Kia Picanto: Engine Mechanical System

Kia Picanto JA 2017-2024 Service & Repair Manual / Engine Mechanical System

Specifications

Description		Specification	Limit
General
Type		in-line, DOHC
Number of cylinders		3
Bore		71.0 mm (2.7952 in.)
Stroke		84.0 mm (3.3070 in.)
Total displacement		998 cc (60.9 cu.in.)
Compression ratio		10.5 : 1
Firing order		1-2-3
Valve timing
Intake valve	Opens	BTDC 40° - ATDC 10°
Intake valve	Closes	ABDC 20.7° - ABDC 70.7°
Exhaust valve	Opens	BBDC 61.27° - BBDC 21.27°
Exhaust valve	Closes	ATDC 10° - ATDC 50°
Valve clearance (At 20°C [68°F])
Intake		0.20 - 0.26 mm (0.0079 - 0.0102 in.)
Exhaust		0.39 - 0.45 mm (0.0154 - 0.0177 in.)
Cylinder head
Flatness of gasket surface		Less than 0.05 mm (0.0020 in.) Less than 0.02 mm (0.0008 in..) / 100 x 100
Flatness of manifold	Intake	Less than 0.1 mm (0.0039 in.)
mounting surface	Exhaust	Less than 0.1 mm (0.0039 in.)
Camshaft
Cam height	Intake	41.79824 mm (1.6456 in.)
Cam height	Exhaust	41.57000 mm (1.6366 in.)
Journal outer Diameter	Intake/Exhaust No.1	36.464 - 36.478 mm (1.4355 - 1.4361 in.)
Journal outer Diameter	Intake/Exhaust No.2~5	20.964 - 20.978 mm (0.8254 - 0.8259 in.)
End play		0.1 - 0.2 mm (0.0039 - 0.0078 in.)
Valve
Valve length	Intake	92.85 mm (3.6555 in.)
Valve length	Exhaust	93.37 mm (3.6759 in.)
Stem outer diameter	Intake	5.465 - 5.480 mm (0.2151 - 0.2157 in.)
Stem outer diameter	Exhaust	5.448 - 5.460 mm (0.2144 - 0.2149 in.)
Face angle
Thickness of valve head (margin)	Intake	1.50 mm (0.0590 in.)
Thickness of valve head (margin)	Exhaust	1.75 mm (0.0688 in.)
Valve stem to valve guide clearance	Intake	0.020 - 0.047 mm (0.00078 - 0.00185 in.)
Valve stem to valve guide clearance	Exhaust	0.040 - 0.064 mm (0.00157 ~ 0.00251 in.)
MLA outer diameter		27.964 - 27.980 mm (1.1010 - 1.1016 in.)
Tappet bore inner diameter		28.000 - 28.025 mm (1.1024 - 1.1033 in.)
MLA to tappet bore clearance		0.020 - 0.061 mm (0.0008 - 0.0024 in.)
Valve guide
Inner diameter	Intake	5.500 - 5.512 mm (0.2165 - 0.2170 in.)
Inner diameter	Exhaust	5.500 - 5.512 mm (0.2165 - 0.2170 in.)
Valve seat
Width of seat contact	Intake	0.85 - 1.15 mm (0.0334 - 0.0452 in.)
Width of seat contact	Exhaust	1.35 - 1.65 mm (0.0531 - 0.0649 in.)
Seat angle	Intake	44.75° - 45.10°
Seat angle	Exhaust	44.75° - 45.10°
Valve spring
Free length		47.9 mm (1.8858 in.)
Load		15.29 ± 0.82 kgf / 34.2 mm (150 ± 8.1N / 1.3465 in.) 26.51 ± 0.95 kgf / 25.7 mm (260 ± 9.4N / 1.0118 in.)
Out of squareness		1.5° MAX
Cylinder block
Cylinder bore		71.00 - 71.03 mm (2.7952 - 2.7964 in.)
Flatness of gasket surface		Less than 0.05 mm (0.0020 in.) Less than 0.02 mm (0.0008 in.) / 100 x 100
Piston
Piston outer diameter		70.965 - 71.995 mm (2.7939 - 2.7951 in.)
Piston to cylinder clearance		0.02 - 0.04 mm (0.0008 - 0.0016 in.)
Ring groove width	No. 1 ring groove	1.235 - 1.250 mm (0.0486 - 0.0492 in)
