2008 Kia Rondo Service & Repair Manual
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2007-08 ENGINE
Mechanical (G4KC - GSL 2.4) - Rondo
GENERAL
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description Specifications Limit
General
Type In-line, Double Overhead Camshaft
Number of cylinders 4
Bore 88mm (3.464in)
Stroke 97mm (3.819in)
Total displacement 2359cc(143.90cu.in)
Compression ratio 10.5 : 1
Firing order 1-3-4-2
Idle RPM 650rpm
Valve timing
Intake valve
Opens ATDC 11° ~ BTDC 34°
Closes ABDC 22° ~ ABDC 67°
Exhaust valve
Opens BBDC 34°
Closes ATDC 10°
Cylinder head
Flatness of gasket surface
Less than 0.05mm (0.0020in)(0.02
mm(0.0008 in)/100 x100)
Flatness of manifold
mounting surface
Intake Less than 0.10mm (0.0039in)
Exhaust Less than 0.10mm (0.0039in)
Camshaft
Cam height
Intake 43.80mm (1.7244in)
Exhaust 45.00mm (1.7716in)
Journal outer Diameter (Intake, Exhaust)
No.1 : 30mm (1.1811in) (Intake)
No.2,3,4,5 : 24mm (0.9449in)
(Intake, Exhaust)
No.1 : 40mm (1.5748in) (Exhaust)
Bearing oil clearance
Intake
No.1 : 0.020 ~ 0.057mm (0.00078 ~
0.00224in)
0.09mm (0.0035in)
No.2,3,4,5 : 0.045 ~ 0.082mm
(0.00177 ~ 0.00323in)
0.12mm (0.0047in)
Exhaust
No.1,2,3,4,5 : 0.045 ~ 0.082mm
(0.00177 ~ 0.00323in)
0.12mm (0.0047in)
2008 Kia Rondo LX
2007-08 ENGINE Mechanical (G4KC - GSL 2.4) - Rondo
2008 Kia Rondo LX
2007-08 ENGINE Mechanical (G4KC - GSL 2.4) - Rondo
End play 0.1 ~ 0.22mm (0.0039 ~ 0.0086in) 0.24mm (0.0094in)
MLA
MLA outer Diameter
31.964 ~ 31.980 mm (1.2584 ~
1.2591 in)
Cylinder head tappet bore inner diameter
32.000 ~ 32.025 mm (1.2598 ~
1.2608 in)
MLA to tappet bore clearance
0.020 ~ 0.061 mm (0.0008 ~ 0.0024
in)
Valve
Valve length
Intake 113.18mm (4.4559in)
Exhaust 105.89mm (4.1689in)
Stem outer diameter
Intake
5.465 ~ 5.480mm (0.2151 ~
0.2157in)
Exhaust
5.458 ~ 5.470mm (0.2149 ~
0.2153in)
Face angle 45.25° ~ 45.75°
Thickness of valve
head (margin)
Intake 1.02mm (0.0401 in)
Exhaust 1.09mm (0.0429in)
Valve stem to valve
guide clearance
Intake
0.020 ~ 0.047mm (0.00078 ~
0.00185in)
0.07mm (0.00275in)
Exhaust
0.030 ~ 0.054mm (0.00118 ~
0.00212in)
0.09mm (0.00354in)
Valve guide
Length 43.8 ~ 44.2mm (1.7244 ~ 1.7401 in)
Inner diameter 5.500-5.512mm (0.2165 ~ 0.2170in)
Valve seat
Width of seat
contact
Intake 1.16 ~ 1.46mm (0.0457 ~ 0.0575in)
Exhaust 1.35 ~ 1.65mm (0.0531 ~ 0.0649in)
Seat angle 44.75° ~ 45.10°
Valve spring
Free length 47.44mm (1.8677in)
Load
19.0 ± 0.6kg/35.0mm
(41.88±1.32lb/1.3779in)
39.8 ± 1.2kg/26.0mm (87.74 ±
2.64lb/1.0236 in)
Squareness Less than 1.5°
Valve clearance
Cold (20°C[68°F])
Intake 0.17 ~ 0.23mm (0.0067 ~ 0.0090in)
Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in)
Cylinder block
Cylinder bore
88.00 ~ 88.03mm (3.4645 ~
3.4657in)
2008 Kia Rondo LX
2007-08 ENGINE Mechanical (G4KC - GSL 2.4) - Rondo
Flatness of gasket surface
Less than 0.05mm (0.0020in)(0.02
