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

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Kia
	Sportage
		Introduction
		Controls and operation receptions
		Current care and maintenance
		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
		Wiring

printable version

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

Adjustment (see. Section Disassembly and assembly of the cylinder components of the service)

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

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

16 ÷ 23

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)

31.3 ÷ 46.1

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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