	No. 2 ring groove	1.23 - 1.25 mm (0.0484 - 0.0492 in.)
	Oil ring groove	2.010 - 2.025 mm (0.0791 - 0.0797 in.)
Piston ring
Side clearance	No. 1 ring	0.05 - 0.08 mm (0.0020 - 0.0031 in.)
	No. 2 ring	0.04 - 0.08 mm (0.0015 - 0.0031 in.)
	Oil ring	0.050 - 0.125 mm (0.0020 - 0.0049 in)
End gap	No. 1 ring	0.13 - 0.25 mm (0.0051 - 0.0048 in.)
	No. 2 ring	0.25 - 0.40 mm (0.0098 - 0.0157 in.)
	Oil ring	0.2 - 0.7 mm (0.0079 - 0.0276 in)
Piston pin
Piston pin outer diameter		17.997 - 18.000 mm (0.7085 - 0.7086 in)
Piston pin hole clearance		0.005 - 0.012 mm (0.0002 - 0.0005 in)
Connecting rod small end hole clearance		0.005 - 0.014 mm (0.0002 - 0.0006 in)
Connecting rod
Connecting rod big end inner diameter		42.000 - 42.018 mm (1.6535 - 1.6542 in.)
Connecting rod bearing oil clearance		0.018 - 0.036 mm (0.0007 - 0.0014 in.)
Side clearance		0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Crankshaft
Main journal outer diameter		47.942 - 47.960 mm (1.8874 - 1.888 in.)
Pin journal outer diameter		38.954 - 38.972 mm (1.5336 - 1.5343 in.)
Main bearing oil clearance		0.006 - 0.024 mm (0.0002 - 0.0009 in.)
End play		0.07 - 0.25 mm (0.0028 - 0.0098 in.)
Engine oil
Oil quantity	Total	3.9 L (1.03 U.S.gal., 4.12 US qt, 3.43 lmp qt)	When replacing a short engine or a block assembly
	Oil pan	3.3 L (0.87 U.S.gal., 3.49 U.S.qt., 2.90 lmp.qt.)
	Drain and refill	3.6 L (0.95 U.S.gal., 3.80 U.S.qt., 3.17 lmp.qt.)	Including oil filter
Oil grade	Recommended	For India, Middle east, Iran, Libia, Algeria, Sudan, Moroco, Tunisia, Egypt - API SM & ILSAC GF-4 or above / 5W-30 - ACEA A5/B5 / 5W-30 For Australia, General export - ACEA A5/B5 / 5W-30 For Europe - API SN & ACEA C2 / 0W-30
Oil grade	Allowed	- API SL or above - ILSAC GF-3 or above - ACEA A3/B3 or A3/B4 - For information on SAE viscosity grades based on ambient temperatures, refer to the “Lubrication System”.	Use if recommended engine oil is not available
Oil pressure (at 1000rpm)		130 kPa (1.3 kgf/cm², 18.9 psi) or above	Oil temperature in oil pan : 110 ± 2°C (230 ± 3.6°F)
Cooling method
Cooling system		Forced circulation with water pump
Coolant quantity		Approx. 5.3 L (1.40 U.S.gal., 5.60 U.S.qt., 4.66 lmp.qt.)
Main thermostat	Type	Wax pellet type
	Opening temperature	88 ± 1.5°C (190.4 ± 2.7°F)
	Full opening temperature	More than 8 mm (0.3150 in.) / 100°C (212°F)
Block Thermostat (for Split Cooling)	Type	Wax pellet type
	Opening temperature	105 ± 1.5°C (221 ± 2.7°F)
	Full opening temperature	More than 8 mm (0.3150 in.) / 120°C (248°F)
Radiator cap	Main valve opening pressure	93.16 ~ 122.58 kPa (0.95 ~ 1.25 kg/cm, 13.51 ~ 17.78 psi)
Radiator cap	Vacuum valve opening pressure	Max 6.8 kPa (Max 0.07 kg/cm, 0.99 psi)
Water temperature sensor
Type		Thermistor type
Resistance	20°C (68°F)	2.45 ± 0.14 kΩ
Resistance	80°C (176°F)	0.3222 kΩ

