Kia Sorento LX (2002), Sorento LX (2003), Sorento LX (2004), Sorento LX (2005), Sorento LX (2006) ENGINE Mechanical
...Page 1
2007 Kia Sorento LX
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
2007-08 ENGINE Mechanical - Sorento
2007-08 ENGINE
Mechanical - Sorento
GENERAL
SPECIFICATION
SPECIFICATION
Description
G6DB-3.3 G6DA-3.8
General
Type V-type, DOHC
Number of cylinders 6
Bore 92 mm
(3.6220in)
Stroke 83.8 mm
(3.2992in)
Total displacement 3.342cc
(203.86cu.in)
Compression ratio 10.4
Firing order 1-2-3-4-5-6
Valve timing
Intake Opens (ATDC) 14° 10°
Closes (ATDC) 66° 66°
Exhaust Opens (BTDC) 52° 52°
Closes (ATDC) 0° 0°
Cylinder head
Flatness of gasket surface Less than 0.05 mm (0.0019in)
[Less than 0.02 mm (0.0008in) /
150x150]
Flatness of
manifold
mounting
Intake
Less than 0.1 mm (0.0039in)
[Less than 0.03 mm
(0.001in)/110x110]
Less than 0.1 mm (0.0039in)
Exhaust
[Less than 0.03 mm
(0.001in)/110x110]
Camshaft
Cam height LH Camshaft Intake 46.3 mm
(1.8228in)
Exhaust 45.8 mm (1.8031 in)
RH Camshaft Intake 46.3 mm
(1.8228in)
Specifications
96 mm
(3.7795in)
87.0 mm
(3.4252in)
3.778cc
(230.55cu.in)
46.8 mm
(1.8425in)
46.8 mm
(1.8425in)
Limit
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Exhaust 45.8 mm (1.8031 in)
Journal outer
diameter
LH, RH
Camshaft
Intake No. 1: 27.964-27.978 mm (1.1009
-1.1015in)
No. 2,3,4: 23.954-23.970 mm
(0.9430-0.9437in)
Exhaust No.1: 27.964-27.978 mm (1.1009-
1.1015in)
No.2,3,4: 23.954-23.970 mm
(0.9430-0.9437in)
Bearing oil
clearance
LH, RH
Camshaft
Intake No.1: 0.027-0.057 mm (0.0011-
0.0022in)
No.2,3,4: 0.030-0.067 mm (0.0012
-0.0026in)
Exhaust No.1: 0.027-0.057 mm (0.0011-
0.0022in)
No.2,3,4: 0.030-0.067 mm
(0.0012-0.0026in)
End play --> 0.02-0.18 mm
(0.0008-0.0071
in)
Valve
Valve length Intake 105.27 mm (4.1445in)
Exhaust 105.50 mm (4.1535in)
Stem outer
diameter
Intake 5.465-5.480 mm (0.2151-0.2157in)
Exhaust 5.458-5.470 mm (0.2149-0.2153in)
Face angle 45.25°-45.75°
Thickness of
valve head
(margin)
Valve stem to
valve guide
clearance
Intake 1.56-1.86 mm (0.06142-0.07323in)
Exhaust 1.73-2.03 mm (0.06811-0.07992in)
Intake 0.020-0.047 mm (0.00078-
0.00185in)
Exhaust 0.030-0.054 mm (0.00118-
0.00212in)
0.07 mm
(0.00275in)
0.09 mm
(0.00354in)
Valve guide
Inner diameter Intake 5.500-5.512 mm (0.2165-0.2170in)
Exhaust 5.500-5.512 mm (0.2165-0.2170in)
Length Intake 41.8-42.2 mm (1.6457-1.6614in)
Exhaust 41.8-42.2 mm (1.6457-1.6614in)
Valve seat
Width of seat
contact
Intake 1.15-1.45 mm (0.05118-0.05709in)
Exhaust 1.35-1.65 mm (0.05315-0.06496in)
Seat angle Intake 44.75°-45.20°
Exhaust 44.75°-45.20°
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Valve spring
Free length 43.86 mm (1.7267 in)
Load 19.3 ± 0.8kg/34.0 mm (42.7 ± 1.8
lb/1.3386 in)
42.3+1.3kg/24.2 mm (93.3 ± 2.9
lb/0.9527 in)
Out of squareness Less than 1.5°
MLA
MLA outer
diameter
Intake 34.964-34.980 mm (1.3765-1.3772
in)
Exhaust 34.964-34.980 mm (1.3765-1.3772
in)
Cylinder head
tappet bore inner
diameter
Intake 35.000-35.025 mm (1.3779-1.3789
in)
Exhaust 35.000-35.025 mm (1.3779-1.3789
in)
MLA to tappet
bore clearance
Intake 0.020-0.061 mm (0.0008-0.0024
in)
Exhaust 0.020-0.061 mm (0.0008-0.0024
in)
0.07 mm
(0.0027 in)
0.07 mm(0.0027
in)
Valve clearance
Intake 0.17-0.23 mm (0.0067-0.0090 in) 0.10-0.30 mm
(0.0039-0.0118
in)
Exhaust 0.27-0.33 mm (0.0106-0.0129 in) 0.20-0.40 mm
(0.0078 -0.0157
in)
Cylinder block
Cylinder bore 92.00-92.03 mm
(3.6220-3.6232
in)
96.00-96.03 mm
(3.7795-3.7807
in)
Flatness of gasket surface Less than 0.05 mm (0.0019 in)
[Less than 0.02 mm (0.0008 in) /
150x150]
Piston
Piston outer diameter 91.96-92.00 mm
(3.6205-3.6220
in)
95.96-95.99 mm
(3.7779-3.7791
in)
Piston to cylinder clearance --> 0.03-0.05 mm
(0.0012-0.0020
in)
Ring groove
width
No. 1 ring groove --> 1.22-1.24
(0.0480-0.0488
1.26 mm
(0.0496 in)
in)
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
No. 2 ring groove 1.22-1.24 mm (0.0480-0.0488 in) 1.26 mm
(0.0496 in)
Oil ring groove 2.01-2.03 mm (0.0791-0.0799 in) 2.05 mm
(0.0807 in)
Piston ring
Side clearance No. 1 ring --> 0.03-0.07 mm
(0.0012 -0.0027
0.1 mm (0.004
in)
in)
No. 2 ring 0.03-0.07 mm (0.0012-0.0027 in) 0.1 mm (0.004
in)
Oil ring 0.06-0.15 mm (0.0024-0.0059 in) 0.2 mm (0.008
in)
End gap No. 1 ring 0.17-0.32 mm (0.0067-0.0126 in) 0.6 mm (0.0236
in)
No. 2 ring 0.32-0.47 mm (0.0126-0.0185 in) 0.7 mm (0.0275
in)
Oil ring 0.20-0.70 mm (0.0078-0.0275 in) 0.8 mm (0.0315
in)
Piston pin
Piston pin outer diameter --> 23.001-23.006
mm (0.9055-
0.9057 in)
Piston pin hole inner diameter --> 23.016-23.021
mm (0.9061-
0.9063 in)
Piston pin hole clearance --> 0.01-0.02 mm
(0.0039-0.0078
in)
Connecting rod small end inner diameter 22.974-22.985 mm (0.9045-0.9049
in)
Connecting rod
Connecting rod big end inner diameter 58.000-58.018 mm(2.2834-2.2842
in)
Connecting rod bearing oil clearance --> 0.038-0.056 mm
(0.0015 -0.0022
in)
Side clearance 0.1-0.25 mm (0.0039-0.0098 in)
Crankshaft
Main journal outer diameter 68.942-68.960 mm (2.7142-2.7149
in)
