Kia Optima: Engine Mechanical System

Kia Optima DL3 2019-2020 Service and Repair Manual / Engine Mechanical System

Special service tools
Special Service Tools

Tool Name / Number
Illustration
Description
Crankshaft front oil seal installer
09231-2E000

Used for installing crankshaft front oil seal
Crankshaft rear oil seal installer
09214-2E000 (Installer)
09231-H1100 (Handle)

Used for installing crankshaft rear oil seal
Valve spring compressor & holder
09222-3K000 (Compressor)
09222-3K100 (Handle)

Used for removing / installing intake or exhaust valve
Valve stem seal installer
09222-2E000

Used for installing valve stem seal
Ring gear stopper
09231-3N100
09231-2B100

Used for keeping ring gear from rotating when removing / installing crankshaft pulley bolt
Ring gear stopper
09231-3D100
09231-2W100

Used for keeping ring gear from rotating when removing / installing crankshaft pulley bolt
Oil pan remover
09215-3C000

Used for removing oil pan
Tensioner stopper pin
09240-2E100

Used for holding compressed piston of tensioner
Oil filter wrench
09263-2E000

Used for removing / installing oil filter
Steel ball installer
0K221-2M100

Used for installing steel ball
Pressure cap pressure checker
0K253-G5100

Used for checking for pressure cap pressure and a coolant leak

Compression test
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 injector connectors (A).

3.

Remove 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 :

1,275 kPa (13.0 kgf/cm², 185 psi)

Minimum pressure :

1,128 kPa (11.5 kgf/cm², 164 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.

Install the other parts reverse order of removal.

6.

Some DTCs may exist after the inspection test and may need to be manually cleared with KDS.

Troubleshooting
Troubleshooting

Symptom
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
Replace the timing chain and sprocket as required.
Worn camshaft lobes
Replace the camshaft.
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 camshaft as required.

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 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 is not cranked.
Crankshaft does 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 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.


Service data
Service Data

Description
Specifications
Limit
General
Type
In - line, DOHC
 
Number of cylinders
4
 
Bore
81.0 mm (3.1890 in.)
 
Stroke
97.0 mm (3.8189 in.)
 
Total displacement
1999 cc (121.99 cu.in.)
 
Compression ratio
10.3±0.2 : 1
 
Firing order
1 - 3 - 4 - 2
 
Valve timing
Intake valve
Open
ATDC 10° - BTDC 40°
 
Close
ABDC 67° - ABDC 17°
 
Exhaust valve
Open
BBDC 54° - BBDC 14°
 
Close
ATDC 1° - ATDC 41°
 
Camshaft
Cam height
Intake
39.0 mm (1.5354 in.)
 
Exhaust
38.66 mm (1.5220 in.)
 
Journal outer diameter
Intake
No.1 : 35.959 - 35.975 mm 
(1.41571 - 1.41634 in.)
No.2,3,4,5 : 22.959 - 22.975 mm 
(0.90390 - 0.90453 in.)
 
Exhaust
No.1 : 35.959 - 35.975 mm 
(1.41571 - 1.41634 in.)
No.2,3,4,5 : 22.959 - 22.975 mm 
(0.90390 - 0.90453 in.)
 
Bearing oil clearance
Intake
No.1 : 0.032 - 0.062 mm 
(0.00126 - 0.00244 in.)
No.2,3,4,5 : 0.032 - 0.062 mm 
(0.00126 - 0.00244 in.)
 
Exhaust
No.1 : 0.032 - 0.062 mm 
(0.00126 - 0.00244 in.)
No.2,3,4,5 : 0.032 - 0.062 mm 
(0.00126 - 0.00244 in.)
 
End play
0. 10 - 0.19 mm (0.0039 - 0.0075 in.)
 
Valve
Valve length
Intake
102.22 mm (4.0244 in.)
101.97 mm (4.0146 in.)
Exhaust
104.04 mm (4.0961 in.)
103.79 mm (4.0862 in.)
Stem outer diameter
Intake
5.465 - 5.480 mm (0.21516 - 0.21575 in.)
 
