2010 Kia Soul

2010 ENGINE General Information (Engine Mechanical System) - 2.0L - Soul

2010 ENGINE

General Information (Engine Mechanical System) - 2.0L - Soul

SPECIFICATIONS
GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Description Specifications Limit
General
Type In-line, Double Overhead
Camshaft
Number of cylinder 4
Bore 82mm (3.228in)
Stroke 93.5mm (3.681in)
Total displacement 1975cc (120.52cu.in)
Compression ratio 10.1 : 1
Firing order 1-3-4-2
Valve timing
Opens (ATDC) ATDC 11° ~ BTDC 29°
Intake valve
Closes (ABDC) ABDC 59° ~ ABDC 19°
Opens (BBDC) 42°
Exhaust
Closes (ATDC) 6°
Valve
Intake 114.34mm (4.5016in)
Valve length
Exhaust 116.8mm (4.598in)
Intake 5.965 ~ 5.98mm (0.2348 ~
0.2354in)
Stem outer diameter
Exhaust 5.950 ~ 5.965mm (0.2343 ~
0.2348in)
Face angle 45° ~ 45°30'
Thickness of valve head (Margin)
Intake 1.6±0.15mm 0.8mm (0.031in)
(0.0630±0.0059in)
Exhaust 1.8±0.15mm 1.0mm (0.039in)
(0.0709±0.0059in)
Valve stem to valve guide clearance
Intake 0.02 ~ 0.05mm (0.0008 ~ 0.10mm (0.0039in)
0.0019in)
Exhaust 0.035 ~ 0.065mm (0.0014 ~ 0.13mm(0.0051in)
0.0026in)
Valve guide

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Intake 45.8~46.2mm
Installed dimension (1.8031~1.8189in)
outer diameter Exhaust 52.8~53.2mm
(2.0787~2.0945in)
Service oversize 0.05, 0.25, 0.50mm (0.002,
0.010, 0.020in) oversize
Valve seat
Intake 1.1 ~ 1.5mm (0.043 ~
0.059in)
Width of seat contact
Exhaust 1.3 ~ 1.7mm (0.051 ~
0.066in)
Oversize 0.3, 0.6mm (0.012,
0.024in) oversize
Valve spring
Free length 48.86mm (1.9236in)
Load 18.8k±0.9kg/39.0mm
(41.4±2.0lb/1.5354in)
41.0±1.5kg/30.5mm
(90.4±3.3lb/1.2008in)
Squareness 1.5° or less
Valve clearance
Intake 0.20mm (0.0079in) 0.17~0.23mm
(0.0067~0.0091in)
Cold (20°C[68°F])
Exhaust 0.28mm (0.0110in) 0.25~0.31mm
(0.0098~0.0122in)
Hot (80°C[176°F]) : Intake 0.29mm (0.0114in)
only for reference Exhaust 0.34mm (0.0134in)
Cylinder head
Flatness of gasket surface Max. 0.03mm (0.0012in) 0.06mm(0.0024in)
Flatness of manifold mounting surface Max. 0.15mm (0.0059in) 0.03mm(0.0012in)
Oversize rework dimensions of valve seat hole
0.3mm (0.012in) O.S. 33.300 ~ 33.325mm
(1.3110 ~ 1.3120in)
Intake
0.6mm (0.024in) O.S. 33.600 ~ 33.625mm
(1.3228 ~ 1.3238in)
0.3mm (0.012in) O.S. 28.800 ~ 28.821mm
(1.1338 ~ 1.1346in)
Exhaust
0.6mm (0.024in) O.S. 29.100 ~ 29.121mm
(1.1456 ~ 1.1465in)
Oversize rework dimensions of valve guide hole (both intake and exhaust)
0.05mm (0.002in) O.S. 11.05 ~ 11.068mm (0.435 ~
0.4357in)
0.25mm (0.010in) O.S. 11.25 ~ 11.268mm (0.443 ~
0.4436in)

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0.50mm (0.020in) O.S. 11.50 ~ 11.518mm (0.453 ~

0.4535in)
Cylinder block
Cylinder bore 82.00 ~ 82.03mm (3.2283 ~
3.2295in)
Out-of-round and taper of cylinder bore Less than 0.01mm
(0.0004in)
Clearance with piston (To set limits to new parts) 0.02 ~ 0.04mm (0.0008 ~
0.0016in)
Piston
Outer diameter (To set limits to new parts) 81.97 ~ 82.00mm (3.2271 ~
3.2283in)
Service oversize 0.25, 0.50mm (0.010,
0.020in) oversize
Piston ring
No. 1 0.04 ~ 0.08mm (0.0015 ~ 0.1mm (0.004in)
0.0031in)
Side clearance
No. 2 0.03 ~ 0.07mm (0.0012 ~
0.0027in)
No. 1 0.20 ~ 0.35mm (0.0079 ~ 1mm (0.039in)
0.0138in)
End gap
No. 2 0.37 ~ 0.52mm (0.0146 ~ 1mm (0.039in)
0.0205in)
Oil ring side rail 0.20 ~ 0.60mm (0.0078 ~ 1mm (0.039in)
0.0236in)
Service oversize 0.25, 0.50mm (0.010,
0.020in.) oversize
Piston pin
Outer diameter 20.001 ~ 20.006mm
(0.7874 ~ 0.7876in)
Hole inner diameter 20.016 ~ 20.021mm
(0.7880 ~ 0.7882in)
Hole clearance 0.010 ~ 0.020mm (0.0004 ~
0.0008in)
Connecting rod small end inner diameter 19.974 ~ 19.985mm
(0.7864 ~ 0.7868in)
Connecting rod
Bend 0.05mm (0.0020in) or less
Twist 0.1mm (0.004in) or less
Connecting rod big end to crankshaft side 0.100 ~ 0.250mm (0.0039 ~ 0.4mm(0.0157in)
clearance 0.010in)
Connecting rod bearing
Oil clearance (To seat limits to new parts) 0.024 ~ 0.042mm (0.0009 ~
0.0017in)

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Undersize 0.25mm (0.01in)

Camshaft
Intake 44.618mm (1.7566in) 44.518mm(1.7527in)
Cam height
Exhaust 44.518mm (1.7527in) 44.418mm (1.7487in)
Journal outer diameter 28mm (1.1023in)
Bearing oil clearance 0.027 ~ 0.061mm (0.0011 ~ 0.1mm(0.0039in)
0.0024in)
End play 0.1 ~ 0.2mm (0.0040 ~
0.0079in)
Crankshaft
Pin outer diameter 44.946 ~ 44.966mm
(1.7695 ~ 1.7703in)
Journal outer diameter 56.942 ~ 56.962mm
(2.2418 ~ 2.2426in)
Bend 0.03mm (0.0012in) or less
Out-of-round, taper of journal and pin 0.01mm (0.0004in) or less 0.030mm (0.0012in)
End play 0.06 ~ 0.260mm (0.0023 ~
0.010in)
Undersize rework 0.25mm (0.010in) 44.725 ~ 44.740mm
dimension of pin (1.7608 ~ 1.7614in)
Undersize rework 0.25mm (0.010in) 56.727 ~ 56.742mm
dimension of journal (2.2333 ~ 2.2339in)
Crankshaft bearing
Oil clearance 0.028 ~ 0.046mm (0.0011 ~
0.0018in)
Flywheel
Runout 0.1mm (0.0039in) 0.13mm(0.0051in)
Cooling method Water-cooled, pressurized.
Forced circulation with
electrical fan
Coolant
Quantity 7.2liter (7.6U.S qts,
6.3lmp.qts)
Radiator
Type Pressurized corrugated fin
type
Radiator cap
Main valve opening pressure 93.16 ~ 122.58kpa (0.95 ~
1.25kg/cm2 , 13.51 ~
17.78psi)
Vacuum valve opening pressure MAX. 6.86 kpa
(0.07kg/cm2 , 1.00 psi)
Thermostat