Pin journal outer diameter 54.954-54.972 mm (2.1635-2.1642
in)
Main bearing oil clearance 0.022-0.040 mm (0.0008-0.0016
in)
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
End play 0.10-0.28 mm (0.0039-0.0110 in)
Oil pump
Relief valve opening pressure 450-550 kPa (4.59-5.61
kgf/cm
2
,65.28-79.79 psi)
Engine oil
Oil quantity (Oil pan) 4.5-5.5L (4.76-5.81 U.S. qts, 3.96-
4.84 Imp. qts)
Oil quantity (Oil filter) 0.4L (0.42 U.S. qts, 0.35 Imp. qts)
Oil quantity (Drain and refill) 5.2L (5.49 U.S. qts, 4.58 Imp. qts)
Oil quality Above SJ or SL
Oil pressure
130 kPa (1.32kgf/cm2 , 18.77 psi)
[at 1000 RPM, 110°C (230°F)]
Cooling system
Cooling method Forced circulation with electrical
fan
Coolant quantity 9.0L (9.40 U.S. qts, 7.83 Imp. qts)
Thermostat Type Wax pellet type
Opening temperature 82 ± 2°C (179.6 ± 35.6°F)
Fully opened temperature 95°C (203°F)
Full lift more than 10 mm (0.3937 in)
Radiator cap Main valve opening pressure 93.16-122.58 kPa (0.95-
1.25kg/cm2 , 13.51-17.78 psi)
Vacuum valve opening pressure
0.98-4.90 kPa (0.01-0.05kg/cm2 ,
0.14-0.71 psi)
Water temperature sensor
Type Thermistor type
Resistance 20°C (68°F) 2.31-2.59 kohms
80°C (176°F) 0.3222 kohms
TIGHTENING TORQUE
TIGHTENING TORQUE
Item Quantity N.m kgf.m lb. ft
Crankshaft pulley bolt 1 284.2-303.8 29.0-31.0 209.76-224.22
Timing chain cover bolt B 17 18.62-21.56 1.9-2.2 13.74-15.91
Timing chain cover bolt C 4 9.80-11.76 1.0-1.2 7.23-8.68
Timing chain cover bolt D 1 58.80-68.80 6.0-7.0 43.40-50.63
Timing chain cover bolt E 1 58.80-68.80 6.0-7.0 43.40-50.63
Timing chain cover bolt F 2 24.50-26.46 2.5-2.7 18.08-19.53
Timing chain cover bolt G 4 21.56-23.52 2.2-2.4 15.91-17.36
Timing chain cover bolt H 1 9.80-11.76 1.0-1.2 7.23-8.68
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Timing chain cover bolt 1 1 9.80-11.76 1.0-1.2 7.23-8.68
Timing chain cover bolt J 1 9.80-11.76 1.0-1.2 7.23-8.68
Cam to cam guide bolt 4 9.80-11.76 1.0-1.2 7.23-8.68
Timing chain auto tensioner bolt 2 9.80-11.76 1.0-1.2 7.23-8.68
Timing chain auto tensioner nut 2 9.80-11.76 1.0-1.2 7.23-8.68
Timing chain guide bolt 4 19.60-24.50 2.0-2.5 14.17-18.08
Oil pump chain cover bolt 3 9.80-11.76 1.0-1.2 7.23-8.68
Oil pump chain tensioner bolt 1 9.80-11.76 1.0-1.2 7.23-8.68
Oil pump chain guide bolt 2 9.80-11.76 1.0-1.2 7.23-8.68
Oil pump chain sprocket bolt 1 18.62-21.56 1.9-2.2 13.74-15.91
Lower oil pan bolt 13 9.80-11.76 1.0-1.2 7.23-8.68
Drive belt auto tensioner bolt(M12) 1 81.4-85.3 8.3-8.7 60.0-62.9
Drive belt auto tensioner bolt(M8) 1 29.4-33.3 3.0-3.4 21.7-24.6
Drive belt idler bolt 1 53.90-57.82 5.5-5.9 39.78-42.67
OCV (oil control valve) bolt 2 9.80-11.76 1.0-1.2 7.23-8.68
Cylinder head bolt 16
39.2 + 120°
+90°
4.0 + 120°
+90°
28.93+ 120° +
90°
Cylinder head bolt 1 18.62-23.52 1.9-2.4 13.74-17.36
CVVT & exhaust cam sprocket bolt 4 64.68-76.44 6.6-7.8 47.74-56.42
Camshaft bearing cap bolt 32 9.80-11.76 1.0-1.2 7.23-8.68
Cylinder head cover bolt 38 9.80-11.76 1.0-1.2 7.23-8.68
Connecting rod bearing bolt 12 19.60 + 90° 2.0 + 90° 14.46 + 90°
Main bearing cap inner bolt (M11) 8 49.00 + 90° 5.0 + 90° 36.16 + 90°
Main bearing cap outer bolt (M8) 8 19.60 + 120° 2.0 + 120° 14.46 + 120°
Main bearing cap side bolt (M8) 6 29.40-31.36 3.0-3.2 21.70-23.14
Oil drain cover bolt 6 9.80-11.76 1.0-1.2 7.23-8.68
Rear oil seal case bolt 6 9.80-11.76 1.0-1.2 7.23-8.68
Baffle plate bolt 12 9.80-11.76 1.0-1.2 7.23-8.68
Upper oil pan bolt 16 9.80-11.76 1.0-1.2 7.23-8.68
Knock sensor bolt 2 15.68-23.52 1.6-2.4 11.57-17.36
Drive plate bolt 8 71.54-75.46 7.3-7.7 52.80-55.69
Oil filter cap 1 24.50 2.5 18.08
Oil drain bolt 1 34.30-44.10 3.5-4.5 25.31-32.55
Oil pump bolt 3 19.60-23.52 2.0-2.4 14.47-17.36
Oil filter body bolt 10 9.80-11.76 1.0-1.2 7.23-8.68
Oil filter body cover bolt 11 9.80-11.76 1.0-1.2 7.23-8.68
Water vent hose bolt 2 9.80-11.76 1.0-1.2 7.23-8.68
Water pump bolt (Timing chain cover bolt
L)
Water pump bolt (Timing chain cover bolt
K)
1 21.56-26.46 2.2-2.7 15.91-19.53
4 9.80-11.76 1.0-1.2 7.23-8.68
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Water pump pulley bolt 4 7.84-9.80 0.8-1.0 5.78-7.23
Water temp, control nut 4 19.6-23.52 2.0-2.4 14.5-17.36
Water temp, control bolt 2 19.6-23.52 2.0-2.4 14.5-17.36
Water inlet pipe bolt 3 16.66-19.60 1.7-2.0 12.30-14.47
Air vent pipe bolt 2 9.80-11.76 1.0-1.2 7.23-8.68
Intake manifold bolt 6 26.5-31.4 2.7-3.2 19.5-23.1
Intake manifold nut 2 18.62-23.52 1.9-2.4 13.74-17.36
Surge tank bolt 1 9.80-11.76 1.0-1.2 7.23-8.68
Surge tank nut 2 18.6-23.5 1.9-2.4 13.7-17.4
Exhaust manifold stay bolt 4 52.0-56.9 5.3-5.8 38.3-42.0
Surge tank bolt 3 18.6-23.5 1.9-2.4 13.7-17.4
Breather pipe bolt 2 9.80-11.76 1.0-1.2 7.23-8.68
Surge tank bracket bolt 2 27.44-31.36 2.8-3.2 20.25-23.14
ETC bracket bolt 2 15.68-25.48 1.6-2.6 11.57-18.80
Exhaust manifold nut 16 39.20-44.10 4.0-4.5 28.93-32.55
Heat protector bolt 6 9.8-11.8 1.0-1.2 7.2-8.7
Front muffler 2 39.20-58.80 4.0-6.0 28.93-43.40
INSPECTION
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)
.