mm(0.0008 in)/100 x100)
Piston
Piston outer diameter
87.975 ~ 88.005mm (3.4636 ~
3.4648in)
Piston to cylinder clearance
0.015 ~ 0.035mm (0.0028 ~
0.0014in)
Ring groove width
No. 1 ring groove 1.22 ~ 1.24mm (0.0006 ~ 0.0488in) 1.26mm (0.0496in)
No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in) 1.26mm (0.0496in)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in) 2.05mm (0.0807in)
Piston ring
Side clearance
No. 1 ring 0.03 ~ 0.07mm (0.0012-0.0028 in) 0.1mm (0.004in)
No. 2 ring 0.03 ~ 0.07mm (0.0012-0.0028 in) 0.1mm (0.004in)
Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in) 0.2mm (0.008in)
End gap
No. 1 ring 0.15 ~ 0.30mm (0.0059 ~ 0.0118in) 0.6mm (0.0236in)
No. 2 ring 0.03 ~ 0.45mm (0.0118 ~ 0.0177in) 0.7mm (0.0275in)
Oil ring 0.20 ~ 0.70mm (0.0078 ~ 0.0275in) 0.8mm (0.0315in)
Piston pin
Piston pin outer diameter
21.001 ~ 21.006mm (0.8268 ~
0.8270 in)
Piston pin hole inner diameter
21.016 ~ 21.021mm (0.8274 ~
0.8276 in)
Piston pin hole clearance
0.010 ~ 0.020mm (0.0004 ~ 0.0008
in)
Connecting rod small end inner diameter
20.974 ~ 20.985mm (0.8257 ~
0.8262 in)
Piston pin press-fit load
2451.7 ~ 12258.3N(250~1250kg,
551.2 ~ 2755.8 lb)
Connecting rod
Connecting rod big end inner diameter
51.000 ~ 51.018mm (2.0079 ~
2.0086 in)
Connecting rod bearing oil clearance
0.028 ~ 0.046mm (0.0011 ~ 0.0018
in)
0.05mm(0.0019in)
Side clearance 0.10 ~ 0.25mm (0.0039 ~ 0.0098 in) 0.35mm (0.0138in)
Crankshaft
Main journal outer diameter
51.942 ~ 51.960mm (2.0449 ~
2.0456in)
Pin journal outer diameter
47.954 ~ 47.972mm (1.8879 ~
1.8886in)
Main bearing oil clearance
0.020 ~ 0.038mm (0.0010 ~ 0.0019
in)
0.1mm (0.004in)
End play 0.07 ~ 0.25mm (0.0027 ~ 0.0098in)
2008 Kia Rondo LX
2007-08 ENGINE Mechanical (G4KC - GSL 2.4) - Rondo
TIGHTENING TORQUE
TIGHTENING TORQUE SPECIFICATION
Engine oil
Option with balance shaft module
Oil quantity(Total) 5.2L (5.49 US qt, 4.58 Imp qt)
When replacing a short
engine or a block
assembly
Oil quantity (Excluding oil filter) 4.0L (4.23 US qt, 3.52 Imp qt)
When replacing an oil
pan only
Oil quantity (Drain and refill including
oil filter)
4.3L (4.54 US qt, 3.78 Imp qt)
Oil type 5W-20(above SJ or SL)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quality 6.7L (7.08US qt, 5.90 lmp qt)
Thermostat
Type Wax pellet type
Opening
temperature
82°C (177°F)
Closing
temperature
77°C (170.6°F)
Pull opening
temperature
95°C (203°F)
Radiator cap
Main valve
opening pressure
93.16 ~ 122.58kpa(0.95 ~
1.25kg/cm
2
, 13.51 ~ 17.78psi)
Vacuum valve
opening pressure
6.86kpa (1psi, 0.07kg/cm
2
) or less
Water temperature sensor
Type Thermister type
Resistance
20°C (68°F) 2.45 ± 0.14kohms
80°C (176°F) 0.3222kohms
Item Quantity N.m kgf.m lb-ft
Ladder frame bolts 10 23.52 ~ 27.44 2.4 ~ 2.8 17.35 ~ 20.24
Oil pump & balance shaft module bolts 4 16.66+ 60° + 60° 1.7+ 60° + 60° 12.29+ 60° + 60°