Exhaust
5.458 - 5.470 mm (0.21488 - 0.21535 in.)
 
Face angle
45.25° - 45.75°
 
Thickness of valve head(margin)
Intake
1.30 mm (0.0512 in.)
 
Exhaust
1.26 mm (0.0496 in.)
 
Valve stem to valve guide clearance
Intake
0.020 - 0.047 mm (0.00079 - 0.00185 in.)
 
Exhaust
0.030 - 0.054 mm (0.00118 - 0.00213 in.)
 
Valve guide
Length
Intake
43.8 - 44.2 mm (1.7244 - 1.7402 in.)
 
Exhaust
43.8 - 44.2 mm (1.7244 - 1.7402 in.)
 
Inner diameters
Intake
5.500 - 5.512 mm (0.21654 - 0.21701 in.)
 
Exhaust
5.500 - 5.512 mm (0.21654 - 0.21701 in.)
 
Valve seat
Width of seat contact
Intake
1.05 - 1.35 mm (0.0413 - 0.0532 in.)
 
Exhaust
1.35 - 1.65 mm (0.0532 - 0.0650 in.)
 
Seat angle
Intake
44° 45' - 45° 6'
 
Exhaust
44° 45' - 45° 6'
 
Valve spring
Free length
45.93 mm (1.8083 in.)
 
Load
19.6 ± 1.0 kg / 37.0 mm 
(43.21 ± 2.20 lb / 1.4567 in.)
45.7 ± 1.8 kg / 27.0 mm 
(100.75 ± 3.97 lb / 1.0630 in.)
 
Out of squareness
Less than 1.5°
 
Cylinder head
Flatness of gasket surface
Less than 0.05 mm (0.0020 in.) for total area
Less than 0.02 mm (0.0008 in.) for a section of
100 mm (3.9370 in.) × 100 mm (3.9370 in.)
 
 
Flatness of manifold mounting surface
Intake
Less than 0.10 mm (0.0039 in.)
 
Exhaust
Less than 0.10 mm (0.0039 in.)
 
Piston
Piston outer diameter
80.97 - 81.00 mm (3.1878 - 3.1890 in.)
 
Piston to cylinder clearance
0.02 - 0.04 mm (0.0008 - 0.0016 in.)
 
Ring groove width
No. 1 ring
1.030 - 1.050 mm (0.04055 - 0.04134 in.)
 
No. 2 ring
1.230 - 1.250 mm (0.04843 - 0.04921 in.)
 
Oil ring
2.010 - 2.025 mm (0.07913 - 0.07972 in.)
 
Piston ring
Side clearance
No. 1 ring
0.040 - 0.080 mm (0.00157 - 0.00315 in.)
 
No. 2 ring
0.040 - 0.080 mm (0.00157 - 0.00315 in.)
 
Oil ring
0.040 - 0.115 mm (0.00157 - 0.00453 in.)
 
End gap
No. 1 ring
0.15 - 0.30 mm (0.0059 - 0.0118 in.)
 
No. 2 ring
0.30 - 0.45 mm (0.0118 - 0.0177 in.)
 
Oil ring
0.20 - 0.70 mm (0.0079 - 0.0276 in.)
 
Piston pin
Piston pin outer diameter
19.997 - 20.000 mm (0.78728 - 0.78740 in.)
 
Piston pin hole inner diameter
20.004 - 20.009 mm (0.78756 - 0.78775 in.)
 
Piston pin hole clearance
0.004 - 0.012 mm (0.00016 - 0.00047 in.)
 
Connecting rod small end hole inner diameter
20.007 - 20.015 mm (0.78768 - 0.78799 in.)
 
Piston pin - to - connecting rod bushing oil clearance
0.007 - 0.018 mm (0.00028 - 0.00070 in.)
 
Connecting rod
Connecting rod big end inner diameter
48.000 - 48.018 mm (1.88976 - 1.89047 in.)
 
Connecting rod bearing oil clearance
0.024 - 0.042 mm (0.00094 - 0.00165 in.)
 
Side clearance
0.10 - 0.25 mm (0.0039 - 0.0098 in.)
 
