Kia Niro: Engine Mechanical System / Specifications

Specifications
Description
 
Specifications
Limit
General
Type
In-line, DOHC
 
Number of cylinders
4
 
Bore
72.0 mm (2.8346 in.)
 
Stroke
97.0 mm (3.8189 in.)
 
Total displacement
1580 cc (96.42 cu.in.)
 
Compression ratio
13.0 : 1
 
Firing order
1-3-4-2
 
Valve timing
Intake valve
Open
ATDC 10° - BTDC 60°
 
Close
ABDC 108.8° - ABDC 33.8°
 
Exhaust valve
Open
BBDC 50.2° - BBDC 10.2°
 
Close
ATDC 3° - ATDC 43°
 
Camshaft
Cam height
 
Intake
36.42 mm (1.4339 in.)
 
Exhaust
36.15 mm (1.4232 in.)
 
Journal outer diameter
Intake
No.1 : 36.459 - 36.473 mm
(1.43539 - 1.43594 in.)
 
No.2, 3, 4, 5 : 22.959 - 22.975 mm
(0.90390 - 0.90453 in.)
 
Exhaust
No.1 : 36.464 - 36.478  mm
(1.43559 - 1.43614 in.)
 
No.2, 3, 4, 5 :  22.964 - 22.978 mm
(0.90409 - 0.90465 in.)
 
End play
0.10 - 0.20 mm (0.0039 - 0.0079 in.)
 
Valve
Valve length
Intake
100.94 mm (3.9740 in.)
101.97 mm (4.0146 in.)
Exhaust
101.09 mm (3.9799 in.)
103.79 mm (4.0862 in.)
Stem outer diameter
Intake
5.465 - 5.480 mm (0.21516 - 0.21575 in.)
 
Exhaust
5.448 - 5.470 mm (0.21449 - 0.21535 in.)
 
Face angle
45.25° - 45.75°
 
Thickness of valve head
(margin)
Intake
1.35 - 1.65  mm (0.0531 - 0.0650 in.)
 
Exhaust
1.60 - 1.90  mm (0.0630 - 0.0748 in.)
 
Valve stem to valve guide clearance
Intake
0.020 - 0.047 mm (0.00079 - 0.00185 in.)
 
Exhaust
0.030 - 0.064 mm (0.00118 - 0.00252 in.)
 
Valve guide
Length
Intake
45.8 - 46.2 mm (1.8031 - 1.8189 in.)
 
Exhaust
45.8 - 46.2 mm (1.8031 - 1.8189 in.)
 
Valve spring
Free length
50.27 mm (1.9791 in.)
 
Load
16.4 ± 0.8 kgf·m / 35.5 mm
(36.16 ± 1.76 lb·f / 1.3976 in.)
26.0 ± 0.9 kgf·m / 22.7 mm
(57.32 ± 1.98 lb·f / 0.8937 in.)
 
Out of squareness
Less than 1.5°
 
Cylinder head
Flatness of gasket surface
Less than 0.05 mm (0.0020 in.) for total area
 
Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) × 100 mm (3.9370 in.)
 
Flatness of manifold mounting surface
Intake
Less than 0.10 mm (0.0039 in.)
 
Exhaust
Less than 0.10 mm (0.0039 in.)
 
Piston
Piston outer diameter
71.965 - 71.995 mm (2.8333 - 2.8344 in.)
 
Piston to cylinder clearance
0.025 - 0.045 mm (0.0010 - 0.0018 in.)
 
Ring groove width
No. 1 ring
1.035 - 1.050  mm (0.04075 - 0.04134 in.)
 
No. 2 ring
1.230 - 1.250 mm (0.04843 - 0.04921 in.)
 
Oil ring
2.010 - 2.025 mm (0.07913 - 0.07972 in.)
 
Piston ring
Side clearance
No. 1 ring
0.050 - 0.080 mm (0.00197 - 0.00315 in.)
 
No. 2 ring
0.040 - 0.080 mm (0.00157 - 0.00315 in.)
 
Oil ring
0.050 - 0.125 mm (0.00197 - 0.00492 in.)
 
End gap
No. 1 ring
0.13 - 0.18 mm (0.0051 - 0.0071 in.)
 
No. 2 ring
0.25 - 0.40 mm (0.0098 - 0.0157 in.)
 
