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2.4L 4-CYLINDER Engine: Specifications Kia Optima I

Mechanical

Crankcase Capacity

Oil capacity is 4.2 qts. (4.0L) with filter.

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Auto Tensioner Bolt15-20 (20-27)
Block Plug Cap15-20 (20-27)
Camshaft Bearing Cap Bolt14-15 (19-20)
Camshaft Position Sensor Bolt11-16 (15-22)
Camshaft Sprocket Bolt59-74 (80-100)
Connecting Rod Cap Bolt
Step 113-16 (18-22)
Step 2Additional 90 Degrees
Crankshaft Pulley Bolt81-96 (110-130)
Cylinder Head Bolts (1)
New Bolts
Step 1(2)
Step 2(3)
Step 3(4)
Original Bolts
Step 1(2)
Step 2(3)
Step 3(3)
Engine Mounts
Bracket Bolt/Nut43-58 (58-79)
Front Roll Stopper
Bracket-To-Sub-Frame Bolt43-58 (58-79)
Bracket-To-Transaxle Bolt43-58 (58-79)
Insulator Bolt/Nut36-47 (49-64)
Insulator Bolt66-81 (90-110)
Rear Roll Stopper
Bracket-To-Sub-Frame Bolt37-48 (50-65)
Bracket-To-Transaxle Bolt44-59 (60-80)
Insulator Bolt/Nut37-48 (50-65)
Transaxle Mount
Bracket Bolt44-59 (60-80)
Insulator Bolt66-81 (90-110)
Sub-Bracket Bolt44-59 (60-80)
Exhaust Manifold Mounting Bolt
M8 Bolt18-22 (25-30)
M10 Bolt26-41 (35-55)
Exhaust Pipe Clamp Bolt14-22 (19-30)
Exhaust Pipe-To-Manifold Nut22-29 (30-39)
Flywheel-To-Crankshaft Bolt94-101 (127-137)
Front Case Bolt14-20 (19-27)
Idler Pulley Bolt33-40 (45-54)
Intake Manifold
Bracket Bolt13-18 (15-24)
Mounting Bolt
M8 Bolt11-15 (15-20)
M10 Bolt13-18 (18-24)
Mounting Nut22-30 (30-41)
Main Bearing Cap Bolt
Step 118 (24)
Step 2Additional 90-94 Degrees
Oil Drain Plug25-33 (34-45)
Oil Pump
Case Bolt14-20 (19-27)
Cover Bolt11-13 (15-18)
Driven Gear Bolt25-29 (34-39)
Sprocket Nut36-43 (49-58)
Oil Screen Bolt11-16 (15-22)
Starter Bolt20-25 (27-34)
Tensioner Pulley Bolt31-40 (42-54)
Tensioner Pulley Bracket Bolt17-20 (23-27)
Throttle Body-To-Intake Manifold Bolt11-15 (15-20)
Timing Belt
Lower & Upper Cover Bolt(5)
Left Rear Cover Bolt
Lower22-30 (30-41)
Upper(6)
Right Rear Cover Bolt(6)
Timing Belt Tensioner Bolt32-40 (43-55)
Water Pump Mounting Bolt11-15 (15-20)
INCH Lbs. (N.m)
Camshaft Position Sensor Bolt89-115 (10-13)
Oil Pan Bolt89-106 (10-12)
Oil Pressure Switch71- 106 (8-12)
Oil Seal Case Bolt89-106 (10-12)
Rear Oil Seal Case Bolt89-106 (10-12)
Rocker Cover Bolt71-89 (8-10)
Thermostat Housing Bolt89-133 (10-15)
Valve Cover Bolts71-89 (8-10)
Water Pump Pulley Bolt71-89 (8-10)
(1) Tighten in sequence with engine cold. (Схема №5) (2) Tighten to 14 ft. lbs. (19 N.m) (3) Tighten bolts in sequence an additional 90 degrees. (Схема №5) (4) Loosen bolts in sequence, and repeat steps 2 and 3. Then tighten an additional 90 degrees. (5) Tighten to 71-89 INCH lbs. (8-10 N.m). (6) Tighten to 89-106 INCH lbs. (10-12 N.m)
(1)Tighten in sequence with engine cold. (Схема №5)
(2)Tighten to 14 ft. lbs. (19 N.m)
(3)Tighten bolts in sequence an additional 90 degrees. (Схема №5)
(4)Loosen bolts in sequence, and repeat steps 2 and 3. Then tighten an additional 90 degrees.
(5)Tighten to 71-89 INCH lbs. (8-10 N.m).
(6)Tighten to 89-106 INCH lbs. (10-12 N.m)

