Kia Rio: Engine Mechanical System

Kia Rio 2017-2020 YB Service Manual / Engine Mechanical System

Specifications

Description		Specification	Limit
General
Type		In-line, DOHC
Number of cylinders		4
Bore		72.0 mm (2.8346 in)
Stroke		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	ATDC 10° - BTDC 60°
Intake valve	Closes	ABDC 74.6° - ABDC 4.6°
Exhaust valve	Opens	BBDC 52.4° - BBDC 12.4°
Exhaust valve	Closes	ATDC 3° - BTDC 43°
Cylinder head
Flatness of gasket surface		Less than 0.05 mm (0.0025 in) Less than 0.02 mm (0.0008 in) / 100 x 100
Flatness of manifold	Intake	Less than 0.1 mm (0.0039 in)
mounting surface	Exhaust	Less than 0.1 mm (0.0039 in)
Camshaft
Cam height	Intake	36.4183 mm (1.4337 in)
Cam height	Exhaust	36.1543 mm (1.4233 in)
Journal outer 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°
Thickness of valve head (margin)	Intake	1.35 - 1.65 mm (0.0531 - 0.0650 in)
Thickness of valve head (margin)	Exhaust	1.60 - 1.90 mm (0.0630 - 0.0748 in)
Valve stem to valve guide clearance	Intake	0.020 - 0.047 mm (0.00078 - 0.00185 in)
Valve stem to valve 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 squareness		1.5° MAX
Cylinder block
Cylinder bore		72.00 - 72.03 mm (2.8346 -2.8358 in)
Flatness of gasket surface		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
Side clearance	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 - 0.0335 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 hole inner diameter		18.013 - 18.017 mm (0.7092 - 0.7093 in)
Piston pin hole clearance		0.010 - 0.017 mm (0.00039 - 0.00067 in)
Connecting rod small end hole inner diameter		17.974 - 17.985 mm (0.7076 - 0.7474 in)
Connecting rod small end hole clearance		0.015 - 0.029 mm (0.00059 - 0.00114 in)
Piston pin press-in 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 include big hole expansion deformation		0.027 - 0.052 mm (0.0011 - 0.0020 in)
Side clearance		0.1 - 0.25 mm (0.0039 - 0.0098 in)
Crankshaft
Main journal outer diameter		47.942 - 47.960 mm (18875-1.8882 in)
Pin journal 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 include big hole expension deformation		0.021 - 0.039 mm (0.0008 - 0.0015 in)
End play		0.07 - 0.25 mm (0.0028-0.0098 in)
Engine oil
Oil quantity	Total	3.55 L (0.94 U.S.gal., 3.75 U.S.qt., 3.12 lmp.qt.)	When replacing a short engine or a block assembly
	Oil pan	3.3 L (0.87 U.S.gal., 3.48 U.S.qt., 2.90 lmp.qt.)
	Drain and refill	3.5 L (0.92 U.S.gal., 3.70 U.S.qt., 3.08 lmp.qt.)	Including oil filter
Oil grade	Recommended	For Europe, Australia, General export, Central & South America - API SN & ACEA C2 / 0W-20 For India, Middle east, Iran, Libia, Algeria, Sudan, Moroco, Tunisia Egypt - API SM & ILSAC GF-4 / 5W-30 - ACEA A5/B5 / 5W-30
Oil grade	Allowed	- API SL or above - ILSAC GF-3 or above - ACEA A3/B3 or A3/B4 For information on SAE viscosity grades based on ambient temperatures, refer to the “Lubrication System”.	Usable if the recommended engine oil is not available
Oil pressure (at 1000rpm)		90 kPa (0.9 kg/cm², 13.05 psi)	Oil temperature in oil pan : 110±2°C (230± 3.6°F)
Cooling method
Cooling system		Forced circulation with water pump
Coolant quantity		MT : Approx. 5.1 L (1.35 U.S.gal., 5.39 U.S.qt., 4.49 lmp.qt.) AT : Approx. 5.5 L (1.45 U.S.gal., 5.81 U.S.qt., 4.84 lmp.qt.)
Thermostat	Type	Wax pellet type
	Opening temperature	88 ± 1.5 °C (190.4 ± 2.7°F)
	Full opening 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)
Water temperature sensor
Type		Thermistor type
Resistance	20°C (68°F)	2.45 ± 0.14 kΩ
Resistance	80°C (176°F)	0.3222 kΩ