3. Remove spark plugs.
Using a 16 mm plug wrench, remove the 6 spark plugs.
4. Check cylinder compression pressure.
a. Insert a compression gauge into the spark plug hole.
b. Fully open the throttle.
c. 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.
Page 8
d. Repeat steps () through (b) for each cylinder.
NOTE: This measurement must be done in as short a time as possible.
Compression pressure: 1,225 kPa (12.5 kgf/cm2 , 177 psi) @ 200-250 RPM
Minimum pressure: 1,078 kPa (11.0 kgf/cm2 , 156psi)
e. 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 () through (b) 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.
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
6. Install ignition coils. See GENERAL (ENGINE ELECTRICAL SYSTEM) .
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature: 20°C) and cylinder head is installed on the cylinder block.
1. Remove the engine cover (A).
Fig. 1: Identifying Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the engine room resonator (A).
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 2: Identifying Engine Room Resonator
Courtesy of KIA MOTORS AMERICA, INC.
3. After disconnecting the MAF sensor connector (A) and the breather hose (B), remove the air cleaner
assembly (C).
Fig. 3: Disconnecting MAF Sensor Connector And Breather Hose
Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the other breather hose (A), the Purge Control Solenoid Valve (PCSV) hose, the Positive
Crankcase Ventilation (PCV) hose (C) and the Electronic Throttle Control (ETC) cooling hoses (D) and
connector (E).
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 4: Disconnecting Purge Control Solenoid Valve (PCSV) Hose And Positive Crankcase
Ventilation (PCV) Hose
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 5: Disconnecting Breather Hose
Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the wiring over the surge tank.
1. Disconnect the injection harness connector (A).
2. Disconnect the camshaft position sensor (CMP) harness connector (B).
3. Disconnect the ground line (C).
4. Disconnect the ignition coil harness connector (D).
5. Disconnect the condenser connector (E).
6. Disconnect the variable induction system (VIS) solenoid valve connector (G).
7. Disconnect the oil control valve (OCV) harness connector (F).
8. Disconnect the injector wiring (H) and ignition coil wiring (I).
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 6: Disconnecting Injection Harness Connector And Ground Line
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 7: Disconnecting Injector Wiring And Ignition Coil Wiring
Courtesy of KIA MOTORS AMERICA, INC.
6. Disconnect the fuel hose tube (A).
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 8: Disconnecting Fuel Hose Tube
Courtesy of KIA MOTORS AMERICA, INC.
7. Remove heater hose (A) and disconnect the brake vacuum hose (B).
Fig. 9: Heater & Brake Vacuum Hoses
Courtesy of KIA MOTORS AMERICA, INC.
8. Disconnect the surge tank stay.
9. Remove the surge tank.
10. Loosen the cylinder head cover bolts and then remove the cover (A) and gasket.
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 10: Identifying Cover
Courtesy of KIA MOTORS AMERICA, INC.
11. Set No.1 cylinder to TDC/compression.
a. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain
cover.
Fig. 11: Identifying Crankshaft Pulley
Courtesy of KIA MOTORS AMERICA, INC.
b. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head
surface as shown in the illustration. If not, turn the crankshaft one revolution (360°)
NOTE: Do not rotate engine counterclockwise
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 12: Identifying Mark Of Camshaft Timing Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
12. Inspect the valve clearance.
a. Check only the valve indicated as shown [No. 1 cylinder: TDC/Compression]. Measure the valve
clearance.
Fig. 13: Identifying Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.
Using a thickness gauge, measure the clearance between the tappet and the base circle of
camshaft.
Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting tappet.
Valve clearance
Specification
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Engine coolant temperature: 20°C [68°F]
Limit
Intake: 0.17-0.23 mm (0.0067-0.0090 in.)
Exhaust: 0.27-0.33 mm (0.0106-0.0129 in.)
b. Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the
lower timing chain cover.
NOTE: Do not rotate engine counterclockwise
c. Check only valves indicated as shown [No. 4 cylinder: TDC/compression]. Measure the valve
clearance.
Fig. 14: Identifying Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.
13. Adjust the intake and exhaust valve clearance.
a. Set the No.1 cylinder to the TDC/compression.
b. Mark on the timing chain on the basis of the marking on sprocket and CVVT.
c. Remove the timing chain.
d. Remove the camshaft bearing caps (A).
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g
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 15: Identifying Camshaft Bearing Caps
Courtesy of KIA MOTORS AMERICA, INC.
e. Remove the camshaft assembly (A).
Fig. 16: Identifying Camshaft Assembly
Courtesy of KIA MOTORS AMERICA, INC.
f. Remove MLAs.
. Measure the thickness of the removed tappet using a micrometer.
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 17: Measuring Thickness Of Tappet
Courtesy of KIA MOTORS AMERICA, INC.
h. Calculate the thickness of a new tappet so that the valve clearance comes within the specified
value.
Valve clearance (Engine coolant temperature: 20°C [68°F])
T: Thickness of removed tappet
A: Measured valve clearance
N: Thickness of new tappet
Intake: N = T + [A-0.20 mm (0.0079 in.)]
Exhaust: N = T + [A-0.30 mm (0.0118 in.)]
i. Select a new tappet with a thickness as close as possible to the calculated value.
NOTE: Tappets are available in 41 size increments of 0.015 mm (0.0006 in.)
from 3.00 mm (0.118 in.) to 3.600 mm (0.1417 in.)
j. Place a new tappet on the cylinder head.
NOTE: Applying engine oil at the selected tappet on the periphery and top
surface.
k. Install the intake and exhaust camshaft.
l. Install the bearing caps.
m. Install the timing chain.
n. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket
and camshaft sprocket timing marks.
o. Recheck the valve clearance.
Page 18
Valve clearance (Engine coolant temperature: 20°C [68°F])
[Specification]
Intake: 0.17-0.23 mm (0.0067-0.0090 in.)
Exhaust: 0.27-0.33 mm (0.0106-0.0129 in.)
TROUBLESHOOTING
TROUBLESHOOTING
Symptom Suspect area Remedy
Worn crankshaft bearings. Loose or
improperly installed engine drive plate.
Engine misfire with
abnormal internal
lower engine noises.
Worn piston rings. (Oil consumption may
or may not cause the engine to misfire.)
Worn crankshaft thrust bearings
Stuck valves (Carbon buildup on the valve
stem)
Engine misfire with
abnormal valve train
noise.
Excessive worn or mis-aligned timing
chain.
Worn camshaft lobes.
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Replace the crankshaft and bearings
as required.
Repair or replace the drive plate as
required.
Inspect the cylinder for a loss of
compression.
Repair or replace as required.
Replace the crankshaft and bearings
as required.
Repair or replace as required.
Replace the timing chain and
sprocket as required.
Replace the camshaft and valve
lifters.
Engine misfire with
coolant consumption.
Engine misfire with
excessive oil
consumption.
Engine noise on startup, but only lasting a
few seconds.
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.
Worn valves, guides and/or valve stem oil
seals.