Tightening Torques

Item	N·m	kgf·m	lb·ft
Engine mounting
Engine mounting bracket and body fixing bolt	49.0 - 63.7	5.0 - 6.5	36.1 - 47.0
Engine mounting bracket and engine support bracket fixing bolt	49.0 - 63.7	5.0 - 6.5	36.1 - 47.0
Engine mounting bracket and engine support bracket fixing nut	49.0 - 63.7	5.0 - 6.5	36.1 - 47.0
Transaxle mounting bracket and body fixing bolt	49.0 - 63.7	5.0 - 6.5	36.1 - 47.0
Transaxle mounting bracket and body fixing nut	49.0 - 63.7	5.0 - 6.5	36.1 - 47.0
Transaxle mounting support bracket to transaxle mounting bracket fixing bolt	88.3 - 107.9	9.0 - 11.0	65.1 - 79.6
Roll rod bracket and sub frame fixing bolt	49.0 - 63.7	5.0 - 6.5	36.1 - 47.0
Roll rod bracket and roll rod mounting support bracket bolt	127.5 - 147.1	13.0 - 15.0	79.6 ~ 94.0
Drive belt system
Drive belt tensioner bolt	19.6 - 26.5	2.0 - 2.7	14.5 - 19.5
Crankshaft damper pulley bolt	[55.9 - 61.8] + [38 - 42°]	[5.7 - 6.3] + [38 - 42°]	[41.2 - 45.6] + [38 - 42°]
Timing system
Timing chain cover & oil pump bolt (A)	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Timing chain cover & oil pump bolt (B)	18.6 - 23.5	1.9 - 2.4	13.7 - 17.4
Timing chain cover & oil pump bolt (C)	44.1 - 53.9	4.5 - 5.5	32.5 - 39.8
Timing chain tensioner bolt	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Timing chain tensioner arm bolt	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Timing chain guide bolt	18.6 - 21.6	1.9 - 2.2	13.7 - 15.9
Cylinder head
Cylinder head cover bolt	[3.9 - 5.9] → [7.8 - 9.8]	[0.4 - 0.6] → [0.8 - 1.0]	[2.9 - 4.3] → [5.8 - 7.2]
CVVT sprocket bolt	63.7 - 73.5	6.5 - 7.5	47.0 - 54.2
Camshaft bearing cap bolt (M6)	[5.9] → [11.8 - 13.7]	[0.6] → [1.2 - 1.4]	[4.3] → [8.7 - 10.1]
Camshaft front bearing cap bolt (M8)	[9.8] → [18.6 - 22.6]	[1.0] → [1.9 - 2.3]	[7.2] → [13.7 - 16.6]
Cylinder head bolt	[12.7 - 16.7] + [90 - 95°] + [120 - 125°]	[1.3 - 1.7] + [90 - 95°] + [120 - 125°]	[9.4 - 12.3] + [90 - 95°] + [120 - 125°]
Cylinder block
Ladder frame bolt	28.4 - 32.4	2.9 - 3.3	21.0 - 23.9
Connecting rod bearing cap bolt	[10.8 - 14.7] + [88 - 92°]	[1.1 - 1.5] + [88 - 92°]	[8.0 - 10.8] + [88 - 92°]
Crankshaft main bearing cap bolt	[17.7 - 21.6] + [88 - 92°]	[1.8 - 2.2] + [88 - 92°]	[13.0 - 15.9] + [88 - 92°]
Piston cooling jet bolt	8.8 - 12.7	0.9 - 1.3	6.5 - 9.4
Fly wheel bolt	68.6 - 78.5	7.0 - 8.0	50.6 - 57.9
Cooling system
Water pump pulley bolt	12.7 - 14.7	1.3 - 1.5	9.4 - 10.8
Water pump bolt	19.6 - 26.5	2.0 - 2.7	14.5 - 19.5
Heater pipe bolt	19.6 - 26.5	2.0 - 2.7	14.5 - 19.5
Water temperature control assembly bolt	19.6 - 26.5	2.0 - 2.7	14.5 - 19.5
Water inlet fitting bolt & nut	18.6 - 23.5	1.9 - 2.4	13.7 - 17.4
Lubrication system
Oil filter	11.8 - 15.7	1.2 - 1.6	8.7 - 11.6
Oil level gauge guide bolt	8.8 - 13.7	0.9 - 1.4	6.5 - 10.1
Oil pan bolt	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Oil pan drain plug	34.3 - 44.1	3.5 - 4.5	25.2 - 32.4
Oil screen bolt	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Oil pressure switch	7.8 - 11.8	0.8 - 1.2	5.8 - 8.7
Intake and exhaust system
Intake manifold bolt & nut	18.6 - 23.5	1.9 - 2.4	13.7 - 17.4
Intake manifold stay bolt	18.6 - 23.5	1.9 - 2.4	13.7 - 17.4
Warm-up catalytic converter (WCC) heat protector bolt	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Warm-up catalytic converter (WCC) upper stay bolt	18.6 - 23.5	1.9 - 2.4	13.7 - 17.4
Warm-up catalytic converter (WCC) lower stay bolt	39.2 - 44.1	4.0 - 4.5	28.9 - 32.5
Warm-up catalytic converter (WCC) nut	49.0 - 53.9	5.0 - 5.5	36.1 - 39.7
Water drain pipe bolt	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Water drain pipe eye bolt	26.4 - 32.3	2.7 - 3.3	19.5 - 32.3
Water feed hose & pipe eye bolt	26.4 - 32.3	2.7 - 3.3	19.5 - 32.3
Oil drain pipe bolt	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Oil feed pipe bolt	11.8 - 17.7	1.2 - 1.8	8.7 - 13.0
Turbo manifold module heat protector	9.8 - 11.8	1.0 - 1.2	7.2 - 8.7
Turbo manifold module nut	35.3 - 41.2	3.6 - 4.2	26.0 - 30.4
Muffler nut	39.2 - 58.8	4.0 - 6.0	28.9 - 43.4
Center muffler pipe and main muffler clamp nut	17.0 - 27.0	1.7 - 2.8	12.5 - 19.9