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Type Wax pellet type with jiggle

valve
Valve opening temperature 82°C (177°F)
Valve closing temperature 77°C (170.6°F)
Full-opening temperature 95°C (201°F)
Coolant pump Centrifugal type impeller
Drive belt
Type V-ribbed belt
Engine coolant temperature sensor
Type Heat-sensitive thermistor
type
Resistance 2.31 ~ 2.59kohms at 20°C
(68°F) 0.3222kohms at 80°
C (176°F)
Oil pump
Clearance between outer circumference and front 0.120 ~ 0.185mm (0.0049 ~
case. 0.0073in)
Front case tip clearance 0.025 ~ 0.069mm (0.0009 ~
0.0027in)
Side clearance
Inner gear 0.04 ~ 0.085mm (0.0016 ~
0.0033in)
Outer gear 0.04 ~ 0.09mm (0.0016 ~
0.0035in)
Engine oil
Total 4.1L (4.33US qt, When replacing a short
3.60lmp.qt) engine or block assembly
Oil pan 3.7L (3.91US qt,
Oil quantity
3.26lmp.qt)
Drain and refill 4.0L (4.23US qt, Including oil filter
3.52lmp.qt)
Recommendation 5W-20/GF4 & SM If not available, refer to
the recommended API or
ILSAC classification and
SAE viscosity number
(Refer to SELECTION
Oil grade OF ENGINE OIL ).
Classification API SL, SM or above Satisfy the requirement of
ILSAC GF3, GF4 or above the API or ILSAC
classification.
SAE viscosity grade Recommended SAE Refer to SELECTION
viscosity number OF ENGINE OIL .
Oil pressure (at 800rpm) 2
100kPa (1.0kg/cm , Oil temperature in oil
14.5psi) pan : 90 ~ 100°C (194 ~

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212°F)
Relief spring
Free height 43.8mm (1.725in.)
Load 3.7kg at 40.1mm
(3.15lb/1.578in)
Air cleaner
Type Dry type
Element Un-woven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers

SERVICE STANDARDS

SERVICE STANDARDS SPECIFICATIONS

Standard value
Antifreeze Mixture ratio of anti-freeze in coolant
Ethylene glycol base for aluminum 50%

TIGHTENING TORQUES

TIGHTENING TORQUE SPECIFICATIONS

Item Nm kgf.m lb-ft
Cylinder Block
Front engine support 34.3 ~ 49.0 3.5 ~ 5.0 25.3 ~ 36.2
bracket bolt
Rear engine support 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
bracket bolt
Engine support bracket 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
stay plate bolt
Main Moving
Connecting rod cap nut 49.0 ~ 52.0 5.0 ~ 5.3 36.2 ~ 38.3
Crankshaft main bearing 27.5~31.4 + (60°~64°) 2.8~3.2 + (60°~64°) 20.3~23.1 + (60°~64°)
cap bolt
Fly wheel M/T bolt 117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 94.0
Drive plate A/T bolt 117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 94.0
Cooling system
Water pump pulley bolts 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Water pump bolts (8X20) 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Water pump bolts (8X35) 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4
Coolant temperature 19.6 ~ 39.2 2.0 ~ 4.0 14.5 ~ 28.9
sensor
Coolant inlet fitting nuts 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5

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Water pump to alternator 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4

brace bolt
Alternator brace to 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4
cylinder block bolt
Thermostat housing bolts 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5
and nuts
Lubrication system
Oil filter 11.8 ~ 15.7 1.2 ~ 1.6 8.7 ~ 11.6
Oil pan bolts 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pan drain plug 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
(Aluminum)
Oil pan drain plug (Steel) 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil screen bolts 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Oil pressure switch 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Intake and Exhaust system
Air cleaner body 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
mounting bolts
Intake manifold to 15.7 ~ 22.6 1.6 ~ 2.3 11.6 ~ 16.6
cylinder head nuts
Intake manifold stay to 17.7 ~ 24.5 1.8 ~ 2.5 13.0 ~ 18.1
cylinder block bolts
Throttle body to surge 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
tank bolts and nuts
Exhaust manifold to 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
cylinder head nuts
Exhaust manifold cover to 16.7 ~ 21.6 1.7 ~ 2.2 12.3 ~ 15.9
exhaust manifold bolts
Oxygen sensor to exhaust 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
manifold
Front muffler to exhaust 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
manifold nuts
Front muffler to catalytic 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
converter nuts
Catalytic converter to 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
center muffler nuts
Center muffler to main 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
muffler nuts
Cylinder head
Cylinder head bolts (M10) 22.6~26.5+(60°~65°)+ 2.3~2.7 + (60°~65°)+ 16.6~19.5+(60°~65°)+
(60°~65°) (60°~65°) (60°~65°)
Cylinder head bolts (M12) 27.5~31.4+(60°~65°) + 2.8~3.2 + (60°~65°)+ 20.3~33.1+(60°~65°)+
(60°~65°) (60°~65°) (60°~65°)
Cylinder head cover bolts 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Camshaft bearing cap 13.7 ~ 14.7 1.4 ~ 1.5 10.1 ~ 10.8

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bolts
Oil control valve bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
OCV filter 40.2 ~ 50.0 4.1 ~ 5.1 29.7 ~ 36.9
CVVT unit to exhaust 64.7 ~ 76.5 6.6 ~ 7.8 47.7 ~ 56.4
camshaft bolt
Timing chain auto 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
tensioner bolts
Timing Belt
Crankshaft pulley bolt 156.9 ~ 166.7 16.0 ~ 17.0 115.7 ~ 123.0
Camshaft sprocket bolt 98.1 ~ 117.7 10.0 ~ 12.0 72.3 ~ 86.8
Timing belt auto tensioner 22.6 ~ 28.4 2.3 ~ 2.9 16.6 ~ 21.0
bolt
Timing belt cover bolts 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Front case bolts 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Timing belt idler bolt 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8

REPAIR PROCEDURES
INSPECTION

Compression Pressure

NOTE: If the 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 wires.

Fig. 1: Identifying Ignition Wires

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Courtesy of KIA MOTORS AMERICA, INC.

3. Remove spark plugs.

Using a 16mm plug wrench, remove the 4 spark plugs.

4. Check cylinder compression pressure

A. Insert a compression gauge into the spark plug hole.

Fig. 2: Checking Cylinder Compression Pressure

Courtesy of KIA MOTORS AMERICA, INC.

B. Fully open the throttle.

C. while cranking the engine, measure the compression pressure.

NOTE: Always use a fully charged battery to obtain engine speed of 250
RPM or more.

D. Repeat steps A through (c) for each cylinder.

NOTE: This measurement must be done in as short a time as possible.

Compression pressure: 1421.96kPa (14.5kgf/cm2 , 206.24psi)

Minimum pressure: 1274.86kPa (13.0kgf/cm2 , 184.90psi)

Difference between each cylinder: 98.07kPa (1.0kgf/cm2 , 14.22psi) or less

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 A through (c) 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.

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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.
6. Install ignition coils.

Timing Belt Tension Adjustment

1. Remove RH front wheel.

2. Remove the 4 bolts and timing belt upper cover (A).

Fig. 3: Identifying Timing Belt Upper Cover & Bolts

Courtesy of KIA MOTORS AMERICA, INC.

3. Loosen the tensioner bolt.

NOTE: When checking the timing belt tension or installing the timing belt
tensioner, the engine oil temperature must be between 15°C (59°F) and 25°
C (77°F)

4. Using a hex wrench, turn the adjuster counterclockwise to make the indicator of the arm (A) located at the
center of the base notch.

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Fig. 4: Turning Adjuster Counterclockwise Using Hex Wrench

Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Do not rotate the adjuster clockwise.

It will result in functional problem with the auto tensioner.

5. Hold the indicator in place while tightening tensioner bolt.

Tightening torque

Tensioner bolt:

22.6 ~ 28.4Nm (2.3 ~ 2.9kgf.m, 16.6 ~ 21.0lb-ft)

6. Turn the crankshaft two revolutions in the operating direction (clockwise) and check that the indicator is
in the center of base.
7. If the indicator is not located at the center of base, loosen the bolt and repeat the above procedure.
8. Install the timing belt upper cover (A).

Tightening torque: 7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Fig. 5: Installing Timing Belt Upper Cover

Courtesy of KIA MOTORS AMERICA, INC.

9. Install RH front wheel.

Valve Clearance Inspection And Adjustment

MLA (Mechanical Lash Adjuster)

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.

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2. Remove the upper timing belt cover (A).

Fig. 6: Identifying Upper Timing Belt Cover

Courtesy of KIA MOTORS AMERICA, INC.

A. Loosen the upper timing cover bolts and then remove the cover.
3. Remove the cylinder head cover.
1. Disconnect the spark plug cables and do not pull on the spark plug boot by force.

