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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Sportage (1999 release)

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Kia Sportage
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Introduction
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Engine
Check compression pressure assessment cylinders
Checking the engine by means of the vacuum gauge
Accessory drive belt
Petrol models
Diesel models
System of cooling, heating, ventilation and air conditioning
The power supply system, motor control / emission control and exhaust
Systems of an electric motor
A five-speed manual gearbox gear
Automatic Transmission
Transmission Line
Brakes
Suspension and steering
Body
Onboard electric
The control body dimensions
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Engine



Specifications

The following are the parameters used when performing the described procedures in this chapter. Detailed regulatory information can be found on branded service stations KIA. Separate characteristics are resulted also in the text of the chapter and in the case of compulsion of their performance are highlighted in bold.

Listed below are the only values that are typical for all engines considered series.

Petrol models

Common parameters

engine's type FE - in-line, 4-cylinder, 16-valve, DOHC, water-cooled, and the timing belt
Location in the engine compartment Longitudinal
Engine volume, l 20
Number of valves per cylinder 4
Bore x stroke mm 86.0 x 86.0
Compression ratio 9.2: 1
The pressure of compression at 250 revs per minute, kgf / cm2
  • Nominal value
13.0
  • The limit value (approximately)
9.61
  • The maximum allowable difference in readings between cylinders
15
Operating procedure of cylinders 1-3-4-2
Idling speed, min -1 820 ? 50
Ignition timing 4 ? ? 2 ? before TDC
Amount of deflection accessory drive belt under the load of 10 kgf, mm
  • Generator belt / belt drive cooling fan
    • New
11.5 ÷ 14.0
    • Second-hand
15 ÷ 16
  • Belt compressor K / V
    • New
4 ÷ 5
    • Second-hand
5 ÷ 6
  • Belt steering pump
    • New
6 ÷ 7
    • Second-hand
8 ÷ 10

Lubrication system

Type Pressurized, with an oil cooler and piston spray
The type and amount of motor oil See. Specifications to the Head Current leaving and service
Pressure warning lamp activation, kgf / cm2 0.25
Oil filter
Type Full flow with the paper work item
Differential pressure reducing pressure 0.8 ÷ 1.2
Oil pump
  • Type. Rotary, trochoidal
  • Oil pressure, kgf / cm2
3.0 ÷ 4.0 (at 3000 rev / min)
  • Opening pressure reducing valve, kgf / cm2
3.0 ÷ 4.0
  • The free length of the plunger spring, mm
45.5
  • Checks (see.
    • Maximum permissible value of the axial backlash gears, mm
0.10
    • Maximum allowable size of the gap, mm between the tops of the teeth of gears, mm
0.18
    • Reserve permissible amount of movement of the outer rotor landing in the working chamber of the pump housing, mm
0.20

Cylinder head

Casting

Height mm 133.96 ÷ 134.06
Maximum permissible value of flatness of mating surfaces (all surfaces) * mm 0.15

* The depth of the groove should not exceed 0.20 mm, otherwise the head to be replaced

Valve seats

The geometrical parameters (see.
  • Corner of a working facet (all valves), degrees
45
  • The width of the contact zone (all valves), mm
1.19 ÷ 1.60

Valves, valve springs, guides

Valves
  • Timing
    • The intake valves
      • Opening
10 ? before TDC
      • Closing
55 ? after BDC
  • The exhaust valves
      • Opening
55 ? before BDC
      • Closing
10 ? ATDC
The geometrical parameters of the valve (see.
  • Corner of a working facet (all valves), degrees
45
  • The diameter of the rod, mm
No data available
  • The diameter of the valve head, mm
No data available
  • Minimum permissible width of the cylindrical part of the plate, mm
    • The intake valves
0.84
    • The exhaust valves
0.89
  • The minimum allowable length (processing limit) mm
    • The intake valves
103.18
    • The exhaust valves
103.94
  • Installation height (distance from the end of the set before the valve spring plate) * mm
    • The intake valves
      • Nominal value
36.37 ÷ 37.27
      • The limit value
37.97
    • The exhaust valves
      • Nominal value
36.36 ÷ 37.26
      • The limit value
37.96
  • Backlash of landing in the guide sleeve, mm
    • Nominal value
      • The intake valves
0.025 ÷ 0.061
      • The exhaust valves
0.030 ÷ 0.066
    • The limit value
0.201

* When adjusting the height of the valve is outside the nominal range, but does not exceed the limit value, a corresponding adjustment can be made by adjusting the spring washers on the plate, otherwise the head must be replaced.