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

Special service tools

Special Service Tools

Tool Name / Number	Illustration	Description
Crankshaft damper pulley adapter 09231-2M100 Crankshaft damper pulley adapter holder 09231-2J210		Used for removing / installing crankshaft damper pulley
Crankshaft front oil seal installer 09214-1R000 Handle 09231-H1100
Valve stem seal installer 09222-1S100
Valve spring compressor 09222-3K000 Valve spring compressor adapter 09222-3K100		Used for removing / installing intake or exhaust valve
Crankshaft rear oil seal installer 09214-03100 Handle 09231-H1100
Oil pan remover 09215-3C000
Oil filter wrench 09263-02000		Used for removing / installing oil filter
Pressure cap pressure checker 0K253-G5100		Used for checking for pressure cap pressure and a coolant leak

Repair procedures

Compression Test

Compression Pressure Inspection

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

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

2.	Remove the air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")

3.	Disconnect the injector connectors (A) and ignition coil connectors (B).

4.	Remove the ignition coils. (Refer to Engine Electrical System - "Ignition Coil")

5.	Remove the three spark plugs using a 16mm spark plug wrench. (Refer to Engine Electrical System - "Spark Plug")

Check the cylinder compression pressure.

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

(2)	Fully open throttle.

(3)

While cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 200rpm or more.

(4)

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

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

Compression pressure : ,1,128 kPa (11.5 kg/cm², 163.6 psi)

Minimum pressure : 1,030 kPa (10.5 kg/cm²,149.3 psi)

Difference between each cylinder : 98 kPa (1.0 kg/cm², 14 psi) or less

(5)

If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat step (1) through (3) for cylinders with low compression.

•	If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.

•	If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.

7.	Reinstall the spark plugs. (Refer to Engine Electrical System - "Spark Plug")

8.	Install the ignition coils. (Refer to Engine Electrical System - "Ignition Coil")

9.	Connect the injector connectors and ignition coil connectors.

10.	Install the air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")

11.	Some DTC's may exist after the inspection test and may need to be manually cleared with KDS.

Troubleshooting

Symptom

Suspect area

Remedy

Engine misfire with abnormal internal lower engine noises.