NOTE: Pulling on or bending the cables may damage the inside conductor.

2. Disconnect the PCV hose (A) and the breather hose (B) from the cylinder head cover.
3. Disconnect the accelerator cable (C) and the auto-cruise cable (D) from the cylinder head cover.

Fig. 7: Identifying Accelerator Cable, Auto-Cruise Cable, PCV Hose, & Breather Hose
Courtesy of KIA MOTORS AMERICA, INC.

4. Loosen the cylinder head cover bolts (B) and then remove the cover (A) and gasket.

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Fig. 8: Identifying Cylinder Head Cover & Bolts

Courtesy of KIA MOTORS AMERICA, INC.

4. Set No. 1 cylinder to TDC/compression.

1. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing belt
cover.

Fig. 9: Aligning Crankshaft Pulley Groove With Timing Mark T Of Lower Timing Belt
Cover
Courtesy of KIA MOTORS AMERICA, INC.

2. Check that the hole of the camshaft timing pulley (A) is aligned with the timing mark of the bearing
cap.

If not, turn the crankshaft one revolution (360°)

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Fig. 10: Checking Alignment Of Camshaft Timing Pulley Hole & Timing Mark Of Bearing Cap
Courtesy of KIA MOTORS AMERICA, INC.

5. Inspect the valve clearance

1. Check only the valve indicated [No. 1 cylinder: TDC/Compression] and measure the valve
clearance.

Fig. 11: Inspecting Valve Clearance

Courtesy of KIA MOTORS AMERICA, INC.

A. Using a thickness gauge, measure the clearance between the tappet shim and the base circle
of camshaft.
B. Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting shim.

Valve clearance

Specification

Engine coolant temperature: 20°C [68°F]

Intake: 0.20mm (0.0079in.)

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2010 ENGINE General Information (Engine Mechanical System) - 2.0L - Soul

Exhaust: 0.28mm (0.0110in.)

Engine coolant temperature: 80°C [176°F]

Intake: 0.29mm (0.0114in.)

Exhaust: 0.34mm (0.0134in.)

Limit

Intake: 0.17 ~ 0.23mm (0.0067 ~ 0.091in.)

Exhaust: 0.25 ~ 0.31mm (0.0098 ~ 0.0122in.)

2. Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the
lower timing belt cover.
3. Check only valves indicated [NO. 4 cylinder: TDC/compression]. Measure the valve clearance.
[See procedure in step 6]

Fig. 12: Aligning Crankshaft Pulley Groove With Timing Mark T Of Lower Timing Belt Cover
Courtesy of KIA MOTORS AMERICA, INC.

6. Adjust the intake and exhaust valve clearance.

1. Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve is upward.
2. Using the SST (09220 - 2D000), press down the valve lifter and place the stopper between the
camshaft and valve lifter and remove the special tool.

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Fig. 13: Adjusting Intake & Exhaust Valve Clearance

Courtesy of KIA MOTORS AMERICA, INC.

3. Remove the adjusting shim with a small screw driver (A) and magnet (B).

Fig. 14: Adjusting Shim With Screw Driver & Magnet

Courtesy of KIA MOTORS AMERICA, INC.

4. Measure the thickness of the removed shim using a micrometer.

Fig. 15: Measuring Thickness Of Shim Using A Micrometer

Courtesy of KIA MOTORS AMERICA, INC.

5. Calculate the thickness of a new shim so that the valve clearance comes within the specified value.

Valve clearance (Engine coolant temperature: 20°C)

T: Thickness of removed shim

A: Measured valve clearance

N: Thickness of new shim

Intake: N = T + [A - 0.20mm (0.0079in.)]

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Exhaust: N = T + [A-0.28mm (0.0110in.)]

6. Select a new shim with a thickness as close as possible to the calculated value. [Refer to the
Adjusting Shim Selection Charts for Intake/Exhaust in Fig. 16 and Fig. 17]

NOTE: Shims are available in 20size increments of 0.04mm (0.0016in.) from

2.00mm (0.079in.) to 2.76mm (0.1087in.)

7. Place a new adjusting shim on the valve lifter.

8. Using the SST (09220 - 2D000), press down the valve lifter and remove the stopper.
9. Recheck the valve clearance.

Valve clearance (Engine coolant temperature: 20°C)

[Specification]

Intake: 0.20mm (0.0079in.)

Exhaust: 0.28mm (0.0110in.)

[Limit] (After adjusting valve clearance)

Intake: 0.17 ~ 0.23mm (0.0067 ~ 0.0091in.)

Exhaust: 0.25 ~ 0.31mm (0.0098 ~ 0.0122in.)

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Fig. 16: Adjusting Shim Selection Chart (Intake)

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 17: Adjusting Shim Selection Chart (Exhaust)

Courtesy of KIA MOTORS AMERICA, INC.

TROUBLESHOOTING
TROUBLESHOOTING

TROUBLESHOOTING CHART
Symptom Suspect area Remedy
Engine misfire with abnormal Loose or improperly installed Repair or replace the flywheel as
internal lower engine noises. engine flywheel. required.
Worn piston rings Inspect the cylinder for a loss of
(Oil consumption may or may not compression.
cause the engine to misfire.) Repair or replace as required.
Worn crankshaft thrust bearings Replace the crankshaft and
bearings as required
Engine misfire with abnormal Stuck valves. Repair or replace as required
valve train noise. (Carbon buildup on the valve stem)
Excessive worn or mis-aligned Replace the timing chain and
timing chain sprocket as required.
Worn camshaft lobes. Replace the camshaft and valve
lifters.

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Faulty cylinder head gasket

Inspect the cylinder head
and/or cranking or other
and engine block for
damage to the cylinder head
damage to the coolant
Engine misfire with coolant and engine block cooling
passages and/or a faulty
consumption system.
head gasket.
Coolant consumption may or
Repair or replace as
may not cause the engine to
required.
overheat.
Engine misfire with excessive Worn valves, guides and/or valve Repair or replace as required.
oil consumption stem oil seals.
Inspect the cylinder for a
Worn piston rings.
loss of compression.
(Oil consumption may or may not
cause the engine to misfire) Repair or replace as
required.
Engine noise on start-up, but Drain the oil.
only lasting a few seconds. Incorrect oil viscosity Install the correct viscosity
oil.
Inspect the thrust bearing
and crankshaft.
Worn crankshaft thrust bearing.
Repair or replace as
required.
Upper engine noise, regardless Low oil pressure Repair or replace as required.
of engine speed. Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain Replace the timing chain and
and/or damaged sprocket teeth. sprockets.
Worn timing chain tensioner, if Replace the timing chain tensioner
applicable. as required.
Inspect the camshaft lobes.
Worn camshaft lobes. Replace the timing camshaft
and valve lifters as required.
Worn valve guides or valve stems. Inspect the valves and valve
guides, then repair as required.
Stuck valves. (Carbon on the valve Inspect the valves and valve
stem or valve seat may cause the guides, then repair as required.
valve to stay open.
Lower engine noise, regardless Low oil pressure. Repair or required.
of engine speed Loose or damaged flywheel. Repair or replace the flywheel.
Inspect the oil pan.
Damaged oil pan, contacting the oil Inspect the oil pump screen.
pump screen. Repair or replace as
required.

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Inspect the oil pump screen.

Oil pump screen loose, damaged or
restricted. Repair or replace as
required.
Inspect the piston, piston pin
Excessive piston-to-cylinder bore
and cylinder bore.
clearance.
Repair as required.
Inspect the piston, piston pin
and the connecting rod.
Excessive piston pin-to-clearance
Repair or replace as
required.
Inspect the following components
and repair as required.

