This document provides detailed specifications, removal, installation, inspection, and troubleshooting procedures for the 2007-08 Kia Amanti engine, specifically focusing on mechanical aspects.
Function Description:
The document describes the mechanical components and systems of the 3.8L V-type, DOHC engine used in the 2007-08 Kia Amanti. It covers the general engine specifications, cylinder head, camshaft, valve train, cylinder block, piston, piston rings, piston pin, connecting rod, crankshaft, oil pump, engine oil, cooling system, timing system (timing chain), engine and transaxle assembly, intake and exhaust systems, and lubrication system. The primary function of this manual is to guide technicians through the proper procedures for maintaining, repairing, and reassembling these engine components to ensure optimal performance and longevity.
Important Technical Specifications:
General Engine Specifications:
- Type: V-type, DOHC
- Number of cylinders: 6
- Bore: 96 mm (3.7795 in)
- Stroke: 87.0 mm (3.4252 in)
- Total displacement: 3,778 cc (230.55 cu. in.)
- Compression ratio: 10.4
- Firing order: 1-2-3-4-5-6
- Idle RPM: 700 RPM
Valve Timing:
- Intake: Opens (ATDC) 10°, Closes (ABDC) 62°
- Exhaust: Opens (BBDC) 42°, Closes (ATDC) 6°
Cylinder Head:
- Flatness of gasket surface: Less than 0.05 mm (0.0019 in.) [Less than 0.02 mm (0.0008 in.)/150 x 150]
- Flatness of manifold mounting (Intake/Exhaust): Less than 0.1 mm (0.0039 in.) [Less than 0.03 mm (0.001 in)/110 x 110]
Camshaft:
- Cam height (LH Camshaft Intake): 46.8 mm (1.8425 in.)
- Cam height (LH Camshaft Exhaust): 45.8 mm (1.8031 in.)
- Cam height (RH Camshaft Intake): 46.8 mm (1.8425 in.)
- Cam height (RH Camshaft Exhaust): 45.8 mm (1.8031 in.)
- Journal outer diameter (No. 1): 27.964 ~ 27.978 mm (1.1009 ~ 1.1015 in.)
- Journal outer diameter (No. 2, 3, 4): 23.954 ~ 23.970 mm (0.9430 ~ 0.9437 in.)
- Bearing oil clearance (No. 1): 0.027 ~ 0.057 mm (0.0011 ~ 0.0022 in.)
- Bearing oil clearance (No. 2, 3, 4): 0.030 ~ 0.067 mm (0.0012 ~ 0.0026 in.)
- End play: 0.02 ~ 0.18 mm (0.0008 ~ 0.0071 in.)
Valve:
- Valve length (Intake): 105.27 mm (4.1445 in.)
- Valve length (Exhaust): 105.50 mm (4.1535 in.)
- Stem outer diameter (Intake): 5.465 ~ 5.480 mm (0.2151 ~ 0.2157 in.)
- Stem outer diameter (Exhaust): 5.458 ~ 5.470 mm (0.2149 ~ 0.2153 in.)
- Face angle: 45.25° ~ 45.75°
- Thickness of valve head (margin) (Intake): 1.56 ~ 1.86 mm (0.06142 ~ 0.07323 in.)
- Thickness of valve head (margin) (Exhaust): 1.73 ~ 2.03 mm (0.06811 ~ 0.07992 in.)
- Valve stem to valve guide clearance (Intake): 0.020 ~ 0.047 mm (0.00078 ~ 0.00185 in.) (Limit: 0.07 mm (0.00275 in.))
- Valve stem to valve guide clearance (Exhaust): 0.030 ~ 0.054 mm (0.00118 ~ 0.00212 in.) (Limit: 0.09 mm (0.00354 in.))
Valve Guide:
- Inner diameter: 5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in.)
- Length: 41.8 ~ 42.2 mm (1.6457 ~ 1.6614 in.)
Valve Seat:
- Width of seat contact (Intake): 1.15 ~ 1.45 mm (0.05118 ~ 0.05709 in.)
- Width of seat contact (Exhaust): 1.35 ~ 1.65 mm (0.05315 ~ 0.06496 in.)
- Seat angle: 44.75° ~ 45.20°
Valve Spring:
- Free length: 43.86 mm (1.7267 in.)
- Load (19.3 ± 0.8 kg/34.0 mm): (42.7 ± 1.8 lb/1.3386 in.)
- Load (42.3 ± 1.3 kg/24.2 mm): (93.3 ± 2.9 lb/0.9527 in.)
- Out of squareness: Less than 1.5°
MLA (Mechanical Lash Adjuster):
- Outer diameter: 34.964 ~ 34.980 mm (1.3765 ~ 1.3772 in.)
- Cylinder head tappet bore inner diameter: 35.000 ~ 35.025 mm (1.3779 ~ 1.3789 in.)