Oil ring
0.10 - 0.40 mm (0.0039 - 0.0157 in.)
 
Piston pin
Piston pin outer diameter
17.997 - 18.000 mm (0.70854 - 0.70866 in.)
 
Piston pin hole inner diameter
18.005 - 18.009 mm (0.70885 - 0.70902 in.)
 
Piston pin hole clearance
0.005 - 0.012 mm (0.00020 - 0.00047 in.)
 
Connecting rod small end hole inner diameter
18.005 - 18.011 mm (0.70885 - 0.70909 in.)
 
Piston pin-to-connecting rod bushing oil clearance
0.005 - 0.014 mm (0.00020 - 0.00055 in.)
 
Connecting rod
Connecting rod big end inner diameter
42.000 - 42.018 mm (1.65354 - 1.65425 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 (1.88748 - 1.88819 in.)
 
Pin journal outer diameter
38.954 - 38.972 mm (1.53362 - 1.53433 in.)
 
Main bearing oil clearance
0.006 - 0.024 mm (0.00024 - 0.00094 in.)
 
End play
0.07 - 0.25 mm (0.0028 - 0.0098 in.)
 
Cylinder block
Cylinder bore
72.00 - 72.03 mm (2.8346 - 2.8358 in.)
 
Flatness of gasket surface
Less than 0.05 mm (0.0020 in.) for total area
 
Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) × 100 mm (3.9370 in.)
 
Engine oil
Oil quantity
Total
4.1 L (1.08 U.S.gal., 4.33 U.S.qt., 3.61 lmp.qt.)
When replacing a short engine or block assembly
Oil pan
3.4 L (0.90 U.S.gal., 3.59 U.S.qt., 2.99 lmp.qt.)
 
Drain and refill
3.8 L (1.00 U.S.gal., 4.02 U.S.qt., 3.34 lmp.qt.)
Including oil filter
Oil grade
Recommended 
ACEA A5 or above
 
Allowed
- API SL or above
- ILSAC GF - 3 or above
- ACEA A3 or above

- For information on SAE viscosity grades based on ambient temperatures, refer to the “Lubrication System”.
Usable if the recommended engine oil is not available
Oil pressure (at 1,000rpm)
98.07 kPa (1.0 kgf/cm², 14.22 psi) or above
Oil temperature (oil pan): 110±2°C (230±35.6°F)
2 Step relief variable oil pump (Rotor type)
Relief valve opening pressure
Primary : 210.84 - 279.49 kPa (2.15 - 2.85 kgf/cm², 30.58 - 40.54 psi)
Secondary : 441.30 - 539.37 kPa (4.50 - 5.50 kgf/cm², 64.01 - 78.23 psi)
 
Side clearance
0.040 - 0.090 mm (0.00157 - 0.00354 in.)
 
Body clearance
0.150 - 0.242 mm (0.0059 - 0.0095 in.)
 
Guide clearance
0.030 - 0.075 mm (0.00118 - 0.00295 in.)
 
Cooling system
Cooling method
Forced circulation with cooling fan
 
Coolant quantity
Approx. 5.8 L (1.53 U.S.gal., 6.13 U.S.qt., 5.10 lmp.qt.)
 
Thermostat
Type
Wax pellet type
 
Opening temperature
88  ± 1.5°C (190.4 ± 34.7°F)
 
Full opening valve lift / temperature
More than 8 mm (0.3 in.) / 100°C (212°F)
 

Liquid Gasket

Location
Product
Mating surface of timing chain cover
Threebond 1217H or equivalent
Front area of mating surface between cam carrier and cylinder head
Front area of mating surface between cylinder block and head
Upper area of mating surface between timing chain cover and cam carrier
Front upper area of cylinder block 
Front upper area of cylinder head gasket
Lower area of cam carrier
Lower area of cylinder block
Mating surface of oil pan