Excessive connecting rod bearing The connecting rod

rod clearance bearings.
The connecting rods.
The crankshaft.
The crankshaft journal.
Inspect the following components,
and repair as required.
Excessive crankshaft bearing
clearance The crankshaft bearing.
The crankshaft journals.
Verify the piston pins and
Incorrect piston, piston pin and connecting rods are installed
connecting rod installation correctly.
Repair as required.
Engine noise under load Low oil pressure Repair or replace as required.
Inspect the following components
and repair as required:

Excessive connecting rod bearing The connecting rod

clearance bearings.
The connecting rods.
The crankshaft
Inspect the following components,
and repair as required.
Excessive crankshaft bearing The crankshaft bearings.
clearance
The crankshaft journals.
The cylinder block
crankshaft

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Engine will not crank-crankshaft 1. Remove spark plugs and

will not rotate check for fluid.
Hydro-locked cylinder 2. Inspect for broken head
gasket.
Coolant/antifreeze in cylinder.
3. Inspect for cracked engine
Oil in cylinder. black or cylinder head.
Fuel in cylinder 4. Inspect for a sticking fuel
injector and/or leaking fuel
regulator.
1. Inspect timing belt and
Broken timing belt and/or timing
gears.
belt and/or timing belt gears.
2. Repair as required.
Material cylinder 1. Inspect cylinder for
damaged components and/or
Broken valve foreign materials.
Piston material 2. Repair or replace as
Foreign material required.
1. Inspect crankshaft and
Seized crankshaft or connecting rod
connecting rod bearing.
bearings.
2. Repair as required.
1. Inspect connecting rods.
Bent or broken connecting rod.
2. Repair as required.
1. Inspect crankshaft.
Broken crankshaft
2. Repair as required.

SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS CHART

Tool (Number and name) Illustration Use
Crankshaft front oil seal Installation of the front oil seal
installer
(09231-23100)

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Valve clearance adjust tool set Removal and installation of

(09220-2D000) the tappet shim

Camshaft oil seal installer Installation of the camshaft oil

(09221-21000) seal

Valve guide installer Removal and installation of

(09221-3F100 A/B) the valve guide

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Valve stem oil seal installer Installation of the valve stem

(09222-22001) oil seal

Valve spring compressor & Removal and installation of

adaptor the intake or exhaust valve
(09222-28000, 09222-28100)

Crankshaft rear oil seal Installation of the crankshaft

installer rear oil seal
(09231-23200, 09231-H1100)

Oxygen sensor socket Removal and installation of

(09392-2H100) the oxygen sensor

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Oil pan remover Removal of the oil pan

(09215-3C000)

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2010 ENGINE

Cylinder Head Assembly (Engine Mechanical System) - 2.0L - Soul

COMPONENTS AND COMPONENTS LOCATION

COMPONENTS

Fig. 1: Identifying Cylinder Head Assembly Components With Torque Specifications (1 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 2: Identifying Cylinder Head Assembly Components With Torque Specifications (2 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

REPAIR PROCEDURES
REMOVAL

Engine removal is not required for this procedure.

CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damaging the cylinder head, wait until the engine coolant

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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
holding the connector portion.

NOTE: Mark all wiring and hoses to avoid mis-connection.

Inspect the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1. Disconnect the battery terminals (A).

Fig. 3: Identifying Battery Terminals

Courtesy of KIA MOTORS AMERICA, INC.

2. Remove the air intake hose and air cleaner assembly.

1. Disconnect the breather hose (A).
2. Remove the intake air hose and the air cleaner assembly (B).

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Fig. 4: Identifying Breather Hose & Air Cleaner Assembly

Courtesy of KIA MOTORS AMERICA, INC.

3. Loosen the radiator drain plug (A) and drain engine coolant. Remove the radiator cap to speed draining.

Fig. 5: Identifying Radiator Drain Plug

Courtesy of KIA MOTORS AMERICA, INC.

4. Remove the upper radiator hose (A) and lower radiator hose (B).

Fig. 6: Identifying Upper Radiator Hose & Lower Radiator Hose

Courtesy of KIA MOTORS AMERICA, INC.

5. Disconnect the engine wiring harness connectors, clamps and hoses.

1. Disconnect the A/C compressor switch connector (A).
2. Disconnect the knock sensor connector (B).
3. Disconnect the TDC sensor connector (C).
4. Disconnect the fuel injector (No. 1) connector (D).
5. Disconnect the fuel injector (No. 2, 3, 4) connector (E).
6. Disconnect the MAP sensor connector (F).

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Fig. 7: Identifying Connectors

Courtesy of KIA MOTORS AMERICA, INC.

7. Disconnect the engine ground line (A).

Fig. 8: Identifying Engine Ground Line

Courtesy of KIA MOTORS AMERICA, INC.

8. Disconnect the PCSV connector (A).

9. Disconnect the TPS connector (B).
10. Disconnect the ISCA connector (C).

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Fig. 9: Identifying Connectors (1 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

11. Disconnect the front heated oxygen sensor connector (A).

12. Disconnect the rear heated oxygen sensor connector (B).
13. Disconnect the oil pressure switch connector (C).
14. Disconnect the OPS connector (D).
15. Disconnect the CKPS connector (E).
16. Disconnect the OTS connector (F).
17. Disconnect the ECTS connector (D).
18. Disconnect the ignition coil connector (E).
19. Disconnect the inhibitor switch connector (F).

Fig. 10: Identifying Connectors (2 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

20. Disconnect the brake booster vacuum hose (A).

21. Disconnect the heater hoses (B).
22. Disconnect the fuel inlet hose (C).

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23. Disconnect the PCSV hose (D).

Fig. 11: Identifying Hoses

Courtesy of KIA MOTORS AMERICA, INC.

6. Remove the cylinder head cover.

1. Disconnect the spark plug cables and do not pull on the spark plug by force.

NOTE: Pulling on or bending the cables may damage the conductor inside.

2. Disconnect the positive crankcase ventilation (PCV) hose (A).

3. Disconnect the accelerator cable (B) and the auto-cruise cable (C) from the cylinder head cover.

Fig. 12: Identifying PCV Hose, Accelerator Cable, & Auto-Cruise Cable
Courtesy of KIA MOTORS AMERICA, INC.

7. Remove the timing belt. (Refer to TIMING SYSTEM (ENGINE MECHANICAL SYSTEM) - 2.0L )
8. Remove the exhaust manifold and intake manifold. (Refer to INTAKE AND EXHAUST SYSTEM
(ENGINE MECHANICAL SYSTEM) - 2.0L )
9. Remove camshaft sprocket.

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1. Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and remove the
bolt and camshaft sprocket (C).

Fig. 13: Removing Camshaft Sprocket

Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Be careful not to damage the cylinder head and valve lifter with the
wrench.

10. Remove the timing chain auto tensioner (A) after installing the auto tensioner stopper pin (B).

Fig. 14: Identifying Timing Chain Auto Tensioner & Auto Tensioner Stopper Pin
Courtesy of KIA MOTORS AMERICA, INC.

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11. Remove the camshaft bearing caps (A) and camshafts (B).

Fig. 15: Identifying Camshafts & Camshaft Bearing Caps

Courtesy of KIA MOTORS AMERICA, INC.

12. Remove the OCV (oil control valve) (A).

Fig. 16: Identifying Oil Control Valve

Courtesy of KIA MOTORS AMERICA, INC.

13. Remove the OCV (oil control valve) filter (A).

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Fig. 17: Identifying OCV Filter

Courtesy of KIA MOTORS AMERICA, INC.

14. Disconnect the water pipe (A) and water hose (B).

Fig. 18: Identifying Water Pipe & Water Hose

Courtesy of KIA MOTORS AMERICA, INC.

15. Remove the cylinder head bolts, then remove the cylinder head.

1. Using 8mm and 10mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in
several passes, in the sequence shown in Fig. 19. Remove the 10 cylinder head bolts and plate washers.

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Fig. 19: Identifying Removal Sequence Of Cylinder Head Bolts

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 replace the cylinder head on wooden
blocks on a bench.

CAUTION: Be careful not to damage the contact surfaces of the cylinder head and
cylinder block.

REPLACEMENT

Valve Guide

1. Using the SST (09221-3F100A), withdraw the old valve guide toward the bottom of cylinder head.

Fig. 20: Replacing Valve Guide

Courtesy of KIA MOTORS AMERICA, INC.

2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
3. Using the SST (09221-3F100A/B), press-fit the valve guide. The valve guide must be press-fitted from
the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in
length.

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Fig. 21: Press-Fitting Valve Guide Using SST

Courtesy of KIA MOTORS AMERICA, INC.

VALVE GUIDE HOLE SIZE CHART

Over size mm (in.) Size mark Oversize valve guide hole size mm (in.)
0.05 (0.002) 5 11.05 ~ 11.068 (0.4350 ~ 0.4357)
0.25 (0.010) 25 11.25 ~ 11.268 (0.4429 ~ 0.4436)
0.50 (0.020) 50 11.50 ~ 11.518 (0.4528 ~ 0.4535)

Valve guide length

Intake : 46mm (1.8in.)