Worn piston rings. (Oil consumption may
or may not cause the engine to misfire)
Incorrect oil viscosity.
Worn crankshaft thrust bearing.
Inspect the cylinder head and
engine block for damage to the
coolant passages and/or a faulty
head gasket.
Repair or replace as required.
Repair or replace as required.
Inspect the cylinder for a loss
of compression.
Repair or replace as required.
Drain the oil.
Install the correct viscosity oil.
Inspect the thrust bearing and
crankshaft.
Repair or replace as required.
Page 19
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
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.
Worn timing chain tensioner, if applicable.
Replace the timing chain and
sprockets.
Replace the timing chain tensioner as
required.
Upper engine noise,
regardless of engine
speed.
Lower engine noise,
regardless of engine
speed.
Inspect the camshaft lobes.
Worn camshaft lobes.
Replace the timing camshaft
and valve lifters as required.
Worn valve guides or valve stems.
Stuck valves (Carbon on the valve stem or
valve seat may cause the valve to stay
open).
Worn drive belt, idler, tensioner and
bearing.
Inspect the valves and valve guides,
then repair as required.
Inspect the valves and valve guides,
then repair as required.
Replace as required.
Low oil pressure. Repair or required.
Loose or damaged drive plate. Repair or replace the drive plate.
Damaged oil pan, contacting the oil pump
Inspect the oil pan.
screen.
Oil pump screen loose, damaged or
restricted.
Excessive piston-to-cylinder bore
clearance.
Excessive piston pin-to-piston clearance.
Inspect the oil pump screen.
Repair or replace as required.
Inspect the oil pump screen.
Repair or replace as required.
Inspect the piston, piston pin
and cylinder bore.
Repair as required.
Inspect the piston, piston pin
and the connecting rod.
Repair or replace as required.
Inspect the following components and
repair as required.
Excessive connecting rod bearing clearance
Excessive crankshaft bearing clearance.
The connecting rod bearings.
The connecting rods.
The crankshaft pin journals.
Inspect the following components,
and repair as required.
The crankshaft bearings.
The crankshaft main journals.
Page 20
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
The cylinder block.
Verify the piston pins and
Incorrect piston, piston pin and connecting
rod installation
connecting rods are installed
correctly.
Repair as required.
Low oil pressure Repair or replace as required.
Inspect the following components and
repair as required:
Engine noise under
load.
Engine will not crankcrankshaft will not
rotate.
Excessive connecting rod bearing
clearance.
Excessive crankshaft bearing clearance.
Hydraulically locked cylinder.
Coolant/antifreeze in cylinder.
Oil in cylinder.
Fuel in cylinder.
Broken timing chain and/or timing chain
and/or timing chain gears.
Material in cylinder.
Broken valve
Piston material
Foreign material
The connecting rod bearings.
The connecting rods.
The crankshaft.
Inspect the following components,
and repair as required.
The crankshaft bearings.
The crankshaft main journals.
The cylinder block.
1. Remove spark plugs and check
for fluid.
2. Inspect for broken head gasket.
3. Inspect for cracked engine
block or cylinder head.
4. Inspect for a sticking fuel
injector and/or leaking fuel
regulator.
1. Inspect timing chain and gears.
2. Repair as required.
1. Inspect cylinder for damaged
components and/or foreign
materials.
2. Repair or replace as required.
Seized crankshaft or connecting rod
bearings.
Bent or broken connecting rod.
Broken crankshaft.
1. Inspect crankshaft and
connecting rod bearing.
2. Repair as required.
1. Inspect connecting rods.
2. Repair as required.
1. Inspect crankshaft.
2. Repair as required.
Page 21
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
SPECIAL SERVICE TOOLS
SPECIAL SERVICE TOOLS
Tool (Number and name) Illustration Use
Crankshaft front oil seal
installer (09231-3C100)
Flywheel stopper (092313C300)
Torque angle adapter
(09221-4A000)
Installation of the front oil seal
Removal and installation of the
flywheel and crankshaft pulley.
Installation of bolts & nuts needing
an angular method
Valve stem seal remover
(09222-29000)
Remover of the valve stem seal
Page 22
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Valve stem seal remover
(09222-3C100)
Valve spring compressor &
holder
(09222-3K000)
(09222-3C300)
Crankshaft rear oil seal
installer
(09231-3C200)
(09231-H1100)
Installation of the valve stem seal
Removal and installation of the
intake or exhaust valve
A. 09222-3K000
B. 09222-3C300 (holder)
Installation of the crankshaft rear oil
seal
A. 09231-3C200
B. 09231-H1100
Oil pan remover (092153C000)
Removal of oil pan
Oil filter wrench (09263- Removal and installation of the oil
Page 23
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
3C100) filter
ENGINE AND TRANSAXLE ASSEMBLY
REMOVAL
CAUTION:
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
NOTE:
Mark all wiring and hoses to avoid mis-connection.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the engine cover (A).
Fig. 18: Identifying Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
2. Recover refrigerant by opening the high & low pressure pipe caps and connecting the refrigerant station.
Refer to AIR CONDITIONING SYSTEM .
Page 24
3. Remove the under cover (A).
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 19: Identifying Under Cover
Courtesy of KIA MOTORS AMERICA, INC.
4. Drain engine oil, transaxle fluid and engine coolant.
5. Disconnect the negative terminal from the battery and remove the battery (A).
6. Remove the intake air hose and air cleaner assembly.
1. Disconnect the MAF connector (A).
2. Disconnect the breather hose (B) from air cleaner hose.
3. Remove the intake air hose and air cleaner assembly (C) with the resonator (D).
Fig. 20: Identifying Air Cleaner Assembly, Resonator And Breather Hose
Courtesy of KIA MOTORS AMERICA, INC.
7. Disconnect the PCM connectors (A).
Page 25
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 21: Disconnecting PCM Connectors
Courtesy of KIA MOTORS AMERICA, INC.
8. Remove the battery tray while recovering refrigerant.
9. Disconnect the high and low pressure pipes from the radiator or the compressor. Refer to AIR
CONDITIONING SYSTEM .
10. Remove the radiator. Refer to RADIATOR.
11. Disconnect the engine wiring harness connectors.
1. Disconnect the oil control valve (OCV) harness connector (A) and the knock sensor (LH) harness
connector (B)
Fig. 22: Disconnecting Oil Control Valve Harness Connector And Knock Sensor Harness
Connector
Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the MAP (A), ETC (B), ignition coil harness connector (C) and the injection harness
connector (D).
Page 26
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 23: Disconnecting MAP, ETC And Ignition Coil Harness Connector
Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the battery connector (A), the power steering switch connector (B) and the knock
sensor (RH) harness connector (C).
Fig. 24: Disconnecting Battery Connector And Power Steering Switch Connector
Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the oxygen sensors (A), CMP (B), CKP (C), VIV (D) and the condenser harness
connector (E).
Page 27
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 25: Disconnecting Oxygen Sensors, CMP, CKP, VIV And Condenser Harness Connector
Courtesy of KIA MOTORS AMERICA, INC.
5. Disconnect the water temperature sensor (WTS) harness connector (A), the oil temperature sensor
(OTS) harness connector (B) and the purge control solenoid valve (PCSV) harness connector (C).
Fig. 26: Disconnecting Water Temperature Sensor Harness Connector And Oil Temperature
Sensor Harness Connector
Courtesy of KIA MOTORS AMERICA, INC.
12. Disconnect the transaxle wire harness connector and remove the transaxle assembly. Refer to
AUTOMATIC TRANSAXLE SYSTEM
.
