KIA Engine V6 G6EA GSL 2.7 Engine Workshop Manual

ENGINE (GV6 DOHC GASOLINE) SPECIAL SERVICE TOOLS EM-2 SYMPTOM-RELATED DIAGNOSTIC PROCEDURE EM-4 SPECIFICATION EM-9 ON-VEHICLE SERVICE PROCEDURE EM-10 REMOVAL AND REPLACEMENT PROCEDURES EM-31 DISASSEMBLY, INSPECTION AND REASSEMBLY PROCEDURE EM-40

ЕМ-2 ENGINE-GV6 DOHC GASOLINE

ЕМ-3 SPECIAL SERVICE TOOLS

ЕМ-4 ENGINE-GV6 DOHC GASOLINE SYMPTOM-RELATED DIAGNOSTIC PROCEDURE Engine Diagnostic chart Problem Engine will not crank Engine cranks normally, but does not start Poor Idle quality White exhaust smoke Possible cause Battery, starting system or other electrical problems Liquid in combustion chamber Seized engine Fuel system malfunction Ignition system malfunction Improper valve clearance Restricted exhaust system Timing belt and/or related parts Low compression due to: stuck or burned valves; worn piston, piston ring or cylinder; failed cylinder head gasket Camshaft worn Fuel system malfunction Emission system malfunction Ignition system malfunction Improper valve clearance Uneven cylinder compression Poor valve-to-valve seat contact Broken valve spring Failed cylinder head gasket Usually caused by water vapor, which is a normal by-product of combustion on cold days Excessive white smoke with engine warmed up could be caused by a failed cylinder head or intake gasket. Could also be a cracked block, cylinder head or intake manifold Action Refer to starting system, section ЕЕ, charging system, section ЕЕ, or electrical troubleshooting manual Remove with suction gun, then crank engine over with spark plugs removed Repair Refer to fuel system, section FL Refer to ignition system, section ЕЕ Check HLA's Refer to exhaust system, section EM-IE Inspect timing belt and related parts; replace if necessary Perform a compression test, as outlined in this section; repair engine as necessary Replace Refer to fuel system, section FL Refer to emission control system, section EC Refer to ignition system, section ЕЕ Check HLA's Perform a compression test, as outlined in this section ; repair engine as necessary Repair or replace Repair Replace None required Repair or replace

SYMPTOM-RELATEDDIAGNOSTICPROCEDURE EM-5 Problem Black exhaust smoke Blue exhaust smoke Valve train noise Insufficient power Abnormal combustion Engine knocks at idle when hot Possible cause Fuel system malfunction / Emission system malfunction Usually caused by oil burning in combustion chambers from: worn rings, worn valve guides, worn valve seals or failed cylinder head gasket Worn valve guides Low oil pressure Improper valve clearance Broken valve spring Sticking valves Camshaft worn or faulty Insufficient compression caused by: 1. Improper valve clearance 2. Leakage from valve seat 3. Seized valve stem 4. Weak or broken valve spring 5. Failed cylinder head gasket 6. Cracked or distorted cylinder head 7. Sticking, damaged or worn piston ring 8. Cracked or worn piston Fuel system malfunction Slipping clutch Dragging brakes Wrong tire size Restricted exhaust system Improper valve clearance Sticking or burned valve Weak or broken valve spring Carbon accumulation in combustion chamber Loose or worn accessory drive belt/tensioner A/C compressor or generator bearing Improper oil viscosity Excessive piston pin clearance Connecting rod clearance Action Refer to fuel system, section FL Refer to emission control system, section EC Replace Repair Refer to lubrication system, section EM-LU Check HLA's Replace Free valves Replace Check HLA's Repair or replace Replace Replace Replace Repair or replace Replace Replace Refer to fuel system, section FL Refer to clutch, section CH Refer to brake system, section BR Refer to wheels and tires, section SS Refer to exhaust system, section EM-IE Check HLA's Replace Replace Eliminate carbon Check belts and tensioners Replace if necessary Replace Install proper oil viscosity for expected temperatures Install new piston, pin and/ or connecting rod Check and replace rods if necessary