Exhaust : 54.5mm (2.15in.)

NOTE: Before the valve guide is press-fitted using the SST (09221-3F100A/B),
remove the valve spring seat to install the valve guide correctly.

4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.

DISASSEMBLY

NOTE: Identify MLA (Mechanical Lash Adjuster), valves, valve springs as they are
removed so that each item can be reinstalled in its original position.

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1. Remove MLAs (A).

Fig. 22: Identifying MLA

Courtesy of KIA MOTORS AMERICA, INC.

2. Remove valves.
1. Using SST (09222-28000, 09222-28100), compress the valve spring and remove retainer lock.

Fig. 23: Compressing Valve Spring & Removing Retainer Lock Using SST
Courtesy of KIA MOTORS AMERICA, INC.

2. Remove the spring retainer.

3. Remove the valve spring.
4. Remove the valve.
5. Remove the oil seal using needle-nose pliers.
6. Using a magnetic finger, remove the spring seat.

INSPECTION

Cylinder Head

1. Inspect for flatness.

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Using a precision straight edge and feeler gauge, measure the contacting surfaces of the cylinder block
and the manifolds for warpage.

Flatness of cylinder head gasket surface

Standard : Less than 0.03mm (0.0012 in)

Limit : 0.06 mm (0.0024 in)

Fig. 24: Checking Flatness Of Contacting Surfaces Of Cylinder Block & 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.

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Fig. 25: Measuring Inside Diameter Of Valve Guide

Courtesy of KIA MOTORS AMERICA, INC.

2. Using a micrometer, measure the diameter of the valve stem.

Fig. 26: 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]

Intake : 0.02 ~ 0.05mm (0.0008 ~ 0.0020in)

Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026in)

[Limit]

Intake : 0.1mm (0.0040in)

Exhaust : 0.13mm (0.0051in)

If the clearance is greater than maximum, replace the valve and valve guide.

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2. Inspect valves.
1. Check that the valve is ground to the correct valve face angle.
2. Check the surface of the valve for wear.

If the valve face is worn, replace the valve.

3. Check the valve head margin thickness.

If the margin thickness is less than minimum, replace the valve.

Margin

[Standard]

Intake : 1.6 mm (0.0630 in)

Exhaust : 1.8 mm (0.0709 in)

[Limit]

Intake : 1.45 mm (0.0571 in)

Exhaust : 1.65 mm (0.0650 in)

Fig. 27: Checking Valve Head Margin Thickness

Courtesy of KIA MOTORS AMERICA, INC.

4. 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.

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Replace the seat if necessary.

Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat. 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.

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 : 48.86mm (1.9236 in)

Load:

18.8±0.9kg/39.0mm (41.4±2.0lb/1.5354in)

41.0±1.5kg/30.5mm (90.4±3.3lb/1.2008in)

Out-of-square : 1.5°

[Limit]

Out-of-square : 3°

Fig. 28: Measuring Free Length & Out-Of-Square Of Valve Spring

Courtesy of KIA MOTORS AMERICA, INC.

If the free length is not as specified, replace the valve spring.

Camshaft

1. Inspect cam lobes.

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Using a micrometer, measure the cam lobe height.

Cam height

[Standard value]

Intake : 44.518~44.718mm (1.7527~1.7605in)

Exhaust : 44.418~44.618mm (1.7487~1.7566in)

Fig. 29: Measuring Cam Lobe Height

Courtesy of KIA MOTORS AMERICA, INC.

If the cam lobe height is less than minimum, 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. 30: Inspecting Camshaft Journal Clearance

Courtesy of KIA MOTORS AMERICA, INC.

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4. Install the bearing caps.

CAUTION: Do not turn the camshaft.

5. Remove the bearing caps.

6. Measure the plastigage at its widest point.

Bearing oil clearance:

[Standard value] : 0.02 ~ 0.061mm (0.0008 ~ 0.0024in)

[Limit] : 0.1mm (0.0039in)

Fig. 31: Measuring Plastigage At Its Widest Point

Courtesy of KIA MOTORS AMERICA, INC.

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.

7. Completely remove the plastigage.

8. Remove the camshafts.
3. Inspect camshaft end play.
1. Install the camshafts.
2. Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play

[Standard value] : 0.1 ~ 0.15mm (0.0039 ~ 0.0059in)

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Fig. 32: Measuring Camshaft End Play

Courtesy of KIA MOTORS AMERICA, INC.

If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.

3. Remove the camshafts.

CVVT Assembly

1. Inspect CVVT assembly.

1. Check that the CVVT assembly will not turn.
2. Apply vinyl tape to all the parts except the one indicated by the arrow in Fig. 33.

Fig. 33: Identifying No-Tape Area

Courtesy of KIA MOTORS AMERICA, INC.

3. Wind tape around the tip of the air gun and apply air of approx. 100kpa (1kgf/cm2 , 14psi) to the
port of the camshaft.

(Perform this order to release the lock pin for the maximum delay angle locking.)

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NOTE: When the oil splashes, wipe it up with a shop rag.

4. Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked
direction shown in Fig. 33) by 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.

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: Moves smoothly in the range about 20°

6. Turn the CVVT assembly with your hand and lock it at the maximum delay angle position.

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. Install the spring seats.
2. Using SST (09222-22001), 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.

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Fig. 34: Pushing In New Oil Seal

Courtesy of KIA MOTORS AMERICA, INC.

3. 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.

4. Using the SST (09222-28000, 09222-28100), 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 spring compressor.

Fig. 35: Compressing Valve Spring & Installing Retainer Locks Using SST
Courtesy of KIA MOTORS AMERICA, INC.

5. 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.

Fig. 36: Tapping Valve Stem

Courtesy of KIA MOTORS AMERICA, INC.

2. Install MLAs.

Check that the MLA rotates smoothly by hand.

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Fig. 37: Identifying MLA

Courtesy of KIA MOTORS AMERICA, INC.

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 gasket (A) on the cylinder block.

Fig. 38: Installing Cylinder Head Gasket On Cylinder Block

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Be careful of the installation direction.

2. Place the cylinder head gently in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.

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2. Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate
washers, in several passes, in the sequence shown in Fig. 39.

Tightening torque

M10:

22.6~26.5Nm (2.3~2.7kgf.m, 16.6~19.5lb-ft) + (60° ~ 65°) + (60° ~ 65°)

M12:

27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) + (60° ~ 65°) + (60° ~ 65°)

Fig. 39: Identifying Tightening Sequence Of Cylinder Head Bolts

Courtesy of KIA MOTORS AMERICA, INC.

4. Install OCV filter (A).

Tightening torque

40.2 ~ 50.0Nm (4.1 ~ 5.1kgf.m, 29.7 ~ 36.9lb-ft)

Fig. 40: Identifying OCV Filter

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Always use a new OCV filter gasket.

Keep the OCV filter clean.

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5. Install OCV (A).

Tightening torque

9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

CAUTION: Do not reuse the OCV when dropped.

Keep clean the OCV.
Do not hold the OCV sleeve (B) during servicing.
When the OCV is installed on the engine, do not rotate the
engine while holding the OCV yoke.

Fig. 41: Identifying OCV & OCV Sleeve

Courtesy of KIA MOTORS AMERICA, INC.

6. Install the camshafts.

1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain
sprocket as shown in Fig. 42.

Fig. 42: Aligning Camshaft Timing Chain With Intake Timing Chain Sprocket & Exhaust
Timing Chain Sprocket
Courtesy of KIA MOTORS AMERICA, INC.

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2. Install the camshafts (A) and bearing caps (B).

Tightening torque

13.7 ~ 14.7Nm (1.4 ~ 1.5kgf.m, 10.1 ~ 10.8lb-ft)

Fig. 43: Identifying Camshafts & Bearing Caps

Courtesy of KIA MOTORS AMERICA, INC.

3. Install the timing chain auto tensioner (A).

Tightening torque

7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

4. Remove the auto tensioner stopper pin (B).

Fig. 44: Identifying Timing Chain Auto Tensioner & Auto Tensioner Stopper Pin
Courtesy of KIA MOTORS AMERICA, INC.

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7. Check and adjust valve clearance.

8. Using the SST (09221-21000), install the camshaft bearing oil seal.

Fig. 45: Installing Camshaft Bearing Oil Seal Using SST

Courtesy of KIA MOTORS AMERICA, INC.