Tightening Torques

Item	N·m	kgf·m	lb·ft
Engine mounting
Engine mounting bracket and body fixing blots	49.0 - 63.7	5.0 - 6.5	36.2 - 47.0
Engine mounting bracket and body fixing nut	49.0 - 63.7	5.0 - 6.5	36.2 - 47.0
Engine mounting insulator to engine mounting support bracket fixing nut	88.3 - 107.9	9.0 - 11.0	65.1 - 79.6
Engine mounting support bracket and engine support bracket fixing bolt	58.8 - 73.5	6.0 - 7.5	43.4 - 54.2
Engine mounting support bracket and engine support bracket fixing nuts	58.8 - 73.5	6.0 - 7.5	43.4 - 54.2
Transaxle mounting bracket and body fixing bolts	49.0 - 63.7	5.0 - 6.5	36.2 - 47.0
Transaxle mounting bracket and body fixing nut	49.0 - 63.7	5.0 - 6.5	36.2 - 47.0
Transaxle mounting insulator and transaxle support bracket fixing bolts	88.3 - 107.9	9.0 - 11.0	65.1 - 79.6
Roll rod bracket and sub frame fixing bolts	49.0 - 63.7	5.0 - 6.5	36.1 - 47.0
Roll rod bracket to roll rod support bracket fixing 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°]
Fly wheel bolts (M/T)	68.6 - 78.5	7.0 - 8.0	50.6 - 57.9
Drive plate bolts (A/T)	68.6 - 78.5	7.0 - 8.0	50.6 - 57.9
Drive Belt System
Drive bealt 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°
Timing 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 cam guide bolts	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Timing chain crank guide boltss	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
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
Camshaft front bearing cap 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°]
Intake CVVT OCV bolt	85.3 - 95.1	8.7 - 9.7	62.9 - 70.2
Exhaust CVVT 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 & nut	19.6 - 26.5	2.0 - 2.7	14.5 - 19.5
Thermostat housing bolt & nuts	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Water inlet fitting bolt & nut	18.6 - 23.5	1.9 - 2.4	13.7 - 17.3
Water temperature control assembly bolts & 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 switch	7.8 - 11.8	0.8 - 1.2	5.8 - 8.7
Intake and Exhaust system
Intake manifold bolts & nuts	18.6 - 23.5	1.9 - 2.4	13.7 - 17.4
Exhaust manifold stay bolts	39.2 - 49.0	4.0 - 5.0	28.9 - 36.2
Exhaust manifold heat protector 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 and catalytic converter & center nuts	39.2 - 58.8	4.0 - 6.0	28.9 - 43.4
catalytic converter & center muffler and rear muffler nuts	39.2 - 58.8	4.0 - 6.0	28.9 - 43.4

Torque-to-yield cylinder head, connecting rod cap and crankshaft main bearing cap bolts must be replaced once removed because the bolts are designed to be permanently elongated beyond the state of elasticity when torqued. If removed bolts are reused, the bolts may break or fail to maintain clamping force.

Special service tools

Special Service Tools

Tool Name / Number	Illustration	Description
Ring gear 09231-3N100 09231-2B100		Used for keeping ring gear from rotating when removing / installing crankshaft pulley bolt
Valve stem seal installer 09222-03100		Used for installing valve stem seal
Valve spring compressor & holder 09222-3K000 (Compressor) 09222-3K100 (Handle)		Used for removing / installing intake or exhaust valve
Crankshaft front oil seal installer 09214-1R000 (Installer) 09231-H1100 (Handle)		Used for installing crankshaft front oil seal
Crankshaft rear oil seal installer 09214-03100 (Installer) 09231-H1100 (Handle)		Used for installing crankshaft rear oil seal
Oil pan remover 09215-3C000		Used for removing oil pan
Oil filter wrench 09263-02000		Used for removing / installing oil filter

Repair procedures

Compression Pressure Inspection

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

1.	Start the engine and allow to warm up to operating temperature. (about five minutes) Stop the engine.

2.	Remove the ignition coil. (Refer to Engine Electrical System - "Ignition Coil")

3.	Remove the spark plugs. (Refer to Engine Electrical System - "Spark Plug")

Check the cylinder compression pressure.

(1)	Insert a compression gauge into the spark plug hole.

(2)	Fully open throttle.

(3)

While cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 250rpm or more.

(4)

Repeat step (1) through (3) for each cylinder.

This measurement must be done in as short atime as possible

Compression pressure :

1,373 kPa (14.0 kg/cm², 199.0 psi)

Minimum pressure :

1,226 kPa (12.5 kg/cm², 178.0 psi)

Difference between each cylinder :

98 kPa (1.0 kg/cm², 14 psi) or less

(5)

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 step (1) through (3) 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.

Reinstall the spark plugs.

Tightening torque :

14.7 - 24.5 N·m (1.5 - 2.5 kgf·m, 10.8 - 18.1 lb·ft)

6.	Connect the injector connectors.

Install the ignition coil.

Tightening torque :

9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

8.	Connect the ignition coil connectors.

9.	Some DTC's may exist after the inspection test and may need to be manually cleard with GDS.

Troubleshooting

Symptom

Suspect area

Remedy

Engine misfire with abnormal internal lower engine noises.

Worn crankshaft bearings.
Loose or damaged engine drive plate.