13. Disconnect the fuel hose tube (A).
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Fig. 27: Disconnecting Fuel Hose Tube
Courtesy of KIA MOTORS AMERICA, INC.
14. Disconnect the front exhaust muffler with the exhaust manifolds.
15. Remove the front wheels and tires. Refer to Suspension system in SUSPENSION SYSTEM (TPMS) .
16. Remove heater hose (A) and disconnect the brake vacuum hose (B).
Fig. 28: Identifying Heater Hose And Brake Vacuum Hose
Courtesy of KIA MOTORS AMERICA, INC.
17. Remove the exhaust and intake manifold covers. Refer to INTAKE AND EXHAUST SYSTEM
.
18. Remove the power steering pump assembly.
19. Remove the hood assembly. Refer to Hood in BODY (INTERIOR AND EXTERIOR) .
20. Install a jack for supporting the engine assembly.
21. Remove the en
ine mounting brackets (A).
Page 29
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 29: Identifying Engine Mounting Brackets
Courtesy of KIA MOTORS AMERICA, INC.
22. Jack up the engine assembly in order to remove the engine from the vehicle.
INSTALLATION
Installation is in the reverse order of removal. Perform the following:
Adjust the shift cable.
Refill the engine with engine oil.
Refill the transaxle with fluid.
Refill the radiator with engine coolant.
Bleed air from the cooling system with the heater valve open.
Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump
runs for approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
TIMING SYSTEM
TIMING CHAIN
COMPONENTS
Page 30
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 30: Identifying Timing Chain Components And Torque Specifications (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Page 31
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 31: Identifying Timing Chain Components And Torque Specifications (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
REMOVAL
Engine removal is required for this procedure.
1. Remove the drive belt (A).
Page 32
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 32: Identifying Drive Belt
Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the power steering pump (A).
Fig. 33: Identifying Power Steering Pump
Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the air compressor (A).
Page 33
Fig. 34: Identifying Air Compressor
Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the alternator (A).
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 35: Identifying Alternator
Courtesy of KIA MOTORS AMERICA, INC.
5. Remove drive belt idler (A).
Page 34
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 36: Identifying Drive Belt Idler
Courtesy of KIA MOTORS AMERICA, INC.
6. Remove drive belt auto tensioner (A).
Fig. 37: Identifying Drive Belt Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
7. Remove water pump pulley (A).
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Fig. 38: Identifying Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.
8. Remove intake manifold.
DISASSEMBLY
1. Remove the engine cover.
Fig. 39: Identifying Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the en
ine room resonator (A).
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Fig. 40: Identifying Engine Room Resonator
Courtesy of KIA MOTORS AMERICA, INC.
3. After disconnecting the MAF sensor connector (A) and the breather hose (B), remove the air cleaner
assembly (C).
Fig. 41: Identifying MAF Sensor Connector And Air Cleaner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
4. After disconnecting the other breather hose (A), the Purge Control Solenoid Valve (PCSV) hose (B), the
Positive Crankcase Ventilation (PCV) hose (C) and the Electronic Throttle Control (ETC) cooling hoses
(D), remove the sur
e tank assembly (E).
Page 37
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 42: Identifying Breather Hose, Purge Control Solenoid Valve Hose And Cooling Hoses
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 43: Identifying Electronic Throttle Control, Cooling Hoses And Surge Tank Assembly
Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the wiring over the surge tank.
1. Disconnect the injection harness connector (A).
2. Disconnect the camshaft position sensor (CMP) harness connector (B).
3. Disconnect the ground lines (C).
4. Disconnect the ignition coil harness connector (D).
5. Disconnect the condenser connector (E).
6. Disconnect the oil control valve (OCV) harness connector (F).
Page 38
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 44: Identifying Oil Control Valve Harness Connector
Courtesy of KIA MOTORS AMERICA, INC.
6. Loosen the cylinder head cover bolts and then remove the cover (A) and gasket.
Fig. 45: Identifying Cylinder Head Cover Bolts
Courtesy of KIA MOTORS AMERICA, INC.
7. Set No.1 cylinder to TDC/compression.
a. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain
cover.
NOTE: Do not rotate engine counterclockwise.
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 46: Aligning Groove With Timing Mark
Courtesy of KIA MOTORS AMERICA, INC.
b. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head
surface as shown in the illustration.
If not, turn the crankshaft one revolution (360°).
Fig. 47: Identifying Camshaft Timing Sprockets Mark
Courtesy of KIA MOTORS AMERICA, INC.
NOTE: Do not rotate engine counterclockwise.
8. Remove the lower oil pan (A).
Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan, and cut off applied
sealer and removed lower oil pan.
Page 40
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 48: Inserting Blade Of SST Between Upper Oil Pan And Lower Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
Insert the SST between the oil pan and the ladder frame by
tapping it with a plastic hammer In the direction of (1) arrow.
After tapping the SST with a plastic hammer along the direction
of (2) arrow around more than 213 edge of the oil pan, remove it
from the ladder frame.
Do not turn over the SST abruptly without tapping. It can result
in damage of the SST.
9. Remove the crankshaft damper pulley (A).
Fig. 49: Identifying Crankshaft Damper Pulley
Courtesy of KIA MOTORS AMERICA, INC.
10. Remove the timing chain cover (A).
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 50: Identifying Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
Be careful not to damage the contact surfaces of cylinder block,
cylinder head and timing chain cover.
Mark on the timing chain on the basis of the marking on sprocket and
CVVT.
11. Install a set pin after compressing the timing chain tensioner.
Fig. 51: Installing Set Pin
Courtesy of KIA MOTORS AMERICA, INC.
12. Remove RH cam-to-cam guide (A).
Page 42
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 52: Identifying RH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
13. Remove RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).
Fig. 53: Identifying RH Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
14. Remove oil pump chain cover (A).
Page 43
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 54: Identifying Oil Pump Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
15. Remove oil pump chain tensioner assembly (A).
Fig. 55: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
16. Remove oil pump chain guide (A).
Page 44
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 56: Identifying Oil Pump Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
17. Remove RH timing chain.
18. Remove RH timing chain guide (A).
Fig. 57: Identifying RH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
19. Remove oil pump chain sprocket (A) and oil pump chain (B).
Page 45
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 58: Identifying Oil Pump Chain Sprocket And Oil Pump Chain
Courtesy of KIA MOTORS AMERICA, INC.
20. Remove crankshaft sprocket (A) (O/P & RH camshaft drive).
Fig. 59: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
21. Remove LH cam-to-cam guide (A).
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Fig. 60: Identifying LH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
22. Remove LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
Fig. 61: Identifying LH Timing Chain Auto Tensioner And LH Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
23. Remove LH timing chain.
24. Remove LH timin
chain guide (A).
Page 47
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 62: Identifying LH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
25. Remove crankshaft sprocket (A) (LH camshaft drive).
Fig. 63: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
26. Remove tensioner adapter assembly (A).
Page 48
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 64: Identifying Tensioner Adapter Assembly
Courtesy of KIA MOTORS AMERICA, INC.
INSPECTION
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.
REASSEMBLY
1. The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result
Page 49
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke.
Fig. 65: Aligning Key With Timing Mark Of Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
2. Install tensioner adapter assembly (A).
Fig. 66: Identifying Tensioner Adapter Assembly
Courtesy of KIA MOTORS AMERICA, INC.