9. Install the camshaft sprocket and tighten the bolt to the specified torque.
1. Temporarily install the camshaft sprocket bolt.
2. Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and tighten the
camshaft sprocket (C) bolt.

Tightening torque

Camshaft sprocket bolt:

98.1 ~ 117.7Nm (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

Fig. 46: Tightening Camshaft Sprocket Bolt

Courtesy of KIA MOTORS AMERICA, INC.

10. Install the timing belt. (Refer to TIMING SYSTEM (ENGINE MECHANICAL SYSTEM) - 2.0L )
11. Install the cylinder head cover.

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1. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).

Fig. 47: Installing Cylinder Head Cover Gasket In Groove Of Cylinder Head Cover
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Before installing the head cover gasket, thoroughly clean the
head cover gasket and the groove.
When installing, make sure the head cover gasket is seated
securely in the corners of the recesses with no gap.

2. Apply liquid gasket to the head cover gasket at the corners of the recess.

Fig. 48: Identifying Liquid Gasket Application Area On Head Cover Gasket
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Use liquid gasket, Loctite No. 5999.

Check that the mating surfaces are clean and dry before
applying liquid gasket
After assembly, wait at least 30 minutes before filling the engine
with oil.

3. Install the cylinder head cover (A) with the 12 bolts (B). Uniformly tighten the bolts in several
passes.

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Tightening torque

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

Fig. 49: Identifying Cylinder Head Cover & Bolts

Courtesy of KIA MOTORS AMERICA, INC.

4. Connect the accelerator cable (B) and the auto-cruise cable (C) from the cylinder head cover.
5. Connect the positive crankcase ventilation (PCV) hose (A).

Fig. 50: Identifying PCV Hose, Accelerator Cable, & Auto-Cruise Cable
Courtesy of KIA MOTORS AMERICA, INC.

6. Connect the spark plug cables.

NOTE: Pulling on or bending the cables may damage the inside conductor.

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Fig. 51: Identifying Spark Plug Cables

Courtesy of KIA MOTORS AMERICA, INC.

12. Install the intake manifold and exhaust manifold. (Refer to INTAKE AND EXHAUST SYSTEM
(ENGINE MECHANICAL SYSTEM) - 2.0L )
13. Connect the engine wiring harness connectors, clamps and hoses.
1. Connect the brake booster vacuum hose (A).
2. Connect the heater hoses (B).
3. Connect the fuel inlet hose (C).
4. Connect the PCSV hose (D).

Fig. 52: Identifying Hoses

Courtesy of KIA MOTORS AMERICA, INC.

5. Connect the front heated oxygen sensor connector (A).

6. Connect the rear heated oxygen sensor connector (B).
7. Connect the oil pressure switch connector (C).
8. Connect the CKPS connector (D).
9. Connect the OCV connector (E).

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10. Connect the OTS connector (F).

11. Connect the ECTS connector (D).
12. Connect the ignition coil connector (E).
13. Connect the inhibitor switch connector (F).

Fig. 53: Identifying Connectors (1 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

14. Connect the PCSV connector (A).

15. Connect the TPS connector (B).
16. Connect the ISCA connector (C).

Fig. 54: Identifying Connectors (2 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

17. Connect the engine ground line (A).

Tightening torque:

9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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Fig. 55: Identifying Engine Ground Line

Courtesy of KIA MOTORS AMERICA, INC.

18. Connect the A/C compressor switch connector (A).

19. Connect the knock sensor connector (B).
20. Connect the TDC sensor connector (C).
21. Connect the fuel injector (No. 1) connector (D).
22. Connect the fuel injector (No. 2,3,4) connector (E).
23. Connect the MAP sensor connector (F).

Fig. 56: Identifying Connectors

Courtesy of KIA MOTORS AMERICA, INC.

14. Install the upper radiator hose (A) and lower radiator hose (B).

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Fig. 57: Identifying Upper Radiator Hose & Lower Radiator Hose
Courtesy of KIA MOTORS AMERICA, INC.

15. Install the air intake hose and air cleaner assembly.
16. Connect the battery terminals.
17. Fill with engine coolant.
18. Start the engine and check for leaks.
19. Recheck engine coolant level and oil level.

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 2010 Kia Soul
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2010 ENGINE

Cylinder Block - 2.0L - Soul

COMPONENTS AND COMPONENT LOCATIONS

COMPONENTS

Fig. 1: Identifying Cylinder Block Components With Torque Specifications (1 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 2: Identifying Cylinder Block Components With Torque Specifications (2 Of 2)

Courtesy of KIA MOTORS AMERICA, INC.

REPAIR PROCEDURES
DISASSEMBLY

1. M/T: remove flywheel.

2. A/T: remove drive plate.
3. Install engine to engine stand for disassembly.
4. Remove timing belt. (Refer to TIMING SYSTEM - 2.0L )
5. Remove cylinder head. (Refer to CYLINDER HEAD ASSEMBLY - 2.0L )
6. Remove oil level gauge assembly (A).

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Fig. 3: Identifying Oil Level Gauge Assembly

Courtesy of KIA MOTORS AMERICA, INC.

7. Remove knock sensor.

8. Remove oil pressure sensor (A).

Fig. 4: Identifying Oil Pressure Sensor

Courtesy of KIA MOTORS AMERICA, INC.

9. Remove water pump.

10. Remove oil pan.
11. Remove oil screen.

Remove the 2 bolts (C), oil screen (A) and gasket (B).

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Fig. 5: Identifying Oil Screen, Gasket, & Bolts

Courtesy of KIA MOTORS AMERICA, INC.

12. Check the connecting rod end play.

13. Remove the connecting rod caps and check oil clearance.
14. 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.

15. Remove front case.

16. Remove rear oil seal case.

Remove the 5 bolts (B) and rear oil seal case (A).

Fig. 6: Identifying Rear Oil Seal Case & Bolts

Courtesy of KIA MOTORS AMERICA, INC.

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17. Remove crankshaft bearing cap and check oil clearance.

18. Check the crankshaft end play.
19. Lift the crankshaft (A) out of the engine, being careful not to damage journals.

NOTE: Arrange the main bearings and thrust washers in the correct order.

Fig. 7: Identifying Crankshaft

Courtesy of KIA MOTORS AMERICA, INC.

20. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and
pin as a set.

21. Remove piston rings.

1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.

NOTE: Arrange the piston rings in the correct order only.

22. 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 play: 0.1~ 0.25mm (0.004 ~ 0.010in)

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Maximum end play: 0.4mm (0.016in)

Fig. 8: Checking Connecting Rod End Play

Courtesy of KIA MOTORS AMERICA, INC.

A. If out-of-tolerance, install a new connecting rod.

B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap nuts.
3. Remove the connecting rod cap and bearing half.
4. Clean the crank pin and bearing.
5. Place plastigage across the crank pin.
6. Reinstall the bearing half and cap, and torque the nuts.

Tightening torque

49.0 ~ 52.0 Nm (5.0 ~ 5.3kgf.m, 36.2 ~ 38.3lb-ft)

NOTE: Do not turn the crankshaft.

7. Remove the 2 nuts, connecting rod cap and bearing half.

8. Measure the plastigage at its widest point.

Standard oil clearance

0.024 ~ 0.042mm (0.0009 ~ 0.0017in)

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Fig. 9: Measuring Plastigage At Widest Point

Courtesy of KIA MOTORS AMERICA, INC.

9. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in CONNECTING
ROD SELECTION), and recheck the clearance.

CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.

CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Connecting rod mark location

Fig. 10: Locating Connecting Rod Mark

Courtesy of KIA MOTORS AMERICA, INC.

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Discrimination Of Connecting Rod

CONNECTING ROD DISCRIMINATION

Class Mark Inside Diameter
A White 48.00 ~ 48.006mm (1.8896 ~
1.8899in.)
B None 48.006 ~ 48.012mm (1.8899 ~
1.8902in.)
C Yellow 48.012 ~ 48.018mm (1.8902 ~
1.8904in.)

Crankshaft Pin Mark Location

Fig. 11: Locating Crankshaft Pin Mark

Courtesy of KIA MOTORS AMERICA, INC.

Fig. 12: Locating Crankshaft Mark

Courtesy of KIA MOTORS AMERICA, INC.