ЕМ-6 ENGINE-GV6 DOHC GASOLINE Problem Engine knocks at Idle when hot Slight noise at Idle, becomes louder as engine speed is increased Engine knocks when cold Knock increases with torque Engine has heavy knock when hot and torque is applied Engine has light knock when hot and under light load conditions Engine knocks during Initial start up and lasts only a few seconds Possible cause Insufficient piston-to-bore clearance Faulty timing belt tensioner or guide Loose damper pulley Valve spring clicking on cap, off square or broken Excessive stem to guide clearance Excessive valve seat runout Excessive piston to wall clearance Loose or broken damper pulley Excessive piston to bore clearance Bent connecting rod Broken damper pulley Accessory belts too tight or damaged Belt tensioned damaged Flywheel cracked or loose clutch plate Excessive main bearing clearance Excessive rod bearing clearance Improper timing Piston pin and/or connecting rod Poor quality fuel Exhaust leak at manifold Excessive rod bearing clearance Improper oil viscosity Action Hone and replace rods if necessary Replace Tighten or replace if necessary Repair or replace Repair Repair Replace pistons Tighten or replace Replace piston Replace Replace Adjust or replace belt Replace Replace flywheel or clutch plate Repair Repair Check timing Replace piston pin and/or rod Use recommended or higher grade fuel Tighten bolts and/or replace exhaust manifold gaskets if necessary Repair Install proper oil viscosity for expected temperatures

\ SYMPTOM-RELATED DIAGNOSTIC PROCEDURE EM-7 Timing belt Diagnostic chart Problem Tooth is broken or cracked Back surface Is cracked and/or worn Side surface is worn and / or frayed Teeth are worn Oil or coolant is on the belt Possible cause Camshaft jamming Tensioner jamming Engine overheating Interference with timing belt cover Improper installation of timing belt Malfunction of timing belt guide plate Poor belt cover sealing Coolant leak at water pump Camshaft malfunction Excessive belt tension Poor oil sealing Coolant leak at water pump Poor belt cover sealing Action Inspect camshaft by removing cylinder head cover Repair or replace if necessary Remove tensioner and inspect Replace if necessary Inspect cooling system Refer to engine cooling system, section EM-CL Remove timing belt cover and inspect Replace if necessary Remove timing belt and reinstall Remove timing belt and inspect guide plate Remove timing belt cover and inspect Replace if necessary Inspect water pump Replace if necessary Inspect camshaft by removing cylinder head cover Repair or replace if necessary Remove tensioner spring and inspect Replace if necessary Inspect front oil seals Replace if necessary Inspect water pump Replace if necessary Remove timing belt cover and inspect Replace if necessary

ЕМ-8 ENGINE-GV6 DOHC GASOLINE HLA(Hydraulic lash adjuster) Diagnostic chart Problem 1 . Noise when engine is started immediately after oil is changed. 2. Noise when engine is started after setting approx. one day. 3. Noise when engine is started after cranking for 3 seconds or more. 4. Noise when engine is started after new HLA is installed. 5. Noise continues more than 1 0 minutes. 6. Noise during idle after high-speed running. Possible cause Oil leakage in Oil passage Oil leakage in HLA Insufficient oil pressure Faulty HLA Incorrect oil amount Deteriorated oil Action Run engine at 2,000-3,000 rpm. If noise stops after 2 seconds - 10 minutes", HLA is normal. If not, replace HLA. * Time required for engine oil to circulate within engine includes tolerance for engine oil condition and ambient temperature. Check oil pressure. If lower than specification, check for cause. Oil pressure: 313.9-490.5 kPa (3.2-5.0 kg/cm 2 , 45.5-71 .1 psi) - 3,000 rpm Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. Measure valve clearance. If more than 0 mm (0 in), replace HLA. Check oil level. Drain or add oil as necessary. Check oil quality. If deteriorated, replace with specified type and amount of oil.

SPECIFICATION EM-9 SPECIFICATION Engine Specification ~— — - — _ Item Engine model ~— — _ Type Cylinder arrangement and number Combustion chamber Valve system Displacement Bore and stroke cu-in (cc) in (mm) Compression ratio Compression pressure Valve timing IN EX Valve clearance in Idle speed *1 Ignition timing *2 psi(kpa, kg/cm 2 )-rpm Open BTDC Close ABDC Open BBDC Close ATDC IN (mm) EX rpm BTDC Firing order GV6 DOHC Gasoline, 4 cycle 90°-V type, 6 cylinder Pentroof DOHC, belt driven 24valve 152.4 (2497) 3.15X3.26 (80X82.8) 10.4:1 191.9(1324,13.5)-290 6° 50° 40° 12° 0: Maintenance-free 0: Maintenance-free 750±50 12°±5° 1-6-5-4-3-2 *1. "P" range position *2. Test terminal ground

ЕМ-10 ENGINE-GV6 DOHC GASOLINE ON-VEHICLE SERVICE PROCEDURE Front timing belt (1) Power steering pump (2) Alternator B-terminal (3) Alternator (4) Drive belt idler (5) Oil level gauge pipe (6) Front timing belt cover (7) Mounting bracket - alternator / power steering pump (8) Engine lifting bracket (9) Drive belt tensioner (10) Crank-shaft pulley (11) Crank-shaft pulley cover (12) A/C compressor (13) A/C compressor bracket (14) Front cover (15) Timing belt auto-tensioner (16) Timing belt

KIA Engine V6 G6EA GSL 2.7 Engine Workshop Manual

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