width	No. 1 ring groove	1.23 ~ 1.25mm (0.0484 ~ 0.0492in)
	No. 2 ring groove	1.22 ~ 1.24mm (0.0480 ~ 0.0488in)
	Oil ring groove	2.51 ~ 2.53mm (0.0988 ~ 0.0996in)
Piston ring
Side clearance	No. 1 ring	0.04 ~ 0.08mm (0.0016 ~ 0.0031 in)	0.1mm (0.0039in)
	No. 2 ring	0.03 ~ 0.07mm (0.0012 ~ 0.0028in)	0.1mm (0.0039in)
	Oil ring	0.06 ~ 0.15mm (0.0024 ~ 0.0059in)	0.2mm (0.0079in)
End gap	No. 1 ring	0..23 ~ 0.38mm (0.0091 ~ 0.0150in)	1.0mm (0.0394in)
	No. 2 ring	0.33 ~ 0.48mm (0.0130 ~ 0.0189in)	1.0mm (0.0394in)
	Oil ring	0.20 ~ 0.60mm (0.0079 ~ 0.0236in)	1.0mm (0.0394in)
Piston pin
Piston pin outer diameter		20.001 ~ 20.006mm (0.7874 ~ 0.7876in)
Piston pin hole inner diameter		20.016 ~ 20.021mm (0.7880 ~ 0.7882in)
Piston pin hole clearance		0.010 ~ 0.020mm (0.0004 ~ 0.0008in)
Connecting rod small end hole inner diameter		19.974 ~ 19.985mm (0.7864 ~ 0.7868in)
Connecting rod small end hole clearance		0.032 ~ -0.016mm (-0.0013 ~ -0.0006in)
Piston pin press-in load		350~1,350 kg (772~2,976 lb)
Connecting rod
Connecting rod big end inner diameter		48.000 ~ 48.018mm (1.8898 ~ 1.8905in)
Connecting rod bearing oil clearance		0.024 ~ 0.044mm (0.0009 ~ 0.0017in)
Side clearance		0.10 ~ 0.25mm (0.0039 ~ 0.0098in)	0.4mm (0.0157in)
Crankshaft
Main journal outer diameter		56.942 ~ 56.962mm (2.2418 ~ 2.2426in)
Pin journal outer diameter		44.946 ~ 44.966mm (1.7695 ~ 1.7703in)
Main bearing oil clearance		0.028 ~ 0.048mm (0.0011 ~ 0.0019in)	0.1mm (0.0039in)
End play		0.06 ~ 0.260mm (0.0024 ~ 0.0102in)	0.3mm (0.0118in)
Flywheel
Runout		0.1mm (0.0039in)	0.13mm (0.0051 in)
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		0.120 ~ 0.185mm (0.0047 ~ 0.0073in)
Relief valve opening pressure		490+/-49.0kpa(5+/-0.5kg/cm 2 , 71 +/-7.1 psi)
Relief spring	Free length	43.8mm (1.7244in)
Relief spring	Load	3.7+/-0.4kg/40.1mm (8.2+/-0.9 lb/1.5787in) 9.7+/-0.4kg/34.3mm (21.4+/-0.9 lb/1.3504in)
Engine oil
Oil quantity (Total)		4.0 L (4.23 US qt, 3.52 lmp qt)
Oil quantity (Oil pan)		3.7 L (3.91 US qt, 3.26 lmp qt)
Oil quantity (Oil filter)		0.3 L (0.32 US qt, 0.26 lmp qt)
Oil quality		Above SL, SJ
Oil pressure (Idle)		156.9kpa (1.6kg/cm 2 , 22.8psi)
Cooling system
Cooling method		Forced circulation with cooling fan
Coolant quantity		6.0 L (6.34 US qt, 5.28 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 kohm
Resistance	80°C (176°F)	0.3222 kohm