Timing chain cover bolts (M8) 6 18.62 ~ 22.54 1.9 ~ 2.3 13.74 ~ 16.63
Timing chain cover bolts (M6) 7 7.84 ~ 9.8 0.8 ~ 1.0 5.78 ~ 7.23
Oil pan bolts (M6 x 10) 16 9.8 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.67
Oil pan bolts (M8 x 103) 2 26.46 ~ 30.38 2.7 ~ 3.1 19.52 ~ 22.41
Engine support bracket bolt (M10 x 40) 1 39.2 ~ 44.1 4.0 ~ 4.5 28.92 ~ 32.53
Engine support bracket bolts (M10 x 45) 2 39.2 ~ 44.1 4.0 ~ 4.5 28.92 ~ 32.53
Engine support bracket bolt (M8 x 30) 1 19.6 ~ 24.5 2.0 ~ 2.5 14.46 ~ 18.07
2008 Kia Rondo LX
2007-08 ENGINE Mechanical (G4KC - GSL 2.4) - Rondo
Camshaft bearing cap bolts (M6) 16 10.78 ~ 12.74 1.1 ~ 1.3 7.95 ~ 9.39
Camshaft bearing cap bolts (M8) 4 27.44 ~ 31.36 2.8 ~ 3.2 20.24 ~ 23.14
Cylinder head bolts 10 34.3 + 90° + 90° 3.5 + 90° +90° 25.3 + 90° + 90°
Engine hanger bolts 2 27.5 ~ 31.4 2.8 ~ 3.2 20.3 ~ 23.1
Cylinder head cover bolts 18 7.84 ~ 9.8 0.8 ~ 1.0 5.78 ~ 7.23
Crankshaft pulley bolt 1 166.6 ~ 176.4 17 ~ 18 122.9 ~ 130.13
Flywheel bolts 7 117.6 ~ 127.4 12 ~ 13 86.75 ~ 93.98
Drive plate bolts 7 117.6 ~ 127.4 12 ~ 13 86.75 ~ 93.98
Timing chain tensioner bolts 2 9.8 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.67
Timing chain tensioner arm bolt 1 9.8 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.67
Timing chain guide bolts 3 9.8 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.67
OCV bolt 1 9.8 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.67
CVVT & camshaft sprocket bolt 1 53.9 ~ 63.7 5.5 ~ 6.5 39.7 ~ 47.0
Balance shaft chain tensioner arm bolt 1 9.8 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.67
Balance shaft chain guide bolts 2 9.8 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.67
Balance shaft chain tensioner bolts 2 9.8 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.67
Water pump bolts 5 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
A/C bracket bolts 4 19.6 ~ 33.0 2.0 ~ 3.36 14.46 ~ 24.3
P/S bracket bolts 2 44.1 ~ 53.9 4.5 ~ 5.5 32.53 ~ 39.70
Tensioner & idler bracket bolts 7 39.2 ~ 44.1 4.0 ~ 4.5 28.92 ~ 32.53
Water temp, control bolts 2 14.7 ~ 19.6 1.5 ~ 2.0 10.84 ~ 14.5
Water temp, control nut 1 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Water inlet pipe nuts 2 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Oil level gauge assembly bolt 1 7.84 ~ 11.76 0.8 ~ 1.2 5.78 ~ 8.67
Ignition coil bolts 4 3.92 ~ 5.88 0.4 ~ 0.6 2.89 ~ 4.34
Intake manifold bolts 3 18.6 ~ 27.4 1.9 ~ 2.8 13.7 ~ 20.2
Intake manifold nuts 2 18.6 ~ 27.4 1.9 ~ 2.8 13.7 ~ 20.2
Intake manifold stay bolts 4 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Exhaust manifold heat protector bolts 4 18.62 ~ 27.44 1.9 ~ 2.8 13.73 ~ 20.24
Exhaust manifold nuts 7 39.2 ~ 44.1 4.0 ~ 4.5 28.92 ~ 32.53
Exhaust manifold stay bolts (M8) 2 18.62 ~ 27.44 1.9 ~ 2.8 13.74 ~ 20.24
Exhaust manifold stay bolt (M10) 1 42.2 ~ 53.9 4.3 ~ 5.5 31.1 ~ 39.8