3. Install crankshaft sprocket (A) (LH camshaft drive).
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Fig. 67: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
4. Install LH timing chain guide (A).
Tightening torque
19.60-24.50 N.m (2.0-2.5 kgf.m, 14.17-18.08 lb-ft)
Fig. 68: Identifying LH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
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 timin
mark of each sprockets should be matched with timing mark (color link) of timing chain at
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
installing timing chain.
Fig. 69: Identifying Timing Mark On Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
6. Install LH timing chain tensioner arm (B).
Tightening torque
18.62-21.56 N.m (1.9-2.2 kgf.m, 13.74-15.91 lb-ft)
7. Install chain tensioner (A).
Tightening torque
9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
Fig. 70: Identifying Chain Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Page 52
8. Install LH cam-to-cam guide (A).
Tightening torque
9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 71: Identifying LH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
9. Install crankshaft sprocket (A) (O/P & RH camshaft drive).
Fig. 72: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
10. Install oil pump chain (B) and oil pump sprocket (A).
Tightening torque
18.62-21.56 N.m (1.9-2.2 kgf.m, 13.74-15.91 lb-ft)
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Fig. 73: Identifying Oil Pump Chain And Oil Pump Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
11. Install RH timing chain guide (A).
Tightening torque
19.60-24.50 N.m (2.0-2.5 kgf.m, 14.17-18.08 lb-ft)
Fig. 74: Identifying RH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
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
installin
timing chain.
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Fig. 75: Matching Timing Mark With Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 76: Matching Timing Mark With Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
13. Install RH timing chain tensioner arm (B).
14. Install RH timing chain auto tensioner (A).
Tightening torque
9.80-11.76 N.m (1.0-1.2 k
f.m, 7.23-8.68 lb-ft)
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 77: Identifying RH Timing Chain Auto Tensioner And Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
15. Install RH cam-to-cam guide (A).
Tightening torque
9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
Fig. 78: Identifying RH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
16. Install oil pump chain guide (A).
Tightening torque
9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
Page 56
2007 Kia Sorento LX
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Fig. 79: Identifying Oil Pump Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
17. Install oil pump chain tensioner assembly (A).
Tightening torque
9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
Fig. 80: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
18. Pull out the pins of hydraulic tensioner (LH & RH).
19. 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)
Page 57
2007 Kia Sorento LX
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Fig. 81: Identifying Oil Pump Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
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.
a. 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.
b. 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: 2.5 mm (0.1 in.)
Fig. 82: Identifying Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
c. After applying liquid sealant TB1217H on timing chain cover.
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2007 Kia Sorento LX
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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: 2.5 mm (0.1 in.)
Fig. 83: Identifying Area For Applying For Sealant
Courtesy of KIA MOTORS AMERICA, INC.
d. Install the new gasket (A) to the timing chain cover.
Fig. 84: Identifying Timing Chain Cover Gasket
Courtesy of KIA MOTORS AMERICA, INC.
e. The dowel pins on the c
linder block and holes on the timing chain cover should be used as a
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reference in order to assemble the timing chain cover to be in exact position.
Tightening torque
B(17): 18.62-21.56 N.m (1.9-2.2 kgf.m, 13.74-15.91 lb-ft)
C(4): 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
D(1): 58.80-68.80 N.m (6.0-7.0 kgf.m, 43.40-50.63 lb-ft)
E(1): 58.80-68.80 N.m (6.0-7.0 kgf.m, 43.40-50.63 lb-ft)
F(2): 24.50-26.46 N.m (2.5-2.7 kgf.m, 18.08-19.53 lb-ft)
G(4): 21.56-23.52 N.m (2.2-2.4 kgf.m, 15.91-17.36 lb-ft)
H(1): 9.80-11.76 N.m (1.0-t.2 kgf.m, 7.23-8.68 lb-ft)
I(1): 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
J(1): 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
K(4): 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
L(1): 21.56-26.46 N.m (2.2-2.7 kgf.m, 15.91-19.53 lb-ft) - New bolt
Fig. 85: Identifying Dowel Pins On Cylinder Block And Holes On Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
f. 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.
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2007-08 ENGINE Mechanical - Sorento
Fig. 86: Installing Timing Chain Cover Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
23. Install lower oil pan.
a. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
b. Before assembling 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: 2.5 mm (0.1 in.).
Fig. 87: Removing Packing Material From Gasket Surfaces
Courtesy of KIA MOTORS AMERICA, INC.
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
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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 oil pan (A).
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)
Fig. 88: Identifying Oil Pan Bolts
Courtesy of KIA MOTORS AMERICA, INC.
24. Using SST (09231-3C300) install crankshaft damper pulley (A).
Tightening torque
284.2-303.8 N.m (29.0-31.0 k
f.m, 209.76-224.22 lb-ft)
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 89: Installing Crankshaft Damper Pulley (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 90: Installing Crankshaft Damper Pulley (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
25. Install cylinder head cover.
a. The hardening sealant located on the upper area between timing chain cover and cylinder head
should be removed before assembling cylinder head cover.
b. After applying sealant (TB1217H), it should be assembled within 5 minutes. Bead width: 2.5 mm
(0.1 in.)
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Fig. 91: Locating Hardening Sealant On Upper Area Between Timing Chain Cover And
Cylinder Head
Courtesy of KIA MOTORS AMERICA, INC.
c. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head
cover was assembled.
d. Install the cylinder head cover bolts as following method.
Tightening torque
9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
Fig. 92: Identifying Cylinder Head Cover Bolts Installing Sequence
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION: Do not reuse cylinder head cover gasket.
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e. Install ignition coil
f. Connect RH ignition coil connector (A), condenser connector (B) and install wiring bracket (C).
Fig. 93: Identifying RH Ignition Coil Connector
Courtesy of KIA MOTORS AMERICA, INC.
g. Install connector bracket from LH cylinder head cover.
INSTALLATION
1. Install intake manifold.
2. Install water pump pulley (A).
Tightening torque
7.84-9.80 N.m (0.8-1.0 kgf.m, 5.78-7.23 lb-ft)
Fig. 94: Identifying Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Page 65
3. 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)
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 95: Identifying Drive Belt Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
4. 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)
Fig. 96: Identifying Drive Belt Idler
Page 66
Courtesy of KIA MOTORS AMERICA, INC.
5. Install alternator
6. Install air compressor
7. Install power steering pump.
8. 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.
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 97: Identifying Drive Belt
Courtesy of KIA MOTORS AMERICA, INC.
CYLINDER HEAD ASSEMBLY
COMPONENTS
Page 67
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2007-08 ENGINE Mechanical - Sorento
Fig. 98: Identifying Cylinder Head Assembly Components With Torque Specification (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
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2007-08 ENGINE Mechanical - Sorento
Fig. 99: Identifying Cylinder Head Assembly Components With Torque Specification (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
REMOVAL
CAUTION:
Use fender covers to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant
temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or
damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while
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holding the connector portion.
NOTE:
Mark all wiring and hoses to avoid mis-connection.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
Engine removal is required for this procedure.
1. Remove exhaust manifold.
2. Remove intake manifold.
3. Remove timing chain.
4. Remove water temperature control assembly.
5. Remove camshaft bearing cap (A).
Fig. 100: Identifying Camshaft Bearing Cap
Courtesy of KIA MOTORS AMERICA, INC.
6. Remove camshaft assembl
(A).
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Fig. 101: Identifying Camshaft Assembly
Courtesy of KIA MOTORS AMERICA, INC.
7. Remove cylinder head bolts, then remove cylinder head.
1. Uniformly loosen and remove the 16 cylinder head bolts, in several passes, in the sequence shown.
Remove the 16 cylinder head bolts and plate washers.
