2.4L 4-CYLINDER Engine: Removal & Installation Kia Optima I

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

Note. During removal of wiring and hoses, label each connection for proper reinstallation.

Scheme 1

Scheme 2

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-121831-S20803520762001091100000). Remove battery and air cleaner. Drain cooling system, engine oil and transaxle oil.
2. Disconnect engine wiring harness and back-up light switch connector. On M/T models, disconnect select control valve connector. On A/T models, disconnect oil cooler lines. On all models, disconnect generator and oil pressure gauge wiring.
3. Disconnect radiator hoses. Disconnect engine ground cable. Disconnect brake booster vacuum hose. Disconnect main fuel line and vapor hoses. Disconnect heater hoses from engine. Disconnect accelerator cable from engine. Disconnect clutch cable, shift control rod and extension rod (M/T). Remove shift control cable from transaxle (A/T).
4. Disconnect vehicle speed sensor connector from transaxle. Place reference marks across connections. Disconnect steering column lower "U" joint at steering gear shaft. Remove engine mount insulator located near power steering reservoir. Remove transaxle mount insulator.
5. Raise and support vehicle. Remove front wheels. Remove ABS sensor and caliper. Suspend caliper to body without disconnecting brake line.
6. Disconnect lower control arm and fork. Separate upper control arm from steering knuckle. Drain transaxle fluid. Disconnect front exhaust pipe from exhaust manifold. Suspend exhaust pipe from bottom of vehicle.
7. Position jack under sub-frame assembly. Ensure cables, hoses and wiring are disconnected from engine. To remove sub-frame, engine, transaxle, steering gear box and axle shaft as an assembly, loosen 6 sub-frame assembly bolts and raise vehicle away from engine assembly. (Scheme 1)
8. Remove axle shafts from transaxle. See «FWD AXLE SHAFTS»(ref-122097) article in DRIVE AXLES. Plug axle shaft holes to prevent dirt from entering transaxle.
9. Remove engine mounts, roll stoppers, and transaxle mount bracket. (Scheme 2) Using chain lift, raise engine off of sub-frame assembly.

Installation

Position engine and transaxle onto sub-frame assembly. Install front roll stopper and rear roll stopper onto sub-frame, engine and transaxle. To complete installation, reverse removal procedure. Ensure cables and drive belts are properly adjusted. Replace all fluids, and check gauges for correct operation. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Scheme 3

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-121831-S20803520762001091100000). Disconnect and remove fuel rail, with injectors and pressure regulator attached.
2. Remove bracket, power transistor and throttle body from intake manifold. Disconnect hose(s) and wiring interfering with manifold removal. Remove intake manifold-to-cylinder head attaching bolts. Remove intake manifold assembly. (Scheme 3) Disassemble as necessary.

To install, reverse removal procedure. Use NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Remove exhaust manifold heat shield. Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold-to-cylinder head attaching bolts. Suspend exhaust pipe from body. Remove exhaust manifold.

To install, reverse removal procedure. Use NEW gasket and retaining nuts. Tighten exhaust manifold nuts to specification. See TORQUE SPECIFICATIONS .

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-121831-S20803520762001091100000). Drain cooling system. Remove intake manifold. See «INTAKE MANIFOLD»(ref-121831-S15607425962001091100000). Remove exhaust manifold. See «EXHAUST MANIFOLD»(ref-121831-S31586022302001091100000).
2. Remove timing belt. See «TIMING BELT»(ref-121831-S21946030842001091100000). Label and disconnect necessary hoses, electrical connections, cables and fuel lines. Remove center cover and spark plug wires. Remove camshafts. See «CAMSHAFTS»(ref-121831-S05636410612001091100000).
3. Loosen head bolts in proper sequence. (Scheme 4) Remove cylinder head and gasket.
4. Remove valve spring retainer lock. Remove valve spring retainer, valve spring, spring seat and valve. Remove and discard valve stem seals.

Scheme 4

1. Install assembled cylinder head using NEW gasket. DO NOT apply sealant onto head gasket.
2. Install head bolts, and tighten in sequence to specification. (Scheme 5) Cylinder head bolt installation and tightening is based on whether NEW or original bolts are being used. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000). To complete installation, reverse removal procedure. Use NEW gaskets on intake and exhaust manifolds. Adjust all control cables.