- MLA to tappet bore clearance: 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in.) (Limit: 0.07 mm (0.0027 in.))
Valve Clearance (Engine coolant temperature: 20°C [68°F]):
- Intake: 0.17 ~ 0.23 mm (0.0067 ~ 0.0090 in.) (Limit: 0.10 ~ 0.30 mm (0.0039~0.0118 in.))
- Exhaust: 0.27 ~ 0.33 mm (0.0106 ~ 0.0129 in.) (Limit: 0.20 ~ 0.40 mm (0.0078 ~ 0.0157 in.))
Cylinder Block:
- Cylinder bore: 96.00 ~ 96.03 mm (3.7795 ~ 3.7807 in.)
- Flatness of gasket surface: Less than 0.05 mm (0.0019 in.) [Less than 0.02 mm (0.0008 in.)/150 x 150]
Piston:
- Outer diameter: 95.96 ~ 95.99 mm (3.7779 ~ 3.7791 in.)
- Piston to cylinder clearance: 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)
- Ring groove width (No. 1/No. 2): 1.22 ~ 1.24 mm (0.0480 ~ 0.0488 in.) (Limit: 1.26 mm (0.0496 in.))
- Ring groove width (Oil ring): 2.01 ~ 2.03 mm (0.0791 ~ 0.0799 in.) (Limit: 2.05 mm (0.0807 in.))
Piston Ring:
- Side clearance (No. 1/No. 2): 0.03 ~ 0.07 mm (0.0012 ~ 0.0027 in.) (Limit: 0.1 mm (0.004 in.))
- Side clearance (Oil ring): 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in.) (Limit: 0.2 mm (0.008 in.))
- End gap (No. 1): 0.17 ~ 0.32 mm (0.0067 ~ 0.0126 in.) (Limit: 0.6 mm (0.0236 in.))
- End gap (No. 2): 0.32 ~ 0.47 mm (0.0126 ~ 0.0185 in.) (Limit: 0.7 mm (0.0275 in.))
- End gap (Oil ring): 0.20 ~ 0.70 mm (0.0078 ~ 0.0275 in.) (Limit: 0.8 mm (0.0315 in.))
Piston Pin:
- Outer diameter: 23.001 ~ 23.006 mm (0.9055 ~ 0.9057 in.)
- Piston pin hole inner diameter: 23.016 ~ 23.021 mm (0.9061 ~ 0.9063 in.)
- Piston pin hole clearance: 0.01 ~ 0.02 mm (0.0004 ~ 0.0008 in.)
- Connecting rod small end inner diameter: 22.974 ~ 22.985 mm
- Connecting rod small end hole clearance: -0.032 ~ -0.016 mm (-0.0012 ~ 0.0006 in.)
Connecting Rod:
- Big end inner diameter: 58.000 ~ 58.018 mm (2.2834 ~ 2.2842 in.)
- Bearing oil clearance: 0.038 ~ 0.056 mm (0.0015 ~ 0.0022 in.)
- Side clearance: 0.1 ~ 0.25 mm (0.0039 ~ 0.0098 in.)
Crankshaft:
- Main journal outer diameter: 68.942 ~ 68.960 mm (2.7142 ~ 2.7149 in.)
- Pin journal outer diameter: 54.954 ~ 54.972 mm (2.1635 ~ 2.1642 in.)
- Main bearing oil clearance: 0.022 ~ 0.040 mm (0.0008 ~ 0.0016 in.)
- End play: 0.10 ~ 0.28 mm (0.0039 ~ 0.0110 in.)
Oil Pump:
- Relief valve opening pressure: 450 ~ 550 kPa (4.59 ~ 5.61 kgf/cm², 65.28 ~ 79.79 psi)
Engine Oil:
- Quantity (Total): 6.0L (6.34 U.S. qts, 5.28 Imp. qts) (When replacing a short engine or block assembly)
- Quantity (Oil pan): 5.5L (5.81 U.S. qts, 4.84 Imp. qts) (When replacing oil pan only)
- Quantity (Drain and refill): 5.2L (5.49 U.S. qts, 4.58 Imp. qts)
- Quality: Above SJ or SL
- Oil pressure: 130 kPa (1.32 kgf/cm², 18.77 psi) [at 1000 RPM, 110°C (230°F)]
Cooling System:
- Cooling method: Forced circulation with electrical fan
- Coolant quantity: 8.7L (9.19 U.S. qts, 7.66 Imp. qts)
Thermostat:
- Type: Wax pellet type
- Opening temperature: 82 ± 2°C (179.6 ± 35.6°F)
- Fully opened temperature: 95°C (203°F)
- Full lift: 10 mm (0.3937 in.) MIN
Radiator Cap:
- Main valve opening pressure: 93.16 ~ 122.58 kPa (0.95 ~ 1.25 kg/cm², 13.51 ~ 17.78 psi)
- Vacuum valve opening pressure: 0.98 ~ 4.90 kPa (0.01 ~ 0.05 kg/cm², 0.14 ~ 0.71 psi)
Water Temperature Sensor:
- Type: Thermistor type
- Resistance (20°C (68°F)): 2.31 ~ 2.59 Kohms
- Resistance (80°C (176°F)): 0.3222 Kohms
Compression Pressure:
- Compression pressure: 1,225 kPa (12.5 kgf/cm², 177 psi)
- Minimum pressure: 1,078 kPa (11.0 kgf/cm², 156 psi)
Usage Features:
The manual outlines various procedures for engine maintenance and repair, including:
- Compression Pressure Inspection: Guides on how to check cylinder compression, including warming up the engine, removing ignition components and spark plugs, inserting a compression gauge, fully opening the throttle, and measuring pressure after 7 cranks. It emphasizes using a fully charged battery for 250 RPM or more and performing measurements quickly. It also provides diagnostic steps for low compression.