Guide bushings
  • Inner diameter (all valves), mm
6.01 ÷ 6.03
    • The intake valves
40.5
    • The exhaust valves
37.6
  • Installation height (distance from the end of the sleeve to the fork spring), mm
    • All valves
11.40 ÷ 11.91
Valve spring
  • Free length (all valves), mm
    • An internal spring
      • Nominal value
38.00
      • The limit value
37.69
    • External spring
      • Nominal value
39.09
      • The limit value
38.71
  • Maximum permissible value violations trimming (all valves), mm
    • An internal spring
No data available
    • External spring
1.35

Valve tappets

Type Hydraulic, with automatic valve clearance compensators

Camshafts

Operating clearance in the bearings, mm 0.036 ÷ 0.084
The height of the cams, mm
  • Nominal value
45,052
  • The limit value
44,851
Bearing neck (see.
  • Diameter, mm
29.939 ÷ 29.964
  • Limit values roundness and taper, mm
0.05

Cylinder block

Casting

Maximum permissible value of flatness mating surface *, mm 0.15
Number of cylinders 4, in-line
Bore, mm
  • Nominal value
85.999 ÷ 86.020
  • Limit values roundness and taper, mm
0.018

* The depth of the groove should not exceed 0.20 mm, otherwise the block must be replaced

Crankshaft and main bearings

Crankshaft end play mm
  • Nominal value
0.079 ÷ 0.180
  • The limit value
0.30
Maximum permissible value of the radial runout of the crankshaft, mm 0.03
Diameter of radical necks, mm
  • Standard size
    • Nominal value
59.936 ÷ 59.954
    • 1st repair size (0.25 mm)
      • Cervical ?? 1, 2, 4 and 5
59.693 ÷ 59.710
      • Sheika number 3
59.687 ÷ 59.705
    • 2nd repair size (0.50 mm)
      • Cervical ?? 1, 2, 4 and 5
59.444 ÷ 59.461
      • Sheika number 3
59.436 ÷ 59.454
    • 3rd oversize (0.75 mm)
      • Cervical ?? 1, 2, 4 and 5
59.192 ÷ 59.210
      • Sheika number 3
59.187 ÷ 59.205
Working backlash in radical bearings, mm
  • Nominal value
    • Cervical ?? 1, 2, 4 and 5
0.025 ÷ 0.043
    • Sheika number 3
0.030 ÷ 0.048
  • The limit value
0.080
Diameter crankpins, mm 50.940 ÷ 50.955
Maximum permissible value of the taper and ovality of necks, mm
  • And crankpins
0.005

The connecting rods and connecting rod bearings

The diameter of the holes in the lower head of the connecting rod, mm No data available
The inner diameter of the sleeve upper crosshead, mm 21.989 ÷ 21.999
Maximum allowable amount of bending and twisting of the rod rod length of 50 mm, mm
  • Bend
0.074
  • Twisting
0.201
Axial backlash of rods on the crankshaft, mm
  • Nominal value
0.10 ÷ 0.28
  • The limit value
0.30
Working backlash in radical bearings, mm
  • Nominal value
0.05 ÷ 0.23
  • The limit value
0.08

The pistons and piston pins and rings

Pistons
  • Diameter, mm
85.943 ÷ 85.964
  • Luft landing cylinder, mm
    • Nominal value
0.048 ÷ 0.061
    • The limit value
0.15
Piston fingers
  • Diameter, mm
21.987 ÷ 21.999
  • Luft landing in pistons, mm
0.005 ÷ 0.10
  • Luft landing rods mm
0.010 ÷ 0.025
Piston rings
  • Luft landing compression rings in the grooves of pistons, mm
    • Nominal values
0.025 ÷ 0.076
    • The limit value
0.15
  • End gap, mm
    • Nominal value
      • The upper compression ring (? 1)
0.15 ÷ 0.30
      • The second compression ring
0.20 ÷ 0.36
      • Scraper ring
0.20 ÷ 0.71
    • The limit value
10

Efforts of a tightening of carving connections, Nanometer

Efforts of a tightening of certain fastener elements can be shown directly in the section where they are highlighted in bold.