Fig. 102: Identifying Cylinder Head Bolt Loosening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION: Head warpage or cracking could result from removing bolts in
an incorrect order.
2. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden
blocks on a bench.
CAUTION: Be careful not to damage the contact surfaces of the cylinder
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head and cylinder block.
DISASSEMBLY
NOTE: Identify MLA, valves and valve springs as they are removed so that each item
can be reinstalled in its original position.
1. Remove MLAs (A).
Fig. 103: Identifying MLAs
Courtesy of KIA MOTORS AMERICA, INC.
2. Remove valves.
1. Using SST (09222-3K000, 09222-3C300), compress the valve spring and remove retainer lock.
Fig. 104: Compressing Valve Spring Using SST
Courtesy of KIA MOTORS AMERICA, INC.
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2. Remove the spring retainer.
3. Remove the valve spring.
4. Remove the valve.
5. Using SST (09222-29000), remove the valve stem seal.
Fig. 105: Removing Valve Stem Seal
Courtesy of KIA MOTORS AMERICA, INC.
NOTE: Do not reuse old valve stem seals.
3. Remove OCV (A).
Fig. 106: Identifying OCV
Courtesy of KIA MOTORS AMERICA, INC.
INSPECTION
Page 73
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block
and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard: Less than 0.05 mm (0.002 in.) [Less than 0.02 mm (0.0008 in.)/150x150]
Flatness of manifold gasket surface
Standard: Less than 0.03 mm (0.001in)/110x110
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 107: Measuring Surface Contacting Cylinder Block And Manifolds
Courtesy of KIA MOTORS AMERICA, INC.
2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If
cracked, replace the cylinder head.
VALVE AND VALVE SPRING
1. Inspect valve stems and valve guides.
1. Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust: 5.500-5.512 mm (0.216-0.217 in.)
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Fig. 108: Measuring Inside Diameter Of Valve Guide
Courtesy of KIA MOTORS AMERICA, INC.
2. Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake: 5.465-5.480 mm (0.2151-0.2157 in.)
Exhaust: 5.458-5.470 mm (0.2149-0.2153 in.)
Fig. 109: Measuring Diameter Of Valve Stem
Courtesy of KIA MOTORS AMERICA, INC.
3. Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
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g
Intake: 0.020-0.047 mm (0.0008-0.0018 in.)
Exhaust: 0.030-0.054 mm (0.0012-0.0021 in.)
[Limit]
Intake: 0.07 mm (0.0027 in.)
Exhaust: 0.09 mm (0.0035 in.)
2. Inspect valves.
1. Check the valve is ground to the correct valve face angle.
2. Check that the surface of the valve for wear. If the valve face is worn, replace the valve.
3. Check the valve head margin thickness.
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake: 1.56-1.86 mm(0.06142-0.07323 in.)
Exhaust: 1.73-2.03 mm(0.06811-0.07992 in.)
Fig. 110: Checking Valve Head Margin Thickness
Courtesy of KIA MOTORS AMERICA, INC.
4. Check the valve len
th.
Page 76
Length
Intake: 105.27 mm (4.1445in)
Exhaust: 105.50 mm (4.1535in)
5. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace
cylinder head. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width
should be within specifications and centered on the valve face.
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
4. Inspect valve springs.
1. Using a steel square, measure the out-of-square of the valve spring.
2. Using a vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height: 43.86 mm (1.7267 in.)
Out-of-square: 1.5°
MLA
Fig. 111: Measuring Free Length Of Valve Spring
Courtesy of KIA MOTORS AMERICA, INC.
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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.)
CAMSHAFT
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.)
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Fig. 112: Measuring Cam Lobe Height
Courtesy of KIA MOTORS AMERICA, INC.
If the cam lobe height is less than standard, replace the camshaft.
2. Inspect camshaft journal clearance.
1. Clean the bearing caps and camshaft journals.
2. Place the camshafts on the cylinder head.
3. Lay a strip of plastigage across each of the camshaft journal.
Fig. 113: Identifying Plastigage
Courtesy of KIA MOTORS AMERICA, INC.
4. Install the bearing caps.
CAUTION: Do not turn the camshaft.
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5. Remove the bearing caps.
6. 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.)
Fig. 114: Measuring Plastigage At Widest Point
Courtesy of KIA MOTORS AMERICA, INC.
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder
head.
7. Completely remove the plastigage.
8. Remove the camshafts.
3. Inspect camshaft end play.
1. Install the camshafts.
2. Usin
a dial indicator, measure the end play while moving the camshaft back and forth.
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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
Fig. 115: Measuring End Play While Moving Camshaft Back And Forth
Courtesy of KIA MOTORS AMERICA, INC.
If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
3. Remove the camshafts.
CVVT ASSEMBLY
1. Inspect CVVT assembly.
1. Check that the CVVT assembly will not turn.
2. Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.
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Fig. 116: Identifying Retard Hole
Courtesy of KIA MOTORS AMERICA, INC.
3. Wind tape around the tip of the air gun and apply air of approx. 150 kPa (1.5 kgf/cm2 , 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.
4. 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.
Fig. 117: Turning CVVT Assembly To Advance Angle Side
Courtesy of KIA MOTORS AMERICA, INC.
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5. 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°
6. Turn the CVVT assembly with your hand and lock it at the maximum delay angle position
(clockwise).
REASSEMBLY
NOTE: Thoroughly clean all parts to be assembled. Before installing the parts, apply
fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1. Install valves.
1. Using SST (09222-3C100), push in a new oil seal.
NOTE: Do not reuse old valve stem seals. Incorrect installation of the seal
could result in oil leakage past the valve guides.
Fig. 118: Pushing Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
2. Install the valve, valve spring and spring retainer.
NOTE: Place valve springs so that the side coated with enamel faces toward
the valve spring retainer and then installs the retainer.
3. Using the SST (09222-3K000, 09222-3C300), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the
valve sprin
compressor.
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Fig. 119: Compressing Valve Spring Using SST
Courtesy of KIA MOTORS AMERICA, INC.
4. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to
ensure proper seating of the valve and retainer lock.
2. Install MLAs.
Check that the MLA rotates smoothly by hand.
Fig. 120: Identifying MLAs
Courtesy of KIA MOTORS AMERICA, INC.
NOTE: MLA can be reinstalled in its original position.
3. Install OCV (A).
Tightening torque
9.80-11.76 N.m (1.0-1.2 k
f.m, 7.23-8.68 lb-ft)
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Fig. 121: Identifying OCV
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
CAUTION:
INSTALLATION
NOTE:
Thoroughly clean all parts to be assembled.
Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC.
1. Install the cylinder head.
a. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
To install OCV with gray colored connector into RH bank.
To install OCV with black colored connector into LH bank.
Do not reuse the OCV when dropped.
Keep clean the OCV.
Do not hold the OCV sleeve during servicing.
When the OCV is installed on the engine, do not move the
engine with holding the OCV yoke.
b. Apply sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.
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Fig. 122: Identifying Cylinder Block Top Face
Courtesy of KIA MOTORS AMERICA, INC.
NOTE: Refer to illustration to apply the sealant.
Bead width: 2.0-3.0 mm
Sealant locations: 1.0-1.5 mm from block surface
Recommended sealant: Liquid sealant TB1217H
Fig. 123: Identifying Gap Between Cylinder Block Front Face And Cylinder Head Gasket
Courtesy of KIA MOTORS AMERICA, INC.
c. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
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The part must be assembled within 5 minutes after sealant was applied.