Worn crankshaft bearings.
Loose or damaged engine drive plate.

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

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

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

Worn crankshaft thrust bearings

Replace the crankshaft and bearings as required.

Engine misfire with abnormal valve train noise.

Stuck valves.
(Carbon buildup on the valve stem)

Repair or replace as required.

Excessive worn or mis-aligned timing chain.

Replace the timing chain and sprocket as required.

Worn camshaft lobes.

Replace the camshaft and valve lifters.

HLA sponge

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

Engine misfire with coolant consumption.

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

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

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

•	Repair or replace as required.

Engine misfire with excessive oil consumption.

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

Repair or replace as required.

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

•	Inspect the cylinder for a loss of compression.

•	Repair or replace as required.

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

Incorrect oil viscosity.

•	Drain the oil.

•	Install the correct viscosity oil.

Worn crankshaft thrust bearing.

•	Inspect the thrust bearing and crankshaft.

•	Repair or replace as required.

Upper engine noise, regardless of engine speed.

Low oil pressure.

Repair or replace as required.

Broken valve spring.

Replace the valve spring.

Worn or dirty valve lifters.

Replace the valve lifters.

Stretched or broken timing chain and/or damaged sprocket teeth.

Replace the timing chain and sprockets.

Worn timing chain tensioner, if applicable.

Replace the timing chain tensioner as required.

Worn camshaft lobes.

•	Inspect the camshaft lobes.

•	Replace the timing camshaft and valve lifters as required.

Worn valve guides or valve stems.

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

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

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

Worn drive belt, idler, tensioner and bearing.

Replace as required.

Lower engine noise, regardless of engine speed.

Low oil pressure.

Repair as required.

Loose or damaged drive plate.

Repair or replace the drive plate.

Damaged oil pan, contacting the oil pump screen.

•	Inspect the oil pan.

•	Inspect the oil pump screen.

•	Repair or replace as required.

Oil pump screen loose, damaged or restricted.

•	Inspect the oil pump screen.

•	Repair or replace as required.

Excessive piston-to-cylinder bore clearance.

•	Inspect the piston, piston pin and cylinder bore.

•	Repair as required.

Excessive piston pin-to-piston clearance.

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

•	Repair or replace as required.

Excessive connecting rod bearing clearance

Inspect the following components and repair as required.

•	The connecting rod bearings.

•	The connecting rods.

•	The crankshaft pin journals.

Excessive crankshaft bearing clearance.

Inspect the following components, and repair as required.

•	The crankshaft bearings.

•	The crankshaft main journals.

•	The cylinder block.

Incorrect piston, piston pin and connecting rod installation

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

•	Repair as required.

Engine noise under load.

Low oil pressure

Repair or replace as required.

Excessive connecting rod bearing clearance.

Inspect the following components and repair as required :

•	The connecting rod bearings.

•	The connecting rods.

•	The crankshaft.

Excessive crankshaft bearing clearance.

Inspect the following components, and repair as required.

•	The crankshaft bearings.

•	The crankshaft main journals.

•	The cylinder block.

Engine will not crank-crankshaft will not rotate.

Hydraulically locked cylinder.

•	Coolant/antifreeze in cylinder.

•	Oil in cylinder.

•	Fuel in cylinder.

•	Remove spark plugs and check for fluid.

•	Inspect for broken head gasket.

•	Inspect for cracked engine block or cylinder head.

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

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

•	Inspect timing chain and gears.

•	Repair as required.

Material in cylinder.

•	Broken valve

•	Piston material

•	Foreign material

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

•	Repair or replace as required.

Seized crankshaft or connecting rod bearings.

•	Inspect crankshaft and connecting rod bearing.

•	Repair as required.

Bent or broken connecting rod.

•	Inspect connecting rods.

•	Repair as required.

Broken crankshaft.

•	Inspect crankshaft.

•	Repair as required.

Cooling System

Cylinder Block Assembly

Cylinder Head Assembly

Drive Belt System

Engine And Transaxle Assembly

Intake And Exhaust System

Lubrication System

Timing System

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