Crankshaft
Main journal outer diameter
54.942 - 54.960 mm (2.16307 - 2.16378 in.)
 
Pin journal outer diameter
44.954 - 44.972 mm (1.76984 - 1.77055 in.)
 
Main bearing oil clearance
0.016 - 0.034 mm (0.00063 - 0.00134 in.)
 
End play
0.07 - 0.25 mm (0.0028 - 0.0098 in.)
 
Cylinder block
Cylinder bore
81.00 - 81.03 mm (3.1890 - 3.1902 in.)
 
Flatness of gasket surface
Less than 0.05 mm (0.0020 in.) for total area
Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) × 100 mm (3.9370 in.)
 
Cooling system
Cooling method
Forced circulation with cooling fan
 
Coolant quantity
Approx. 6.3 L (1.66 U.S.gal., 6.66 U.S.qt., 5.54 lmp.qt.)
 
Thermostat
Type
Wax pellet type
 
Opening 
temperature
88±1.5°C (190.4±34.7°F)
 
Full opening valve lift / temperature
More than 8 mm (0.3 in.) / 100°C (212°F)
 
Radiator cap
Main valve opening pressure
125.52 - 154.94 kpa
(1.28 - 1.58 kg/cm², 18.21 - 22.47 psi).
 
Vacuum valve opening pressure
0 - 6.86 kPa (0 - 0.07 kgf/cm², 0 - 1.00 psi)
 

Liquid Gasket

Location
Product
Mating surface of timing chain cover
Threebond 1217H or equivalent
Front area of mating surface between cam carrier and cylinder head
Front area of mating surface between cylinder block and head
Upper area of mating surface between timing chain cover and cam carrier
Front upper area of cylinder block 
Front upper area of cylinder head gasket
Lower area of cam carrier
Lower area of cylinder block
Mating surface of oil pan
Mating surface of oil pressure switch
THREEBOND 2403

Lubricant
Lubricant

Description
Specifications
Limit
Engine oil
Oil quantity
Total
4.5 L (1.19 U.S.gal., 4.76 U.S.qt., 3.96 lmp.qt.)
When replacing a short engine or block assembly
Oil pan
3.7 L (0.98 U.S.gal., 3.91 U.S.qt., 3.26 lmp.qt.)
 
Drain and refill
4.0 L (1.06 U.S.gal., 4.23 U.S.qt., 3.52 lmp.qt.)
Including oil filter
Oil grade
Specifications
All (Except Middle east, India, Libia, Algeria, Morocco, Tunisia, Sudan, Egypt, Iran) :
- ILSAC GF-4 & API SM or above / 5W-20
- ACEA A5 or above / 5W-20
Middle east, India, Libia, Algeria, Morocco, Tunisia, Sudan, Egypt, Iran :
- ACEA A5 or above / 5W-30
  

If oil of acceptable viscosity is not available, refer to "Lubrication System" for recommended SAE viscosity number

 
Oil pressure (at 1,000rpm)
98.07 kPa (1.0 kgf/cm², 14.22 psi) or above
Oil temperature (oil pan): 110±2°C (230±35.6°F)

Tightening torque
Tightening Torques

Item
N•m
kgf•m
lb•ft
lb•inIb.in
Engine mounting
Engine mounting bracket and body fixing blots
68.6 - 88.3
7.0 - 9.0
50.6 - 65.1

Engine mounting support bracket and engine support bracket fixing bolt
88.3 - 107.9
9.0 - 11.0
65.1 - 79.6

Engine mounting support bracket and engine support bracket fixing nuts
88.3 - 107.9
9.0 - 11.0
65.1 - 79.6

Engine mounting insulator and engine support bracket fixing nut
88.3 - 107.9
9.0 - 11.0
65.1 - 79.6

Transaxle mounting bracket and body fixing bolts
68.6 - 88.3
7.0 - 9.0
50.6 - 65.1

Transaxle mounting insulator and transaxle support bracket fixing bolts
107.9 - 127.5
11.0 - 13.0
79.6 - 94.0