Scheme 5

1. Remove drive belts and drive pulleys from crankshaft and water pump. Remove timing belt covers. To align timing marks, rotate engine clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing marks align with upper surface of rocker cover. Dowel pin of camshaft sprocket should be pointing upward. (Scheme 6)and (Scheme 7).
2. Remove timing belt auto tensioner. If reusing timing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt. Remove camshaft sprockets.
3. Remove plug at left side of block and insert a screwdriver to hold left counterbalance shaft in position. Screwdriver will have to be inserted at least 2.36" (60 mm). Remove oil pump sprocket nut and sprocket. (Scheme 7)
4. Loosen right counterbalance shaft sprocket mounting bolt. Remove tensioner "B" and timing belt "B". (Scheme 7) Remove crankshaft sprocket "B" from crankshaft.

Scheme 6

Scheme 7

1. Install crankshaft sprocket "B" onto crankshaft. Ensure flange is properly positioned. Lightly oil outer surface of spacer, and then install spacer onto right counterbalance shaft, with rounded edge of spacer inward.
2. Install counterbalance shaft sprocket. Tighten flange bolt tightly by hand. Align timing marks on each sprocket and on front case. (Scheme 8)
3. When installing timing belt "B", ensure there is no slack in tension side. Install tensioner "B" in center of pulley of left side of mounting bolt, and in pulley flange toward front of engine. (Scheme 9) Align timing mark of right counterbalance shaft sprocket with timing mark on front case.
4. To tighten timing belt "B", lift tensioner "B" so tension side is pulled tight. Tighten bolt to secure tensioner "B". DO NOT turn shaft or belt will be over-tightened.
5. Ensure timing marks are aligned. Ensure center of span on tension side of timing belt "B" can be depressed by hand. Ensure belt deflection is.20-.30" (5-7 mm).
6. Install crankshaft sprocket flange and sprocket. Ensure flange is mounted in proper direction, with chamfered side toward block. Install special washer and sprocket bolt to crankshaft. Tighten sprocket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000).
7. Insert long screwdriver through plug hole in left side of cylinder block to hold counterbalance shaft in position. Install oil pump sprocket, and tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000). Install camshaft sprockets, and tighten bolts. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000).
8. If auto tensioner rod is fully extended, place it into a soft-jaw vise, and compress rod until hole in rod lines up with hole in auto tensioner housing. Insert stiff wire to hold rod in this position. Install auto tensioner, leaving wire in place.
9. Install crankshaft sensor. Set timing marks of camshaft sprockets with notches on upper side of rocker cover and dowel pins straight up. Align crankshaft sprocket timing marks. Align oil pump sprocket timing marks.
10. Install timing belt around tensioner pulley and crankshaft sprocket. Secure belt onto tensioner pulley by hand. Pull other side of belt, and install it around oil pump sprocket. Install belt around idler pulley.
11. Install belt around intake camshaft sprocket. Turn exhaust camshaft sprocket one tooth clockwise to align its timing mark with cylinder head top surface. Pull belt with both hands, and install around exhaust camshaft sprocket.
12. Gently raise tensioner pulley so belt will not sag, and then temporarily tighten center bolt. Ensure timing mark of each sprocket is still aligned. Remove wire from auto tensioner.
13. Rotate crankshaft 2 complete turns clockwise. Leave in this position for about 15 minutes. Measure auto tensioner protrusion "A" (distance between tensioner arm and auto tensioner body). Ensure auto tensioner protrusion is.23-35" (6-9 mm). (Scheme 10) Install timing belt lower cover and upper cover. Note proper location of each bolt. (Scheme 11)

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Disconnect negative battery terminal. Drain cooling system. Remove breather hose between air cleaner and valve cover. Remove air cleaner. Remove center cover, ignition coil and spark plugs.
2. Remove timing belt cover and timing belt. See «TIMING BELT»(ref-121831-S21946030842001091100000) . Remove valve cover. Remove crank angle sensor from rear of exhaust camshaft. Remove camshaft sprockets. Loosen bearing cap bolts, and remove bearing caps, camshafts, rocker arms and lash adjusters.

1. Lubricate camshafts with engine oil. Install camshafts. Install bearing caps. Ensure bearing caps are in proper position. Ensure camshaft can be easily turned by hand. After checking, remove bearing caps and camshafts. Install crank angle sensor on rear of exhaust camshaft. Install lash adjusters and rocker arms.
2. Install camshafts. Ensure dowel pins are pointing upward. Install and tighten bearing caps, in 2-3 steps, to specification. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000).
3. Apply engine oil onto outside of NEW camshaft oil seals. Install oil seals, using Seal Installer (09221-21000) and Guide (09221-21100). Install camshaft sprockets. Tighten sprocket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000).
4. Apply sealant onto lower side of NEW valve cover gasket on semi-circular sections. (Scheme 12) Install cover and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000).
5. Install spark plugs and ignition coil. Install center cover. Ensure dowel pin of sprocket side of camshaft is straight up. Install air cleaner and breather hose. Refill cooling system. Reconnect negative battery cable.

