KIA SEDONA Service & Repair Manual (2006 2007 2008 2009) - !
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CHAPTER 2:
Engine Mechanical System
2007 > J2.9L DIESEL CRDI(VGT) >
SPECIAL SERVICE TOOLS
Tool (Number and name) Illustration Use
Valve spring lifter pivot.
(0K993 120 004)
Removal or installation of the valve spring
Valve spring lifter arm.
(0K993 120 001)
Removal or installation of the valve spring
Valve seal installer.
(09222-22001)
Installation of the valve seal
Camshaft pulley holder.
(09231 - 4X100)
Installation of the camshaft
Pressure gauge adapter.
(0K552 131 002)
Measurement of compression pressure
End york holder.
(09517-21700)
Removal or installation of the crankshaft
pulley bolt
(used with 09231-H1000)
Crankshaft pulley adapter. Removal or installation of the crankshaft
Crankshaft pulley adapter.
(09231-H1000)
Removal or installation of the crankshaft
pulley bolt
(used with 09517-21700)
Oil pan remover.
(09215-3C000)
Removal of the oil pan
2007 > J2.9L DIESEL CRDI(VGT) >
TROUBLESHOOTING
Symptom Suspect area Remedy
Engine misfire with abnormal
internal lower engine noises.
Loose or improperly installed engine
flywheel.
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 can
cause the valve not to close properly.)
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 lifers.
Engine misfire with coolant
consumption
a. Faulty cylinder head gasket and/or
cracking or other damage to the
cylinder head and engine block
cooling system .
b. Coolant consumption may or may not
cause the engine to overheat.
a. Inspect the cylinder head and engine
block for damage to the coolant
passages and/or a faulty head
gasket.
b. Repair or replace as required.
Engine misfire with excessive
oil consumption
Worn valves, valve 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)
Inspection 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 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.
Lower engine noise, regardless
of engine speed.
Low oil pressure. Repair or replace damaged components
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 and cylinder bore.
Repair as required.
Excessive piston pin-to-bore 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.
a. The connecting rod bearings.
b. The connecting rods.
c. The crankshaft.
d. The crankshaft journal.
Excessive crankshaft bearing clearance. Inspect the following components and
repair as required.
a. The crankshaft bearings.
b. The crankshaft journals.
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.
a. The connecting rod bearings.
b. The connecting rods.
c. The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components and
repair as required.
a. The crankshaft bearings.
b. The crankshaft journals.
c. The cylinder block crankshaft bearing
bore.
Engine will not crank.
(crankshaft will not rotate)
Hydraulically locked cylinder.
a. Coolant/antifreeze in cylinder.
b. Oil in cylinder.
c. 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
gears.
Inspect timing chain and gears.
Repair as required.
Foreign material in cylinder.
a. Broken valve.
b. Piston material.
c. Foreign material.
Inspect cylinder for damaged
components and/or foreign materials.
Repair or replace as required.
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$35.99
The KIA SEDONA Service & Repair Manual is a comprehensive guide tailored to assist both professional mechanics and DIY enthusiasts in maintaining and repairing their vehicles. This manual covers the 2006, 2007, 2008, and 2009 models of the KIA SEDONA.
With detailed step-by-step instructions, diagrams, and illustrations, this manual provides all the necessary information to tackle any repair or service task for your KIA SEDONA. From routine maintenance procedures to complex engine repairs, this manual is your go-to resource for keeping your vehicle in top shape.
Whether you are a seasoned mechanic or a DIY enthusiast, the KIA SEDONA Service & Repair Manual is an essential tool that will save you time and money. It covers a wide range of topics, including engine, transmission, suspension, brakes, electrical system, and more.
Investing in this manual is a wise decision for any owner of a 2006-2009 KIA SEDONA. It will empower you with the knowledge and confidence to perform repairs and maintenance tasks with ease. Don't let vehicle issues slow you down, get your hands on the KIA SEDONA Service & Repair Manual today!