Fig. 124: Assembling Cylinder Head Gaskets On Cylinder Block
Courtesy of KIA MOTORS AMERICA, INC.
NOTE: Be careful of the installation direction.
Fig. 125: Identifying Mark On Cylinder Head
Courtesy of KIA MOTORS AMERICA, INC.
d. Install the cylinder head.
NOTE: Remove the extruded sealant after assembling cylinder heads.
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Fig. 126: Identifying Cylinder Head
Courtesy of KIA MOTORS AMERICA, INC.
2. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
1. Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
2. Using SST (09221 -4A000), install and tighten the cylinder head bolts and plate washers, in several
passes, in the sequence shown.
Tightening torque
1st step: 39.2 N.m (4.0 kgf.m, 28.9 lb-ft)
2nd step: 120°
3rd step: 90°
18.62-23.52 N.m (1.9-2.4 kgf.m, 13.74-17.36 lb-ft) (A)
NOTE: Always use new cylinder head bolt.
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Fig. 127: Identifying Cylinder Head Bolt Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 128: Identifying Cylinder Head Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Page 89
2007-08 ENGINE Mechanical - Sorento
Fig. 129: Checking Cylinder Head Bolt Tightening Torque
Courtesy of KIA MOTORS AMERICA, INC.
4. Install the CVVT and camshaft sprocket.
Tightening torque
64.68-76.44 N.m (6.6-7.8 kgf.m, 47.74-56.4 lb-ft)
2007 Kia Sorento LX
Fig. 130: Identifying CVVT And Camshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
Install camshaft-inlet to dowel pin of CVVT assembly.
At this time, attend not to be installed to oil hole of camshaft-inlet.
Hold the hexagonal head wrench portion of the camshaft with a vise,
and install the bolt and CVVT assembly.
Do not rotate CVVT assembly when camshaft is installed to dowel pin
of CVVT assembly.
5. Install camshafts (A).
NOTE:
Apply a light coat of engine oil on camshaft journals.
Assemble the key groove of camshaft rear side to the same level of
head top surface.
Be careful the right, left bank, intake, exhaust side before
assembling.
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Fig. 131: Identifying Camshafts
Courtesy of KIA MOTORS AMERICA, INC.
INTAKE CAMSHAFT
Fig. 132: Identifying Intake Camshaft
Courtesy of KIA MOTORS AMERICA, INC.
INTAKE CAMSHAFT SPECIFICATION
LH RH
3.3L
3.8L
A: Ø27 mm (1.0630 in.) A: Ø30 mm (1.1811 in.)
B: Ø27 mm (1.0630 in.) B: Ø30 mm (1.1811 in.)
A: Ø30 mm (1.1811 in.) A: Ø27 mm (1.0630 in.)
B: Ø27 mm (1.0630 in.) B: Ø30 mm (1.1811 in.)
EXHAUST CAMSHAFT
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Fig. 133: Identifying Exhaust Camshaft
Courtesy of KIA MOTORS AMERICA, INC.
EXHAUST CAMSHAFT SPECIFICATION
LH RH
3.3L/3.8L A: Ø27 mm (1.0630 in.) A: Ø30 mm (1.1811 in.)
Fig. 134: Identifying Intake And Exhaust Camshaft
Courtesy of KIA MOTORS AMERICA, INC.
INTAKE AND EXHAUST CAMSHAFT SPECIFICATION
LH RH
3.3L
3.8L
A: Ø30 mm(1.1811 in.) A: Ø30 mm(1.1811 in.)
B: Ø27 mm(1.0630 in.) B: Ø27 mm(1.0630 in.)
A: Ø30 mm(1.1811 in.) A: Ø30 mm(1.1811 in.)
B: Ø27 mm(1.0630 in.) B: Ø27 mm(1.0630 in.)
6. Install camshaft bearing caps with the order below.
Tightening torque
1st step: 5.9 N.m (0.6 kgf.m, 4.3 lb-ft)
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2nd step: 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
Fig. 135: Identifying Camshaft Bearing Caps Order
Courtesy of KIA MOTORS AMERICA, INC.
NOTE: Be careful the right, left bank, intake, exhaust side before assembling.
Fig. 136: Identifying Marks On Bearing Caps
Courtesy of KIA MOTORS AMERICA, INC.
A. L(LH), R(RH)
B. I (Intake), None (Exhaust)
C. Journal number
D. Front mark
CAUTION: Rotate the crankshaft not to contact the valves to the pistons by
making the pistons below 10 mm (0.3937 in.) from the top of
cylinder block.
Page 93
7. Install water temperature control assembly.
8. Install timing chain.
9. Check and adjust valve clearance.
10. Install the exhaust manifold.
11. Install the intake manifold.
ENGINE BLOCK
COMPONENTS
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
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Fig. 137: Identifying Engine Block Components With Torque Specification (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 138: Identifying Engine Block Components With Torque Specification (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
REMOVAL
CAUTION:
Use fender covers to avoid damaging painted surfaces.
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To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
NOTE:
Mark all wiring and hoses to avoid mis-connection.
Inspection the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove exhaust manifold.
2. Remove intake manifold.
3. Remove timing chain.
4. Remove water temperature control assembly.
5. Remove cylinder head.
6. Remove oil pump.
7. Remove oil filter assembly.
8. Remove A/C compressor (A) from engine.
Fig. 139: Locating A/C Compressor On Engine
Courtesy of KIA MOTORS AMERICA, INC.
9. Remove alternator (A) from engine.
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Fig. 140: Locating Alternator On Engine
Courtesy of KIA MOTORS AMERICA, INC.
10. Remove power steering pump (A) from engine.
Fig. 141: Locating Power Steering Pump On Engine
Courtesy of KIA MOTORS AMERICA, INC.
DISASSEMBLY
1. Remove drive plate.
2. Remove knock sensor (A).
Page 97
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 142: Identifying Knock Sensor
Courtesy of KIA MOTORS AMERICA, INC.
3. Remove upper oil pan (A).
Fig. 143: Identifying Upper Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
4. Remove baffle plate (A).
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2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 144: Identifying Baffle Plate
Courtesy of KIA MOTORS AMERICA, INC.
5. Remove rear oil seal case (A).
Fig. 145: Identifying Rear Oil Seal Case
Courtesy of KIA MOTORS AMERICA, INC.
6. Remove oil drain cover (A).
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g
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 146: Identifying Oil Drain Cover
Courtesy of KIA MOTORS AMERICA, INC.
7. Check the connecting rod end play.
8. Check the connecting rod oil clearance.
9. Remove piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
NOTE:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in the
correct order.
10. Remove crankshaft main bearing cap and check oil clearance.
11. Check the crankshaft end play.
12. Lift the crankshaft (A) out of en
ine, being careful not to damage journals.
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y
2007 Kia Sorento LX
2007-08 ENGINE Mechanical - Sorento
Fig. 147: Identifying Crankshaft
Courtesy of KIA MOTORS AMERICA, INC.
NOTE: Arrange the main bearings and thrust bearings in the correct order.
13. Check fit between piston and piston p in.
Try to move the piston back and forth on the piston p in. If any movement is felt, replace piston and
piston pin as a set.
14. Remove piston rings.
1. Using a piston ring expender, remove the 2 compression rings.
2. Remove 2 side rails and the spacer by hand.
NOTE: Arrange the piston rings in the correct order only.
15. Disconnect connecting rod from piston.
INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod end play.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end pla
: 0.1-0.25 mm (0.004-0.010 in.)
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