- Valve Clearance Inspection and Adjustment: Details the process for inspecting and adjusting valve clearance when the engine is cold. This involves removing the engine cover, air cleaner, surge tank, and cylinder head cover, setting the No. 1 cylinder to TDC/compression, checking camshaft timing marks, measuring valve clearance with a thickness gauge, calculating required tappet thickness, and installing new tappets.
- Engine and Transaxle Assembly Removal and Installation: Provides a comprehensive step-by-step guide for removing and installing the entire engine and transaxle assembly. This includes disconnecting various hoses, wiring, and components, draining fluids, and supporting the assembly with a jack.
- Timing System (Timing Chain) Removal and Installation: Describes the procedures for removing and installing timing chain components, including the crankshaft pulley, timing chain cover, and various tensioners and guides. It emphasizes marking components and ensuring proper alignment.
- Cylinder Head Assembly Removal and Reassembly: Covers the removal of cylinder head bolts in a specific sequence to prevent warpage, disassembling valves, and reassembling with new seals and proper torque.
- Engine Block Disassembly and Reassembly: Details the process of disassembling and reassembling the engine block components, including pistons, connecting rods, crankshaft, and main bearings. It provides instructions for checking clearances and selecting appropriate bearings.
- Cooling System Maintenance: Includes procedures for engine coolant refilling and bleeding, radiator cap testing, and radiator pressure testing.
- Lubrication System Maintenance: Covers checking engine oil quality and level, selecting appropriate engine oil, and oil pump and oil filter assembly removal and installation.
- Intake and Exhaust System Maintenance: Provides steps for removing and installing intake and exhaust manifolds, including associated components and tightening torques.
Maintenance Features:
- Sealant Application: Many installation steps require the application of liquid sealant (e.g., TB1217H) to ensure proper sealing. Specific bead widths and assembly timeframes (within 5 minutes of application) are provided.
- Torque Specifications: Detailed tightening torque specifications are provided for almost every bolt and nut, often including multi-step tightening sequences and angular tightening methods (e.g., +90°, +120°).
- Special Service Tools (SST): The manual lists and illustrates various SSTs required for specific tasks, such as crankshaft front oil seal installer (09231-3C100), flywheel stopper (09231-3C300), torque angle adapter (09221-4A000), valve stem seal remover (09222-29000), valve stem seal installer (09222-3C100), valve spring compressor & holder (09222-3K000, 09222-3C300), crankshaft rear oil seal installer (09231-3C200, 09231-H1100), oil pan remover (09215-3C000), and oil filter wrench (09263-3C100).
- Component Identification and Arrangement: Emphasizes identifying and arranging components (e.g., MLAs, valves, valve springs, piston rings, main bearings, thrust bearings) in their original positions during removal to ensure correct reinstallation.
- Fluid Management: Instructions for draining and refilling engine oil, transaxle fluid, and engine coolant are provided, along with warnings about handling hot fluids and proper disposal of used oil.
- Gasket and O-ring Replacement: Repeatedly stresses the importance of using new gaskets, O-rings, and oil seals during reassembly.
- Cleaning Procedures: Advises cleaning sealing faces, piston ring grooves, and other components thoroughly before reassembly.
- Troubleshooting Chart: Includes a comprehensive troubleshooting chart to diagnose common engine issues such as misfire, noise, and excessive fluid consumption, linking symptoms to suspect areas and recommended remedies.
- Safety Precautions: Contains numerous CAUTION and NOTE advisories, including warnings about damaging painted surfaces, unplugging wiring connectors carefully, waiting for the engine to cool, handling metal gaskets, not turning the crankshaft during certain procedures, and proper handling of mineral oil to prevent skin irritation.
- Coolant Concentration: Specifies maintaining a 50% minimum coolant concentration for corrosion protection and warns against mixing different brands or using additional rust inhibitors.
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