Bolts Timing covers 10
Bolt crankshaft gear 162
Bolts gears camshafts 56
Timing belt tensioners 43
Bolts cylinder head cover 7
Cylinder head bolts 84
Bolts / nuts of the inlet pipeline 22
Bolts intake manifold support bracket 45
Nuts of fastening of a final collector 42
Bolts thermofilter exhaust manifold 25
Nuts of fastening of the tread of the exhaust manifold 4
Bolts of a pulley / vibration damper Crankshaft 15
Bolt CMP sensor 10
Bolts of covers of bearings of camshafts 22
Lubricators in the cylinder block 15
Bolts main bearing caps of the crankshaft 85
Nuts caps bottom heads of rods 67
Bolts rear engine cover 10
Bolts of fastening of the oil pump assembly
  • A bolts (8 mm)
22
  • The bolts (10 mm)
44
Screws oil pump 7.5
Bolts sump 9.5
Bolts maslozabornika assembly with strainer (see. 9.5
Flywheel bolts 99.5
Bolts clutch 22
Bolts dome clutch / torque converter
  • 14 mm
108
  • 10 mm
38
  • 6 mm
7
Bolts of fastening of the water pump 22
Mounting bolts of the cooling fan 8
Bolts cooling fan assembly 37
Nuts of fastening of the fan wheel cooling system 22
Bolts thermostat 22
Support bracket generator 45
Bolts / Nuts support the suspension of the power unit 38
Bolt the motor to the ground bus body 25
Bolts protection crankcase

Diesel models

Listed below are the only values that are typical for all engines considered series.

Common parameters

engine's type RF TCI - line 4 - cylinder, 8 - valve OHC, water-cooled, and the timing belt, turbocharged with intercooler (Intercooler) forced air
Location in the engine compartment Longitudinal
Engine volume, l 20
Number of valves per cylinder 2
Bore x stroke mm 86.0 x 86.0
Compression ratio 21.1: 1
The pressure of compression at 200 revs per minute, kgf / cm2
  • Nominal value
thirty
  • The limit value (approximately)
27
  • The maximum allowable difference in readings between cylinders
thirty
Operating procedure of cylinders 1-3-4-2
Moments injection 11 ? after TDC
The injection pressure, kgf / cm2 150
Idling speed, min -1 800 ? 25
Amount of deflection accessory drive belt under the load of 10 kgf, mm
Generator belt / belt drive cooling fan
  • New
11.5 ÷ 14.0
  • Second-hand
15 ÷ 16
Belt compressor K / V
  • New
4 ÷ 5
  • Second-hand
5 ÷ 6
Belt steering pump
  • New
6 ÷ 7
  • Second-hand
8 ÷ 10

Lubrication system

Type Pressurized, with an oil cooler and piston spray
The type and amount of motor oil See. Specifications to the Head Current leaving and service
Oil pressure, kgf / cm2 4.1 ÷ 4.9 (at 3000 rev / min)
Pressure warning lamp activation, kgf / cm2 0.3
Oil filters
  • Type
Full flow with paper work items
  • Opening pressure reducing valve, kgf / cm2
10
Oil Cooler
  • Type
Water-cooled
  • Opening pressure reducing valve, kgf / cm2
20
Oil pump
  • Type
Gear with sickle insert
  • Checks (see.
    • Opening pressure control valve, kgf / cm2
5.7
    • Maximum permissible value of the axial backlash gears, mm
0.15
    • Maximum allowable size of the gap between the tops of the gear teeth and the crescent insert, mm
0.35
    • Maximum permissible amount of movement of the outer landing gear in the working chamber, mm
0.20

Cylinder head

Casting

Maximum permissible value of flatness of mating surfaces (see. mm
  • Mating surface with the cylinder block
    • Long (longitudinal and diagonal) measurements
0.05
    • Short (transverse) measurements
0.02
  • Surface mating with the intake manifold and the exhaust manifold
0.20
Maximum allowable amount of protrusion of the liner of the combustion chamber (see. mm 0.05
Maximum allowable depth of planting the liner of the combustion chamber (see. mm 0.04
The length of the cylinder head bolts, mm

1 - To oil
2 - Bolt length (Benchmark)

  • Nominal value
112.7 ÷ 113.3
  • The limit value
114.5

Valve seats

The geometrical parameters (see.
  • Corner of a working facet, hail
    • The intake valves
thirty
    • The exhaust valves
45
  • The width of the chamfer mm
    • The intake valves
1.30 ÷ 1.90
    • The exhaust valves
1.64 ÷ 2.04
  • Planting depth in the head (inlet and exhaust valves), mm
    • Nominal value
0.75 ÷ 1.05
    • The limit value
1.55