Scheme 12

Drain cooling system. Disconnect radiator outlet hose and coolant by-pass hose from water pump. Remove drive belt and water pump pulley. Remove timing belt covers and tensioner. See TIMING BELT . Remove water pump mounting bolts. Remove generator brace. Remove water pump.

Clean mounting surfaces. Install NEW "O" ring into groove on front end of coolant pipe. Coat "O" ring with anti-freeze. DO NOT use oil or grease. Install NEW water pump gasket. Install water pump. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install generator brace. Install timing tensioner and timing belt covers. Install water pump pulley and drive belt. Reconnect coolant hoses. Refill cooling system, and check for leaks.

1. Disconnect the ground cable from the battery terminal.
2. Disconnect the fan motor connector.
3. Loosen the radiator drain plug to drain the coolant.
4. Disconnect the upper and lower hoses and overflow tube after making marks on the radiator hose and the hose clamp.
5. For vehicles with automatic transaxle, disconnect the oil cooler hoses from the automatic transaxle. NOTE: Cover or plug the hose and nipple part of the radiator so that dust, foreign materials, etc. do not enter after the hose has been disconnected from the radiator
6. Remove the radiator mounting bolt.
7. Remove the radiator together with the fan motor.
8. Remove the radiator fan motor, condenser fan motor from the radiator.

1. Fill the radiator and reservoir tank with clean coolant mixture.
2. Run the engine until the coolant has warmed up enough so that the thermostat valve opens, and then stop the engine.
3. Remove the radiator cap and pour the coolant to the filler neck of the radiator. Fill the reservoir tank with the coolant to the upper level.
4. Check that there is no leakage from the radiator, hoses or connections.

Drain coolant to below thermostat housing level. Remove thermostat housing bolts and remove thermostat housing. Remove thermostat.

Install thermostat in opening in cylinder head/intake manifold. Install thermostat housing with sealant and NEW thermostat gasket. Tighten thermostat housing bolts to specifications. See TORQUE SPECIFICATIONS . Refill engine with 50/50 coolant water mixture. Start engine and ensure there are no coolant leaks.

Remove timing belt. See TIMING BELT . Remove oil pan bolts. Remove oil pan. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Remove timing belt. See «TIMING BELT»(ref-121831-S21946030842001091100000) under REMOVAL & INSTALLATION. Remove oil pan. See «OIL PAN»(ref-121831-S26288190162001091100000) under REMOVAL & INSTALLATION. Remove oil screen and gasket.
2. Remove relief plunger and gasket. Remove relief spring and valve from oil filter bracket. Remove oil pressure switch. Remove oil filter bracket and gasket. With removal tool, remove plug cap from oil pump portion of front case.
3. Remove cylinder block plug from left side, and insert long screwdriver into the hole to hold counterbalance shaft in position. Remove oil pump driven gear and left counterbalance shaft retaining bolt. (Scheme 13)
4. Remove front case mounting bolts. Remove front case and gasket. Remove 2 counterbalance shafts from cylinder block, if necessary. Remove oil pump cover from case. Remove oil pump gears. (Scheme 13)

Scheme 13

Reassembly & Installation

1. Apply engine oil onto gears. Position gears into case, and align timing marks. With special tool, install crankshaft front oil seal into front cover. Temporarily tighten flange bolts (except those for filter bracket). Install front case assembly with NEW gasket. Install proper length bolts in appropriate locations. (Scheme 14) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000).
2. Insert long screwdriver into plug hole in left side of block. Install gear and tighten retaining nut to front end of counterbalance shaft. Install NEW "O" ring into groove of front case. Install front case plug cap, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000).
3. Install oil screen with NEW gasket. Apply sealant into groove in oil pan. Install and tighten oil pan bolts. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000). Install oil pressure switch after applying threadlock sealant to threads. Install block plug cap, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-121831-S42667572292001091100000).
4. Install oil filter bracket with relief spring and valve. Install relief plunger and NEW gasket. Install timing belt. See «TIMING BELT»(ref-121831-S21946030842001091100000) under REMOVAL & INSTALLATION.

Scheme 14