Kia Stinger: Engine Mechanical System

Kia Stinger CK 2018-2020 Service Manual / Engine Mechanical System

Repair procedures
Compression Pressure Inspection
  

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.

Disconnect the ignition extension connector (A).

3.

Remove the spark plugs.

(Refer to Engine Electrical System - "Spark Plug")

4.

Check cylinder compression pressure.

(1)

Insert a compression gauge into the spark plug hole.

(2)

Fully open the throttle.

(3)

While cranking the engine, measure the compression pressure.

  

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

(4)

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

  

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

Compression pressure :

1078 kPa (11.0 kgf/cm², 156 psi) / 200 - 250 rpm

Minimum pressure :

931 kPa (9.5 kgf/cm², 135 psi)

Difference between each cylinder :

100 kPa (1.0 kgf/cm², 15 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 steps (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.

5.

Reinstall spark plugs.

6.

Install ignition coils.

7.

Connect the injector extension connector and ignition coil connectors.

8.

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

Troubleshooting
Troubleshooting

Symptoms
Suspect area
Remedy
Engine misfire with abnormal internal lower engine noises.
Worn crankshaft bearings
Loose or out of specification engine flywheel
Replace the crankshaft and bearings as required.
Repair or replace the flywheel 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
Out of specification valve clearances
Replace the timing chain and sprocket as required.
Worn camshaft lobes.
Replace the camshaft and valve lifters.
Engine misfire with coolant consumption

Faulty cylinder head gasket 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.
(Check and compare with known good vehicle to determine normal condition.)
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.

Out of specification valve clearances
Worn valve guides or valve stems.
Inspect the valves and valve guides, then repair or replace 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 or replace as required.
Worn drive belt, idler, tensioner and bearing.
Replace as required
Lower engine noise, regardless of engine speed
Low oil pressure
Repair or replace as required
Loose or damaged flywheel.
Repair or replace the flywheel.
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 or replace 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 or replace as required.

The connecting rod bearings.

The connecting rods.

The crankshaft pin journals.

Excessive crankshaft bearing clearance
Inspect the following components, and repair or replace 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 or replace as required :

The connecting rod bearings.

The connecting rods.

The crankshaft

Excessive crankshaft bearing clearance
Inspect the following components, and repair or replace 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

1)

Remove spark plugs and check for fluid.

2)

Inspect for broken head gasket.

3)

Inspect for cracked engine block or cylinder head.

4)

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

Broken timing chain and/or timing chain and/or timing chain gears.
1)

Inspect timing chain and gears.

2)

Repair as required.

Material in cylinder

Broken valve

Piston material

Foreign material

1)

Inspect cylinder for damaged components and/or foreign materials.

2)

Repair or replace as required.

Seized crankshaft or connecting rod bearings.
1)

Inspect crankshaft and connecting rod bearing.

2)

Repair as required.

Bent or broken connecting rod.
1)

Inspect connecting rods.

2)

Repair as required.

Broken crankshaft
1)

Inspect crankshaft.

2)

Repair as required.


Special service tools
Special Service Tools

Tool Name / Number
Illustration
Description
Crankshaft damper pulley fixing tool
0K231-2C100
Crankshaft damper pulley adapter holder
09231-2J210Crankshaft damper pulley fixing tool washer
09231-D2100

Used for keeping crankshaft damper pulley from rotating when removing / installing crankshaft damper pulley bolt
Crankshaft front oil seal installer
0K231-2C200




Valve stem seal installer
09222-4A000


Valve spring compressor
09222-3K000
Holder
09222-3K100

Used for removing / installing intake or exhaust valve.



Crankshaft rear oil seal installer
09214-2W200
Handle
09231-H1100




Oil pan remover
09215-3C000


Oil filter wrench
09263-2E000

Used for removing / installing oil filter.
E-CVVT plug installer (A)
E-CVVT cover installer (B)
Handle (C)
09243-2C200



Water Pump Belt
Remover & Installer
09252 - C1000

Used for removing / installing water pump belt.

Engine support fixture (bar)
09200-3N000


Engine support fixture (supporter)
09200-2S000
09200-2S100
09200-2S200



※ Engine support fixture special tool assembly drawing

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