Discrimination Of Crankshaft

CRANKSHAFT DISCRIMINATION
Class Mark Outside Diameter Of Pan
I Yellow 44.960 ~ 44.966mm (1.7700 ~
1.7703in.)
II None 44.954 ~ 44.960mm (1.7698 ~
1.7700in.)

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III White 44.948 ~ 44.954mm (1.7696 ~

1.7698in.)

Place Of Identification Mark (Connecting Rod Bearing)

Fig. 13: Locating Connecting Rod Bearing Mark

Courtesy of KIA MOTORS AMERICA, INC.

Discrimination Of Connecting Rod Bearing

CONNECTING ROD BEARING DISCRIMINATION

Class Mark Thickness Of Bearing
AA Blue 1.514 ~ 1.517mm (0.0596 ~
0.0597in.)
A Black 1.511 ~ 1.514mm (0.0595 ~
0.0596in.)
B None 1.508 ~ 1.511mm (0.0594 ~
0.0595in.)
C Green 1.505 ~ 1.508mm (0.0593 ~
0.0594in.)
D Yellow 1.502 ~ 1.505mm (0.0591 ~
0.0593in)

11. Selection of connecting rod.

CONNECTING ROD SELECTION

Connecting Rod Identification Assembling Classification Of
Crankshaft Identification Mark Mark Bearing
A (White) D (Yellow)
I (Yellow) B (None) C (Green)
C (Yellow) B (None)
A (White) C (Green)
II (None) B (None) B (None)
C (Yellow) A (Black)

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A (White) B (None)
III (White) B (None) A (Black)
C (Yellow) AA (Blue)

3. Check the connecting rod.

1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at
disassembly match. When a new connecting rod is installed, make sure that the notches for holding
the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced
as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is
close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent
or distorted should be replaced.

Allowable bend of connecting rod:

0.05mm/100mm (0.0020 in./3.94 in) or less

Allowable twist of connecting rod:

0.1mm/100mm (0.0039 in./3.94 in) or less

4. Check the crankshaft bearing oil clearance.

1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
2. Clean each main journal and bearing half with a clean shop tower.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and caps, then torque the bolts.

Tightening torque:

27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.11lb-ft) + 60° ~ 64°

NOTE: Do not turn the crankshaft.

5. Remove the cap and bearing again, and measure the widest part of the plastigage.

Standard oil clearance:

0.028 ~ 0.046mm (0.0011 ~ 0.0018in)

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Fig. 14: Measuring Widest Part Of Plastigage

Courtesy of KIA MOTORS AMERICA, INC.

6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in CYLINDER
BLOCK SELECTION), and recheck the clearance.

CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.

CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Crankshaft Bore Mark Location

Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal
bores.

Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the
correct bearings.

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Fig. 15: Locating Crankshaft Bore Mark

Courtesy of KIA MOTORS AMERICA, INC.

Discrimination Of Cylinder Block

CYLINDER BLOCK DISCRIMINATION

Class Mark Inside Diameter
a A 59.000 ~ 59.006mm (2.3228 ~
2.3230in.)
b B 59.006 ~ 59.012mm (2.3230 ~
2.3233in.)
c C 59.012 ~ 59.018mm (2.3233 ~
2.3235in.)

Crankshaft Journal Mark Location

Fig. 16: Locating Crankshaft Journal Mark

Courtesy of KIA MOTORS AMERICA, INC.

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Fig. 17: Locating Crankshaft Mark

Courtesy of KIA MOTORS AMERICA, INC.

Discrimination Of Crankshaft

CRANKSHAFT DISCRIMINATION
Class Mark Outside Diameter Of Journal
I Yellow 54.956 ~ 54.962mm (2.1636 ~
2.1638in.)
II None 54.950 ~ 54.956mm (2.1633 ~
2.1636in.)
III White 54.944 ~ 54.950mm (2.1631 ~
2.1633in.)

Place Of Identification Mark (Crankshaft Bearing)

Fig. 18: Identifying Identification Mark Of Crankshaft Bearing

Courtesy of KIA MOTORS AMERICA, INC.

Discrimination Of Crankshaft Bearing

CRANKSHAFT BEARING DISCRIMINATION

Class Mark Thickness Of Bearing
AA Blue 2.014 ~ 2.017mm (0.0793 ~
0.0794in.)
A Black 2.011 ~ 2.014mm (0.0791 ~

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0.0793in.)
B None 2.008 ~ 2.011mm (0.0790 ~
0.0791in.)
C Green 2.005 ~ 2.008mm (0.0789 ~
0.790in.)
D Yellow 2.002 ~ 2.005mm (0.0788 ~
0.0789in.)

Selection

CRANKSHAFT BEARING SELECTION

Crankshaft Bore Identification Assembling Classification Of
Crankshaft Identification Mark Mark Bearing
a (A) D (Yellow)
I (Yellow) b (B) C (Green)
c (C) B (None)
a (A) C (Green)
II (None) b (B) B (None)
c (C) A (Black)
a (A) B (None)
III (White) b (B) A (Black)
c (C) AA (Blue)

5. Check crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.

Standard end play:

0.06 ~ 0.26mm (0.0023 ~ 0.010in)

Limit: 0.30mm (0.0118in)

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Fig. 19: Checking Crankshaft End Play

Courtesy of KIA MOTORS AMERICA, INC.

If the end play is greater than maximum, replace the thrust bearings as a set.

Thrust bearing thickness:

2.44 ~ 2.47mm (0.096 ~ 0.097in)

6. Inspect main journals and crank pins

Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter:

56.942 ~ 56.962mm (2.2418~2.2426in)

Crank pin diameter:

44.946 ~ 44.966mm (1.7695 ~ 1.7703in)

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Fig. 20: Measuring Diameter Of Each Main Journal & Crank Pin
Courtesy of KIA MOTORS AMERICA, INC.

Cylinder Block

1. Remove gasket material.

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2. Clean cylinder block

Using a soft brush and solvent, thoroughly clean the cylinder block.

3. Inspect top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket
for warpage.

Flatness of cylinder block gasket surface

Standard: Less than 0.03mm (0.0012 in)

Limit: 0.05 mm (0.0020 in)

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Fig. 21: Inspecting Top Surface Of Cylinder Block For Flatness

Courtesy of KIA MOTORS AMERICA, INC.

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratches.

If deep scratches are present, replace the cylinder block.

5. Inspect cylinder bore diameter

Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial
directions.

Standard diameter:

82.00 ~ 82.03mm (3.2283 ~ 3.2295in)

Fig. 22: Inspecting Cylinder Bore Diameter

Courtesy of KIA MOTORS AMERICA, INC.

6. Check the cylinder bore size code on the cylinder block bottom face.

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Fig. 23: Checking Cylinder Bore Size Code On Cylinder Block Bottom Face
Courtesy of KIA MOTORS AMERICA, INC.

CYLINDER BORE SIZE CODE CHART

Class Cylinder Bore Inner Diameter Size code
A 82.00 ~ 82.01mm (3.228~ A
3.2287in)
B 82.01 ~ 82.02mm (3.2287~ B
3.2291in)
C 82.02 ~ 82.03mm (3.2291~ C
3.2295in.)

7. Check the piston size code on the piston top face.

Fig. 24: Checking Piston Size Code On Piston Top Face

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Stamp the grade mark of basic diameter with rubber stamp.

PISTON SIZE CODE CHART

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Class Piston Outer Diameter Size Code

A 81.97 ~ 81.98mm (3.2271 ~ A
3.2275in)
B 81.98 ~ 81.99mm (3.2275 ~ B
3.2279in)
C 81.99 ~ 82.00mm (3.2279 ~ C
3.2283in)

8. Select the piston related to cylinder bore class.

Clearance

0.02 ~ 0.04mm (0.00078 ~ 0.00157in.)

Boring Cylinder

1. Oversize pistons should be selected according to the largest bore cylinder.

PISTON SELECTION CHART

Identification Mark Size
0.25 0.25mm (0.010in)
0.50 0.50mm (0.020in)

NOTE: The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D., calculate the new bore size.

New bore size = Piston O.D. + 0.02 to 0.04 mm

(0.0008 to 0.0016 in.) (clearance between piston and cylinder) - 0.01 mm (0.0004 in.) (honing margin.)

4. Bore each of the cylinders to the calculated size.

CAUTION: To prevent distortion that may result from temperature rise during
honing, bore the cylinder holes in the firing order.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.