GENERAL SPECIFICATIONS

TIGHTENING TORQUE

Item	Quantity	Tightening torque
Item	Quantity	N.m	Kgf.m	Lb-ft
Cylinder block
Engine support (front) bracket bolt	3	34.3 ~ 49.0	3.5 ~ 5.0	25.3 ~ 36.2
Engine support (rear) bracket bolt	2	34.3 ~ 49.0	3.5 ~ 5.0	25.3 ~ 36.2
Engine support bracket stay plate bolt	1	42.2 ~ 53.9	4.3 ~ 5.5	31.1 ~ 39.8
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	58.8 ~ 78.5	6.0 ~ 8.0	43.4 ~ 57.9
Engine mounting support bracket and engine support bracket fixing bolt	1	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Engine mounting support bracket and engine support bracket fixing nut	2	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Transaxle mounting bracket and body fixing bolt	4	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Transaxle mounting insulator and transaxle support bracket fixing bolt	1	88.3 ~ 107.9	9.0 ~ 11.0	65.1 ~ 79.6
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	49.0 ~ 52.0	5.0 ~ 5.3	36.2 ~ 38.3
Crankshaft main bearing cap bolt	10	27.5~31.4+60°~64°	2.8~3.2+60°~64°	20.3~23.1+60°~64°
Flywheel bolt (M/T)	6	117.7 ~ 127.5	12.0 ~ 13.0	86.8 ~ 94.0
Drive plate bolt (A/T)	6	117.7 ~ 127.5	12.0 ~ 13.0	86.8 ~ 94.0
Timing belt
Timing belt upper cover bolt	4	7.8 ~9.8	0.8 ~1.0	5.8 ~7.2
Timing belt lower cover bolt	5	7.8 ~9.8	0.8 ~1.0	5.8 ~7.2
Timing belt under cover bolt	3	9.8 ~11.8	1.0 ~1.2	7.2 ~8.7
Crankshaft pulley bolt	1	166.7 ~176.5	17.0 ~18.0	123.0 ~130.2
Camshaft sprocket bolt	1	98.1 ~117.7	10.0 ~12.0	72.3 ~86.8
Timing belt tensioner bolt	1	42.2 ~53.9	4.3 ~5.5	31.1 ~39.8
Timing belt idler bolt	1	42.2 ~53.9	4.3 ~5.5	31.1 ~39.8
Cylinder head
Engine cover bolt	5	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	22	13.7 ~14.7	1.4 ~1.5	10.1 ~10.8
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 X 99)	8	22.6~26.5+60°~65°+60°~65°	2.3~2.7+60°~65°+60°~65°	16.6~19.5+60°~65°+60°~65°
Cylinder head bolt (12 X 151)	2	27.5~31.4+60°~65°+60°~65°	2.8~3.2+60°~65°+60°~65°	20.3~23.1+60°~65°+60°~65°
Cooling system
Water pump pulley bolt	4	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Water pump bolt (8 X 20)	1	11.8 ~ 14.7	1.2 ~ 1.5	8.7 ~ 10.8
Water pump bolt (8 X 35)	2	11.8 ~ 14.7	1.2 ~ 1.5	8.7 ~ 10.8
Water pump and alternator brace fixing bolt (8 X 45)	2	19.6 ~ 26.5	2.0 ~ 2.7	14.5 ~ 19.5
Alternator brace and cylinder block fixing bolt	2	11.8 ~ 14.7	1.2 ~ 1.5	8.7 ~ 10.8
Thermostat housing bolt	1	14.7 ~ 19.6	1.5 ~ 2.0	10.8 ~ 14.5
Thermostat housing nut	1	14.7 ~ 19.6	1.5 ~ 2.0	10.8 ~ 14.5
Water temperature sensor	1	19.6 ~ 39.2	2.0 ~ 4.0	14.5 ~ 28.9
Water inlet fitting nut	2	14.7 ~ 19.6	1.5 ~ 2.0	10.8 ~ 14.5
Lubrication system
Oil filter	1	11.8 ~ 15.7	1.2 ~ 1.6	8.7 ~ 11.6
Front case bolt (8 X 20)	4	19.6 ~ 26.5	2.0 ~ 2.7	14.5 ~ 19.5
Front case bolt (8 X 25)	1	19.6 ~ 26.5	2.0 ~ 2.7	14.5 ~ 19.5
Front case bolt (8 X 38)	1	19.6 ~ 26.5	2.0 ~ 2.7	14.5 ~ 19.5
Front case bolt (8 X 45)	2	19.6 ~ 26.5	2.0 ~ 2.7	14.5 ~ 19.5
Oil pan bolt (6 X 16)	15	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Oil pan bolt (6 X 50)	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Oil pan bolt (6 X 118)	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Oil pan and transaxle fixing bolt	3	29.4 ~ 41.2	3.0 ~ 4.2	21.7 ~ 30.4
Oil pan drain bolt	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
Intake and exhaust system
Intake manifold and cylinder head fixing nut	9	15.7 ~ 22.6	1.6 ~ 2.3	11.6 ~ 16.6
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	42.2 ~ 53.9	4.3 ~ 5.5	31.1 ~ 39.8
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	4	16.7 ~ 21.6	1.7 ~ 2.2	12.3 ~ 15.9
Air cleaner assembly fixing bolt	3	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Throttle body and surge tank fixing bolt	4	18.6 ~ 27.5	1.9 ~ 2.8	13.7 ~ 20.3
Exhaust manifold and front muffler fixing bolt	2	39.2 ~ 58.8	4.0 ~ 6.0	28.9 ~ 43.4
Front muffler fixing clip bolt	1	29.4 ~ 39.2	3.0 ~ 4.0	21.7 ~ 28.9
Front muffler and center muffler fixing nut	2	39.2 ~ 58.8	4.0 ~ 6.0	28.9 ~ 43.4
Center muffler and main muffler fixing nut	2	39.2 ~ 58.8	4.0 ~ 6.0	28.9 ~ 43.4

TIGHTENING TORQUE SPECIFICATIONS