Tightening Torques

Item
N·m
kgf·m
lb·ft
Engine mounting
Engine mounting bracket to body fixing bolt
49.0 - 63.7
5.0 - 6.5
36.2 - 47.0
Engine mounting support bracket to engine mounting insulator fixing nut
88.3 - 107.9
9.0 - 11.0
65.1 - 79.6
Engine mounting support bracket to engine support bracket fixing bolt
58.8 - 73.5
6.0 - 7.5
43.4 - 54.2
Engine mounting support bracket to engine support bracket fixing nut
58.8 - 73.5
6.0 - 7.5
43.4 - 54.2
Transaxle mounting bracket to body fixing bolt
49.0 - 63.7
5.0 - 6.5
36.2 - 47.0
Transaxle mounting support bracket  to transaxle mounting insulator fixing bolt
107.9 - 127.5
11.0 - 13.0
79.6 - 94.0
Roll rod bracket to sub frame fixing bolt 
49.0 - 63.7
5.0 - 6.5
36.2 - 47.0
Roll rod bracket to roll rod support bracket fixing bolt & nut
107.9 - 127.5
11.0 - 13.0
79.6 - 94.0
Drive belt system
Hydraulic tensioner 
27.5 - 31.4
2.8 - 3.2
20.3 - 23.1
Mechanical tensioner 
18.6 - 23.5 
1.9 - 2.4 
13.7 - 17.4 
Idler 
39.2 - 49.0 
4.0 - 5.0 
28.9 - 36.2 
Crankshaft pulley bolt
[64.7 - 71.6] + [39 - 41°]
[6.6 - 7.3] + [39 - 41°] 
[47.7 - 52.8] + [39 - 41°]
Timing system
Timing chain cover bolt
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
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 cam guide bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Timing chain guide bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Cylinder head
Ignition coil bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
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]
Intake CVVT OCV bolt
[47.1 - 52.0] + [25 - 31°]
[4.8 - 5.3] + [25 - 31°]
[34.7 - 52.0] + [25 - 31°]
Exhaust CVVT bolt 
63.7 - 73.5
6.5 - 7.5
47.0 - 54.2
Camshaft bearing cap bolt (M6)
11.8 - 13.7
1.2 - 1.4
8.7 - 10.1
Camshaft bearing cap bolt (M8)
18.6 - 22.6
1.9 - 2.3
13.7 - 16.6
Cylinder head bolt
[12.7 - 16.7] + [120 - 125°] + [120 - 125°]
[1.3 - 1.7] + [120 125°] + [120 - 125°]
[9.4 - 16.7] + [120 - 125°] + [120 - 125°]
Cylinder block
Fly wheel bolt
78.5 - 88.3
8.0 - 9.0
57.9 - 65.1
Connecting rod bearing cap bolt
[10.8 - 14.7] + [88 - 92°]
[1.1 - 1.5] + [88 - 92°]
[8.0 - 10.8] + [88 - 92°]
Main bearing cap bolt
[17.7 - 21.6] + [88 - 92°]
[1.8 - 2.2] + [88 - 92°]
[13.0 - 15.9] + [88 - 92°]
Ladder frame
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
Lubrication system
Oil drain plug
34.3 - 44.1
3.5 - 4.5
25.3 - 32.5
Oil filter
11.8 - 15.7
1.2 - 1.6
8.7 - 11.6
Oil pan bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Oil screen bolt
24.5 - 31.4
2.5 - 3.2
18.1 - 23.1
Oil pump cover
5.9 - 8.8
0.6 - 0.9
4.3 - 6.5
Oil pressure switch
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Cooling system
Water pump pulley bolt
7.8 - 11.8
0.8 - 1.2
5.8 - 8.7
Water pump bolt
7.8 - 11.8
0.8 - 1.2
5.8 - 8.7
Water inlet fitting nut
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
Water temperature control assembly bolt & nut
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
Heater pipe bolt
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
Intake and exhaust system
Air intake hose clamp bolt
2.9 - 4.9
0.3 - 0.5
2.2 - 3.6
Air cleaner assembly bolt
3.9 - 5.9
0.4 - 0.6
2.9 - 4.3
Intake manifold stay bolt
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
Intake manifold bolt
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
Intake manifold nut
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
EGR cooler bolt 
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4
Exhaust manifold heat protector bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7
Exhaust manifold stay bolt
39.2 - 49.0
4.0 - 5.0
28.9 - 36.2
Exhaust manifold nut
34.3 - 39.2
3.5 - 4.0
25.3 - 28.9
Muffler nut
39.2 - 58.8
4.0 - 6.0
28.9 - 43.4

  

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.

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