Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2007 Kia Rondo L4-2.4LFACTORY OEM SERVICE PROCEDURE
System Specifications
Cylinder Block
Cylinder Bore
Specification 88.00 - 88.03 mm (3.4645 - 3.4657 in)
Flatness of gasket surface
Specification Less than 0.05 mm (0.0020 in) (0.02 mm (0.0008 in)/100 x 100)
Crankshaft
Main journal outer diameter
Specification 51.942 - 51.960 mm (2.0449 - 2.0456 in)
Pin journal outer diameter
Specification 47.954 - 47.972 mm (1.8879 - 1.8886 in)
Main bearing oil clearance
Specification 0.020 - 0.038 mm (0.0010 - 0.0019 in)
Limit 0.1 mm (0.004 in)
End play
Specification 0.07 - 0.25 mm (0.0027 - 0.0098 in)
Main Bearing Cap
Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown.
Retighten the bearing cap bolts by 45° in the numerical order shown.
Connecting rod
Connecting rod big end inner diameter
Specification 51.000 - 51.018 mm (2.0079 - 2.0086 in)
Connecting rod bearing oil clearance
Specification 0.028 - 0.046 mm (0.0011 - 0.0018 in)
Limit 0.05 mm (0.0019 in)
Side clearance
Specification 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit 0.35 mm (0.0138 in)
Connecting rod bearing cap bolts 19.6 Nm (2.0 kgf-m, 14.46 lb-ft) + 90°
Piston
Piston outer diameter
Specification 87.975 - 88.005 mm (3.4636 - 3.4648 in)
Piston to cylinder clearance
Specification 0.015 - 0.035 mm (0.0028 - 0.0014 in)
Ring groove width
No. 1 ring groove
Specification 1.22 - 1.24 mm (0.0006 - 0.0488 in)
Limit 1.26 mm (0.0496 in)
No. 2 ring groove
Specification 1.22 - 1.24 mm (0.0480 - 0.0488 in)
Limit 1.26 mm (0.0496 in)
Oil ring groove
Specification 2.01 - 2.03 mm (0.0791 - 0.0799 in)
Limit 2.05 mm (0.0807 in)
Piston ring
Side clearance
No. 1 ring
Specification 0.03 - 0.07 mm (0.0012-0.0028 in)
Limit 0.1 mm (0.004 in)
No. 2 ring
Specification 0.03 - 0.07 mm (0.0012-0.0028 in)
Limit 0.1 mm (0.004 in)
Oil ring
Specification 0.06 - 0.15 mm (0.0024 - 0.0059 in)
Limit 0.2 mm (0.008 in)
End gap
No. 1 ring
Specification 0.15 - 0.30 mm (0.0059 - 0.0118 in)
Limit 0.6 mm (0.0236 in)
No. 2 ring
Specification 0.30 - 0.45 mm (0.0118 - 0.0177 in)
Limit 0.7 mm (0.0275 in)
Oil ring
Specification 0.20 - 0.70 mm (0.0078 - 0.0275 in)
Limit 0.8 mm (0.0315 in)
Crankshaft pulley bolt 166.6 - 176.4 Nm (17 - 18 kgf-m, 122.9 - 130.13 lb-ft)
Cylinder Bore
Specification 88.00 - 88.03 mm (3.4645 - 3.4657 in)
Flatness of gasket surface
Specification Less than 0.05 mm (0.0020 in) (0.02 mm (0.0008 in)/100 x 100)
Crankshaft
Main journal outer diameter
Specification 51.942 - 51.960 mm (2.0449 - 2.0456 in)
Pin journal outer diameter
Specification 47.954 - 47.972 mm (1.8879 - 1.8886 in)
Main bearing oil clearance
Specification 0.020 - 0.038 mm (0.0010 - 0.0019 in)
Limit 0.1 mm (0.004 in)
End play
Specification 0.07 - 0.25 mm (0.0027 - 0.0098 in)
Main Bearing Cap
Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown.
Retighten the bearing cap bolts by 45° in the numerical order shown.
Connecting rod
Connecting rod big end inner diameter
Specification 51.000 - 51.018 mm (2.0079 - 2.0086 in)
Connecting rod bearing oil clearance
Specification 0.028 - 0.046 mm (0.0011 - 0.0018 in)
Limit 0.05 mm (0.0019 in)
Side clearance
Specification 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit 0.35 mm (0.0138 in)
Connecting rod bearing cap bolts 19.6 Nm (2.0 kgf-m, 14.46 lb-ft) + 90°
Piston
Piston outer diameter
Specification 87.975 - 88.005 mm (3.4636 - 3.4648 in)
Piston to cylinder clearance
Specification 0.015 - 0.035 mm (0.0028 - 0.0014 in)
Ring groove width
No. 1 ring groove
Specification 1.22 - 1.24 mm (0.0006 - 0.0488 in)
Limit 1.26 mm (0.0496 in)
No. 2 ring groove
Specification 1.22 - 1.24 mm (0.0480 - 0.0488 in)
Limit 1.26 mm (0.0496 in)
Oil ring groove
Specification 2.01 - 2.03 mm (0.0791 - 0.0799 in)
Limit 2.05 mm (0.0807 in)
Piston ring
Side clearance
No. 1 ring
Specification 0.03 - 0.07 mm (0.0012-0.0028 in)
Limit 0.1 mm (0.004 in)
No. 2 ring
Specification 0.03 - 0.07 mm (0.0012-0.0028 in)
Limit 0.1 mm (0.004 in)
Oil ring
Specification 0.06 - 0.15 mm (0.0024 - 0.0059 in)
Limit 0.2 mm (0.008 in)
End gap
No. 1 ring
Specification 0.15 - 0.30 mm (0.0059 - 0.0118 in)
Limit 0.6 mm (0.0236 in)
No. 2 ring
Specification 0.30 - 0.45 mm (0.0118 - 0.0177 in)
Limit 0.7 mm (0.0275 in)
Oil ring
Specification 0.20 - 0.70 mm (0.0078 - 0.0275 in)
Limit 0.8 mm (0.0315 in)
Crankshaft pulley bolt 166.6 - 176.4 Nm (17 - 18 kgf-m, 122.9 - 130.13 lb-ft)
Factory Service Tools
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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