Valves, valve springs, guides

Valves
  • Timing
    • The intake valves
      • Opening
13 ? before TDC
      • Closing
31 ? after BDC
    • The exhaust valves
      • Opening
60 ? before BDC
      • Closing
8 ? ATDC
  • The geometrical parameters of the valves
    • Corner of a working facet, hail
      • The intake valves
thirty
      • The exhaust valves
45
    • The diameter of the rod (see. mm
      • The intake valves
        • Nominal value
7.970 ÷ 7.985
        • The limit value
7,920
      • The exhaust valves
        • Nominal value
7.965 ÷ 7.980
        • The limit value
7,915
    • The diameter of the valve head, mm
      • The intake valves
39.3 ÷ 39.5
      • The exhaust valves
35.0 ÷ 35.2
    • Planting depth valve head (see. mm *
        • The inlet and outlet valves
0.75 ÷ 1.05

* See. Section Maintenance of the cylinder head and timing components (Part Diesel models)

Backlash of landing in the guide sleeve (see. and mm
  • Nominal value
    • The intake valves
0.040 ÷ 0.075
    • The exhaust valves
0.045 ÷ 0.080
  • The limit value
0.10
The guide sleeve (see.
  • The length of the valve guide, mm
    • The intake valves
40.5
    • The exhaust valves
37.6
Valve spring (see.
  • Free length mm
    • Nominal value (all valves)
45.11
    • Limit values (all valves in the compressive load 23 kgf)
39
    • Maximum permissible value violations trimming (all valves), mm
1.58

Valve tappets

Planting pusher in receptacle (see.
  • The outer diameter of the pusher, mm
  • The diameter of the nest under landing pusher mm
34.959 ÷ 34.965
  • Landing clearance, mm
34.990 ÷ 35.010
    • Nominal value
0.025 ÷ 0.061
    • The limit value
0.10
Shims See. Section Checking and adjusting the valve clearances
Valve clearance, mm
  • The intake valves
0.20 ÷ 0.30
  • The exhaust valves
0.30 ÷ 0.40

Camshaft

The amount of axial clearance (see. mm
  • Nominal value
0.02 ÷ 0.15
  • The limit value
0.2
Maximum permissible value of the radial run-out (see. mm 0.10
Operating clearance in the bearings (see. mm
  • Nominal value
0.025 ÷ 0.066
  • The limit value
0.1
The height of the jaw (see. mm
  • Nominal value
    • The drive of inlet valves
43.79
    • Drive exhaust valves
42.11
  • The limit value
    • The drive of inlet valves
45.30
    • Drive exhaust valves
44.90
Bearing neck (see.
  • Diameter, mm
    • Nominal value
31.96 ÷ 31.98
    • The limit value
31.86
  • Limit values roundness and taper, mm
0.05

Cylinder block

Casting

Maximum permissible value of flatness of the mating surface (see. mm
  • Long (longitudinal and diagonal) measurements
0.05
  • Short (transverse) measurements
0.02
Number of cylinders 4, in-line
Bore, mm
  • Nominal value
86.000 ÷ 86.022
  • The maximum allowable variation between the cylinders
0.019

Persistent half rings of a cranked shaft.

Flywheel

Maximum permissible value of cross-beats (see. mm 0.2
Maximum allowable depth of bore mm 0.5

Crankshaft and main bearings

Crankshaft end play mm
  • Check
    • The amount of axial clearance (see. mm
      • Nominal value
0.04 ÷ 0.28
      • The limit value
0.2
    • Nominal thickness of persistent half rings, mm
2.00 ÷ 2.05
    • The thickness of the repair persistent half rings, mm
2.18 ÷ 2.23
    • Maximum permissible value of the radial runout of the crankshaft (see. mm
0.05
The diameters of the necks and rear crankshaft pins, mm

Arrangement for indigenous crankshaft (1) and connecting rod (2) of the necks, and the stud (3) for planting the housing rear oil seal

  • Indigenous gang
    • Standard size
      • Nominal value
59.937 ÷ 59.955
      • The limit value
59.887 ÷ 59.905
    • 1st repair size (0.25 mm)
      • Nominal value
59.687 ÷ 59.705
      • The limit value
59.637 ÷ 59.655
    • 2nd repair size (0.50 mm)
      • Nominal value
59.437 ÷ 59.455
      • The limit value
59.387 ÷ 59.405
    • 3rd oversize (0.75 mm)
      • Nominal value
59.187 ÷ 59.205
      • The limit value
59.137 ÷ 59.155
  • Crankpins
    • Standard size
      • Nominal value
50.940 ÷ 50.955
      • The limit value
50.890 ÷ 50.905
    • 1st repair size (0.25 mm)
      • Nominal value
50.690 ÷ 50.705
      • The limit value
50.640 ÷ 50.655
    • 2nd repair size (0.50 mm)
      • Nominal value
50.440 ÷ 50.455
      • The limit value
50.390 ÷ 50.405
    • 3rd oversize (0.75 mm)
      • Nominal value
50.190 ÷ 50.205
      • The limit value
50.140 ÷ 50.155
  • Rear trunnion
89.946 ÷ 90.000
    • Limit values roundness and taper necks, mm
0.05
    • Working backlash in radical bearings (see. mm
      • Nominal value
0.031 ÷ 0.050
      • The limit value
0.08