Replace the crankshaft and bearings as required.
Repair or replace the drive plate as required.

Worn piston rings.
(Oil consumption may or may not cause the engine to misfire.)

Inspect the cylinder for a loss of compression.Repair or replace as required.

Worn crankshaft thrust bearings

Replace the crankshaft and bearings as required.

Engine misfire with abnormal valve train noise.

Stuck valves.
(Carbon buildup on the valve stem)

Repair or replace as required.

Excessive worn or mis-aligned timing chain.

Replace the timing chain and sprocket as required.

Worn camshaft lobes.

Replace the camshaft and valve lifters.

HLA sponge

Run the engine at 2500-3000rpm within 15 minutes.
If it dosen't disappear, refer to cylinder head assembly in this group.

Engine misfire with coolant consumption.

•	Faulty cylinder head gasket and/or cranking or other damage to the cylinder head and engine block cooling system.

•	Coolant consumption may or may not cause the engine to overheat.

•	Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket.

•	Repair or replace as required.

Engine misfire with excessive oil consumption.

Worn valves, guides and/or valve stem oil seals.

Repair or replace as required.

Worn piston rings.
(Oil consumption may or may not cause the engine to misfire)

•	Inspect the cylinder for a loss of compression.

•	Repair or replace as required.

Engine noise on start-up, but only lasting a few seconds.

Incorrect oil viscosity.

•	Drain the oil.

•	Install the correct viscosity oil.

Worn crankshaft thrust bearing.

•	Inspect the thrust bearing and crankshaft.

•	Repair or replace as required.

Upper engine noise, regardless of engine speed.

Low oil pressure.

Repair or replace as required.

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 applicable.

Replace the timing chain tensioner as required.

Worn camshaft lobes.

•	Inspect the camshaft lobes.

•	Replace the timing camshaft and valve lifters as required.

Worn valve guides or valve stems.

Inspect the valves and valve guides, then repair as required.

Stuck valves.Carbon on the valve stem or valve seat may cause the valve to stay open.

Inspect the valves and valve guides, then repair as required.

Worn drive belt, idler, tensioner and bearing.

Replace as required.

Lower engine noise, regardless of engine speed.

Low oil pressure.

Repair as required.

Loose or damaged drive plate.

Repair or replace the drive plate.

Damaged oil pan, contacting the oil pump screen.

•	Inspect the oil pan.

•	Inspect the oil pump screen.

•	Repair or replace as required.

Oil pump screen loose, damaged or restricted.

•	Inspect the oil pump screen.

•	Repair or replace as required.

Excessive piston-to-cylinder bore clearance.

•	Inspect the piston, piston pin and cylinder bore.

•	Repair as required.

Excessive piston pin-to-piston clearance.

•	Inspect the piston, piston pin and the connecting rod.

•	Repair or replace as required.

Excessive connecting rod bearing clearance

Inspect the following components and repair as required.

•	The connecting rod bearings.

•	The connecting rods.

•	The crankshaft pin journals.

Excessive crankshaft bearing clearance.

Inspect the following components, and repair as required.

•	The crankshaft bearings.

•	The crankshaft main journals.

•	The cylinder block.

Incorrect piston, piston pin and connecting rod installation

•	Verify the piston pins and connecting rods are installed correctly.

•	Repair as required.

Engine noise under load.

Low oil pressure

Repair or replace as required.

Excessive connecting rod bearing clearance .

Inspect the following components and repair as required :

•	The connecting rod bearings.

•	The connecting rods.

•	The crankshaft.

Excessive crankshaft bearing clearance.

Inspect the following components, and repair as required.

•	The crankshaft bearings.

•	The crankshaft main journals.

•	The cylinder block.

Engine will not crank-crankshaft will not rotate.

Hydraulically locked cylinder.

•	Coolant/antifreeze in cylinder.

•	Oil in cylinder.

•	Fuel in cylinder.

•	Remove spark plugs and check for fluid.

•	Inspect for broken head gasket.

•	Inspect for cracked engine block or cylinder head.

•	Inspect for a sticking fuel injector and/or leaking fuel regulator.

Broken timing chain and/or timing chain and/or timing chain gears.

•	Inspect timing chain and gears.

•	Repair as required.

Material in cylinder.

•	Broken valve

•	Piston material

•	Foreign material

•	Inspect cylinder for damaged components and/or foreign materials.

•	Repair or replace as required.

Seized crankshaft or connecting rod bearings.

•	Inspect crankshaft and connecting rod bearing.

•	Repair as required.

Bent or broken connecting rod.

•	Inspect connecting rods.

•	Repair as required.

Broken crankshaft.

•	Inspect crankshaft.

•	Repair as required.

Cooling System

Cylinder Block

Cylinder Head Assembly

Drive Belt System

Engine And Transaxle Assembly

Intake And Exhaust System

Lubrication System

Timing System

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