Front muffler bolts 2 39.2 ~ 58.8 4.0 ~ 6.0 28.92 ~ 43.37
Engine cover nuts 2 3.92 ~ 5.88 0.4 ~ 0.6 2.89 ~ 4.34
Engine cover mounting bracket bolts 2 7.84 ~ 11.76 0.8 ~ 1.2 5.78 ~ 8.67
Crankshaft position sensor & cover bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oxygen sensor 1 34.3 ~ 44.1 3.5 ~ 4.5 25.30 ~ 32.53
Knock sensor 1 16.66 ~ 23.5 1.7 ~ 2.4 12.29 ~ 17.4
Oil temperature sensor 1 19.6 ~ 39.2 2.0 ~ 4.0 14.46 ~ 28.92
Camshaft position sensor 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pressure switch 1 7.84 ~ 11.76 0.8 ~ 1.2 5.78 ~ 8.67
2008 Kia Rondo LX
2007-08 ENGINE Mechanical (G4KC - GSL 2.4) - Rondo
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This is the complete official full factory service repair manual for Kia Rondo 2008. It is a genuine repair service factory manual that covers all aspects of repair for the Kia Rondo 2008, including but not limited to:
- Kia Rondo 2008 General Maintenance
- Kia Rondo 2008 Troubleshooting
- Kia Rondo 2008 Engine Service / Repair
- Kia Rondo 2008 Transmission Service / Repair
- Kia Rondo 2008 Brake System
- Kia Rondo 2008 Wiring Diagram
- Kia Rondo 2008 Electrical System
- Kia Rondo 2008 Suspension
- Kia Rondo 2008 Periodic Lubrication
- Kia Rondo 2008 Steering
- Kia Rondo 2008 Cooling System
- Kia Rondo 2008 Fuel Injection / Fuel System
- Kia Rondo 2008 Emission System
- Kia Rondo 2008 Heater/ Air Conditional
- Kia Rondo 2008 Engine Control System
- Kia Rondo 2008 Chassis / Body
- Kia Rondo 2008 Restraint System
- Kia Rondo 2008 Interior
- Kia Rondo 2008 Differential / Drive
- Kia Rondo 2008 Axle
- And more...
The manual contains necessary illustrations, diagrams, and specifications to guide the mechanic through any repair procedure. It also includes an advanced troubleshooting guide to help diagnose and correct any problem. This highly detailed manual contains everything needed to repair, maintain, rebuild, refurbish, or restore the vehicle. All diagnostic and repair procedures are covered in great detail.
The manual is available in English and can be printed without any restriction. It is in a format that can work under all PC-based Windows operating systems and Mac as well. It saves to the hard drive and can be burned to CD-ROM. All pages are printable, allowing for easy access to the necessary information.
With detailed substeps, notes, cautions, warnings, numbered instructions, illustrations, and photos, this manual provides comprehensive guidance for every repair procedure. It also makes it easy to diagnose and repair problems with the vehicle's electrical system, as troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
This manual is a valuable resource for both professional technicians and DIY enthusiasts, providing incredibly detailed, step-by-step instructions and photos to guide through all service, maintenance, repairs, and tuning.