Standard: 0.02-0.04 mm (0.0008-0.0016 in.)

NOTE: When boring the cylinders, finish all of the cylinders to the same oversize.
Do not bore only one cylinder to the oversize.

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Piston And Rings

1. Clean piston
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
3. Using solvent and a brush, thoroughly clean the piston.

NOTE: Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 47 mm (1.85 in.) from the top land of
the piston.

Standard diameter

81.97 ~ 82.00mm (3.2272 ~ 3.2283in)

Fig. 25: Measuring Piston Outside Diameter

Courtesy of KIA MOTORS AMERICA, INC.

3. Calculate the difference between the cylinder bore diameter and the piston diameter.

Piston-to-cylinder clearance

0.02 ~ 0.04mm (0.0008 ~ 0.0016in)

4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.

Piston ring side clearance

No. 1: 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in)

No. 2: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in)

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Oil ring: 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in)

Limit

No. 1: 0.1mm (0.004in)

No. 2: 0.1mm (0.004in)

Oil ring: 0.2 mm (0.0079 in)

Fig. 26: Measuring Clearance Between Piston Ring & Wall Of Ring Groove
Courtesy of KIA MOTORS AMERICA, INC.

If the clearance is greater than maximum, replace the piston.

5. Inspect piston ring end gap.

To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.
If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder
bore diameter against the wear limits. If the bore is over the service limit, the cylinder block must be
rebored.

Piston ring end gap

Standard

No. 1: 0.20 ~ 0.35mm (0.0079 ~ 0.0138 in)

No. 2: 0.37 ~ 0.52mm (0.0146 ~ 0.0205 in)

Oil ring: 0.20 ~ 0.60 mm (0.0079 ~ 0.0236 in)

Limit

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No. 1, 2, oil ring: 1.0mm (0.039in)

Fig. 27: Measuring Piston Ring End Gap

Courtesy of KIA MOTORS AMERICA, INC.

Piston Pins

1. Measure the diameter of the piston pin.

Piston pin diameter

20.001 ~ 20.006mm (0.7874 ~ 0.7876in)

Fig. 28: Measuring Diameter Of Piston Pin

Courtesy of KIA MOTORS AMERICA, INC.

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2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance

0.01 ~ 0.02mm (0.0004 ~ 0.0008in)

3. Check the difference between the piston pin diameter and the connecting rod small end diameter.

Piston pin-to-connecting rod interference

-0.032 ~ -0.016mm (-0.0013 ~ -0.00006in)

Oil Pressure Switch

1. Check the continuity between the terminal and the body with an ohmmeter.

If there is no continuity, replace the oil pressure switch.

Fig. 29: Checking Continuity Between Oil Pressure Switch Terminal & Body
Courtesy of KIA MOTORS AMERICA, INC.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) is applied through the oil hole, the switch is operating
properly. Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

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Fig. 30: Checking Continuity Between Oil Pressure Switch Terminal & Body
Courtesy of KIA MOTORS AMERICA, INC.

REASSEMBLY

NOTE: Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating
surfaces.
Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble piston and connecting rod.

1. Use a hydraulic press for installation.
2. The piston front mark and the connecting rod front mark must face the timing belt side of the
engine.

Fig. 31: Identifying Front Marks Of Piston & Connecting Rod

Courtesy of KIA MOTORS AMERICA, INC.

2. Install piston rings.

1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.

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3. Position the piston rings so that the ring ends are as shown in Fig. 32.

Fig. 32: Installing Piston Rings

Courtesy of KIA MOTORS AMERICA, INC.

3. Install connecting rod bearings.

1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).

Fig. 33: Identifying Bearing & Connecting Rod Cap

Courtesy of KIA MOTORS AMERICA, INC.

4. Install main bearings.

NOTE: Upper 1, 2,4,5 bearings have an oil groove of oil holes; Lower bearings do
not.

1. Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings
(A).

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Fig. 34: Pushing In Upper Bearings

Courtesy of KIA MOTORS AMERICA, INC.

2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower
bearings.
5. Install thrust bearings.

Install the 2 thrust bearings under the No. 3 journal position of the cylinder block with the oil grooves
facing outward.

Fig. 35: Installing Thrust Bearings

Courtesy of KIA MOTORS AMERICA, INC.

6. Place crankshaft on the cylinder block.

7. Place main bearing caps on cylinder block.
8. Install main bearing cap bolts.

NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
Always use new main bearing cap bolts.

1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.

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2. Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown
in Fig. 36.

Tightening torque

27.5 ~ 31.4Nm (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft) + 60 ~ 64°

Fig. 36: Identifying Tightening Sequence Of Bearing Cap Bolts

Courtesy of KIA MOTORS AMERICA, INC.

3. Check that the crankshaft turns smoothly.

9. Check crankshaft end play.
10. Install piston and connecting rod assemblies.

NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves
and cylinder bores.

1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of
the connecting rod bolts.
2. Install the ring compressor, check that the bearing is securely in place, then position the piston in
the cylinder, and tap it in using the wooden handle of a hammer.
3. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment
before pushing the piston into place.
4. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the nuts: 49.0 ~
52.0Nm (5.0 ~ 5.3kgf.m, 36.2 ~ 38.3lb-ft)

NOTE: Maintain downward force on the ring compressor to prevent the rings from
expanding before entering the cylinder bore.

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Fig. 37: Installing Piston & Connecting Rod Assemblies

Courtesy of KIA MOTORS AMERICA, INC.

11. Install a new gasket and rear oil seal case (A) with 5 bolts (B).

Tightening torque

9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Fig. 38: Identifying Rear Oil Seal Case & Bolts

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Check that the mating surfaces are clean and dry.

12. Install rear oil seal.

1. Apply engine oil to a new oil seal lip.
2. Using SST (09231-23200, 09231-H1100) and a hammer, tap in the oil seal until its surface is flush
with the rear oil seal retainer edge.

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Fig. 39: Installing Oil Seal Using SST & Hammer

Courtesy of KIA MOTORS AMERICA, INC.

13. Install front case.

14. Install oil screen.

Install a new gasket (A) and oil screen (B) with 2 bolts (C).

Tightening torque

14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)

Fig. 40: Identifying Gasket, Oil Screen, & Bolts

Courtesy of KIA MOTORS AMERICA, INC.

15. Install oil pan.

1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.

NOTE: Check that the mating surfaces are clean and dry before applying
liquid gasket.

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2. Apply liquid gasket as an even bead, centered between the edges of the mating surface.

Use liquid gasket 'TB 1217H' or equivalent.

NOTE: To prevent leakage of oil, apply liquid gasket to the inner

threads of the bolt holes.
Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.
After assembly, wait at least 30 minutes before filling the engine
with oil.

3. Install the oil pan with the 19 bolts.

Uniformly tighten the bolts in several passes.

Tightening torque

9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

16. Install water pump. (Refer to COOLING SYSTEM - 2.0L )

17. Install oil pressure sensor.
1. Apply adhesive to 2 or 3 threads.

Adhesive: Three bond 2310/2350 or equivalent.

2. Install the oil pressure sensor (A).

Tightening torque

14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)

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Fig. 41: Identifying Oil Pressure Sensor

Courtesy of KIA MOTORS AMERICA, INC.

18. Install knock sensor.

Tightening torque

16.7 ~ 26.5Nm (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lb-ft)

19. Install oil level gauge assembly.

1. Install a new O-ring on the oil level gauge.
2. Apply engine oil on the O-ring.
3. Install the oil level gauge assembly (A) with the bolt.

Tightening torque

18.6 ~ 23.5Nm (1.9~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

Fig. 42: Identifying Oil Level Gauge Assembly

Courtesy of KIA MOTORS AMERICA, INC.

20. Install cylinder head. (Refer to CYLINDER HEAD ASSEMBLY - 2.0L )

21. Install timing belt. (Refer to TIMING SYSTEM - 2.0L )
22. Remove engine stand.
23. A/T: Install drive plate (A) with adapter plate (B).

Tightening torque

117.7 ~ 127.5Nm (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lb-ft)

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Fig. 43: Identifying Drive Plate & Adapter Plate

Courtesy of KIA MOTORS AMERICA, INC.

24. M/T: Install flywheel.

Tightening torque

117.7 ~ 127.5Nm (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lb-ft)

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