Roll rod bracket and sub frame fixing bolts
49.0 - 63.7
5.0 - 6.5
36.1 - 47.0

Roll rod bracket to roll rod support bracket fixing bolt
107.9 - 127.5
11.0 - 13.0
79.6 - 94.0

Cylinder head
Engine cover mounting bolt
7.8 - 9.8
0.8 - 1.0
5.8 - 7.2

Cylinder head cover bolt
[3.9 - 5.9] + [7.8 - 9.8]
[0.4 - 0.6] + [0.8 - 1.0]
[2.9 - 4.3] + [5.8 - 7.2]
[34.5 - 52.1] + [69.0 - 86.7]
CVVT bolt (LH/RH)
64.7 - 76.5
6.6 - 7.8
47.7 - 56.4

Camshaft bearing cap bolt (M6)
11.8 - 13.7
1.2 - 1.4
8.7 - 10.1

Camshaft bearing cap bolt (M8)
18.6 - 22.6
1.9 - 2.3
13.7 - 16.6

Cam carrier bolt
18.6 - 22.6
1.9 - 2.3
13.7 - 16.6

Cylinder head bolt
[32.4 - 36.3] + [90 - 95°] + [90 - 95°]
[3.3 - 3.7] + [90 - 95°] + [90 - 95°]
[23.9 - 26.8] + [90 - 95°] + [90 - 95°]

Engine hanger bolt (Front/Rear)
34.3 - 39.2
3.5 - 4.0
25.3 - 28.9

Camshaft position sensor (LH/RH)
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Oil control valve (OCV) bolt (LH/RH)
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Cylinder block
Drive plate bolt (A/T)
117.7 - 127.5
12.0 - 13.0
86.8 - 93.9

Connecting rod bearing cap bolt
[17.7 - 21.6] + [88 - 92°]
[1.8 - 2.2] + [88 - 92°]
[13.0 - 15.9] + [88 - 92°]

Lower crankcase bolt
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4

Main bearing cap bolt
[27.5 - 31.4] + [120 - 125°]
[2.8 - 3.2] + [120 - 125°]
[20.3 - 23.1] + [120 - 125°]

Crankshaft position sensor bolt
10.8 - 11.8
1.1 - 1.2
8.0 - 8.7

Knock sensor
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4

Lubrication system
Oil drain plug
34.3 - 44.1
3.5 - 4.5
25.3 - 32.5

Oil filter
11.8 - 15.7
1.2 - 1.6
8.7 - 11.6

Oil pan bolt
11.8 - 13.7
1.2 - 1.4
8.7 - 10.1

Oil screen bolt
19.6 - 26.5
2.0 - 2.7
14.5 - 19.5

Oil screen nut
11.8 - 13.7
1.2 - 1.4
8.7 - 10.1

Oil pressure switch
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Cooling system
Water pump pulley bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Water pump bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Water inlet fitting nut
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4

Water temperature control assembly bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Heater pipe bolt
19.6 - 23.5
2.0 - 2.4
14.5 - 17.4

Intake and exhaust system
Air cleaner assembly bolt
7.8 - 9.8
0.8 - 1.0
5.8 - 7.2

Electronic throttle control (ETC) module bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Intake manifold stay bolt
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4

Intake manifold bolt
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4

Intake manifold nut
18.6 - 23.5
1.9 - 2.4
13.7 - 17.4

Exhaust manifold heat protector bolt
9.8 - 11.8
1.0 - 1.2
7.2 - 8.7

Exhaust manifold stay bolt
39.2 - 49.0
4.0 - 5.0
28.9 - 36.2

Exhaust manifold nut
29.4 - 34.3
3.0 - 3.5
21.7 - 25.3

Muffler nut
39.2 - 58.8
4.0 - 6.0
28.9 - 43.4


Severe Condition
General market Maintenance Under Severe Usage Conditions The following items must be serviced more frequently on cars mainly used under severe driving conditions. Refer to the cha ...

Cooling System
Troubleshooting Engine Overheat Troubleshooting Inspection Remedy Visual inspection Inspect for shortage of coolant in reservoi ...

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