The connecting rods and connecting rod bearings

The distance between the centers of the holes in the crosshead, mm 151.95 ÷ 152.05
Maximum allowable amount of bending / torsion rod rod 100 mm in length (see. mm 0.16
The inner diameter of the sleeve upper crosshead, mm 30.014 ÷ 30.030
Maximum allowable landing backlash of the piston pin in the connecting rod head (see. Section Disassembly and assembly of the cylinder components of the service), mm 0.05
Axial backlash of rods on the crankshaft (see. mm
  • Nominal value
0.11 ÷ 0.262
  • The limit value
0.35
Working backlash in radical bearings (see. mm
  • Nominal value
0.027 ÷ 0.065
  • The limit value
0.08

The pistons and piston pins

The diameter of the piston (see. mm 85.942 ÷ 85.968
Backlash landing pistons in the cylinders, mm
  • Nominal value
0.047 ÷ 0.065
  • The limit value
0.15
The width of the grooves under the landing of piston rings, mm
  • The top compression ring
2.04 ÷ 2.08
  • The second compression ring
2.03 ÷ 2.05
  • Scraper ring
3.02 ÷ 3.04
Backlash of landing of piston rings in the grooves of pistons, mm
  • Nominal values
    • The top compression ring
0.05 ÷ 0.09
    • The second compression ring
0.04 ÷ 0.08
    • Scraper ring
0.03 ÷ 0.07
  • The limit value
0.20
  • Maximum allowable size of the gap piston ring (see. mm
10

Efforts of a tightening of carving connections, Nanometer

Efforts of a tightening of certain fastener elements can be shown directly in the section where they are highlighted in bold.


Timing cover 7.0 ÷ 9.8
The gauge-switch of pressure of oil 11.7 ÷ 17.6
Bolt camshaft sprocket 54.9 ÷ 64.7
Bolt crankshaft gear 179.5 ÷ 193.2
Bolt gear pump 686.8 ÷ 78.4
The crankshaft pulley bolt 22.5 ÷ 32.3
Locking bolt tensioner timing belt 31.4 ÷ 46.1
Bolts cylinder head cover 7.0 ÷ 9.8
Bolts of fastening of the inlet pipeline 15.6 ÷ 26.4
Bolts of fastening of a final collector 21.5 ÷ 26.4
Nuts camshaft bearing cap (see. Section Maintenance of the cylinder head and camshaft components) 19.6 ÷ 26.4
Cylinder head bolts (see. Section Maintenance of the cylinder head and camshaft components)
  • Step 1
31
  • Step 2
To hold at an angle of 90 ? ÷ 105 ?
  • Step 3
To hold at an angle of 90 ? ÷ 105 ?
Lubricators in the cylinder block 11.7 ÷ 17.6
Bolts main bearing caps of the crankshaft (see. 82.4 ÷ 88.2
Bolts of covers of the bottom heads of rods 64.7 ÷ 68.6
Bolts rear engine cover 7.0 ÷ 9.8
Bolts of fastening of the oil pump assembly
  • M8
16 ÷ 23
  • M10
32 ÷ 47
Bolts sump 7.0 ÷ 9.8
Bolts maslozabornika assembly with strainer (see. 7.0 ÷ 9.8
Bolts motor end plate

Details of the installation of the end plate (1) of the engine

15.6 ÷ 22.5
Flywheel bolts 159.8 ÷ 169.6
Bolts clutch 21.5 ÷ 32.7
Bolts of fastening of the water pump 31.3 ÷ 46.1
Bolts of the support bracket of the cooling fan 31.3 ÷ 46.1
Bolts thermostat 15.6 ÷ 22.5
Bolts oil cooler (see. Illustration details the installation of oil cooler)
  • M10
31.3 ÷ 46.1
  • M6
7.0 ÷ 9.8
Bolts water tube cooler
  • Bracket
18.6 ÷ 25.5
  • Flange
8.0 ÷ 10.7
Oil filter 19.6 ÷ 24.5
Support bracket generator 31.3 ÷ 46.1
Reliance power train 31.3 ÷ 46.1




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