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

ApplicationSpecification
Displacement143.5 Cu. In. (2.4L)
Bore3.41" (86.6 mm)
Stroke3.94" (100 mm)
Compression Ratio10:1
Fuel SystemMFI

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

ApplicationIn. (mm)
Crankshaft
End Play.0098 (.250)
Main Bearings
Journal Diameter2.2434-2.2442 (56.982-57.002)
Journal Out-Of-Round.0006 (.015)
Journal Taper.0002 (.005)
Oil Clearance
No. 1, 2, 4 & 5.007-.0014 (.018-.036)
No. 3.0009-.0016 (.023-.041)
Connecting Rod Bearings
Journal Diameter1.7709-1.7717 (44.981-45.001)
Journal Out-Of-Round.0006 (.015)
Journal Taper.0002 (.005)
Oil Clearance.0008-.0020 (.020-.051)

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

ApplicationIn. (mm)
Maximum Bend.002 (.051)
Maximum Twist.004 (.10)
Side Play
Standard.004-.010 (.10-.025)
Service Limit.016 (.41)

CONNECTING RODS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

ApplicationIn. (mm)
Pistons
Clearance.0008-.0012 (.20-.030)
Diameter (2)3.3453-3.3465 (84.97-85.001)
Rings
No. 1
End Gap.0098-.0138 (.250-.351)
Side Clearance.0012-.0028 (.030-.070)
No. 2
End Gap.0157-.0216 (.399-.549)
Side Clearance.0008-.0024 (.020-.060)
No. 3 (Oil)
End Gap.0039-.0157 (.099-.399)
Side ClearanceN/A
(1) Pin specifications are not available from manufacturer. (2) Diameter is measured at 90-degree angle to piston pin. See CYLINDER BLOCK ASSEMBLY under OVERHAUL.
(1)Pin specifications are not available from manufacturer.
(2)Diameter is measured at 90-degree angle to piston pin. See CYLINDER BLOCK ASSEMBLY under OVERHAUL.

PISTONS, PINS (1) & RINGS

CYLINDER BLOCK SPECIFICATIONS

ApplicationIn. (mm)
Cylinder Bore
Standard Diameter3.3453-3.3465 (84.971-85.001)
Maximum Taper.0004 (.010)
Maximum Out-Of-Round.0004 ( .010)
Deck Warpage (1)
Allowable Limit.002 (.051)
Service Limit.004 (.10)
(1) If deck warpage exceeds specification, machine deck surface. DO NOT remove more than a combined total of .008" (.20 mm) material from original surfaces of cylinder head and cylinder block
(1)If deck warpage exceeds specification, machine deck surface. DO NOT remove more than a combined total of .008" (.20 mm) material from original surfaces of cylinder head and cylinder block

CYLINDER BLOCK

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

ApplicationSpecification
Intake Valves
Length4.311" (109.5 mm)
Stem Diameter.2585-.2591" (6.566-6.581 mm)
Valve Head Thickness (Margin)
Standard Margin.040" (1.02 mm)
Minimum Margin Limit.028" (.71 mm)
Exhaust Valves
Length4.319" (109.70 mm)
Stem Diameter.2571-.2579" (6.530-6.551)
Valve Head Thickness (Margin)
Standard Margin.059" ( 1.5 mm)
Minimum Margin Limit.039" (.99 mm)
Valve Springs
Free Length1.804" (45.82 mm)
Out-Of-Square (Maximum)1.5°
Pressure @ Installed Height (1)55 lb. (248 N)
(1) Installed height information not available.
(1)Installed height information not available.

VALVES & VALVE SPRINGS

CYLINDER HEAD SPECIFICATIONS

ApplicationSpecification
Maximum Warpage
Gasket Surface.0012" (.03 mm)
Manifold Surface.0059" (.150 mm)
Valve Seats
Seat Angle44-44.5°
Seat Width.035-.051" (0.89-1.30 mm)
Valve Guides
Intake Valve
Length1.791" (45.49 mm)
Valve Stem Guide-To-Guide Oil Clearance
Standard.0008-.0019" (.020-.048 mm)
Service Limit.004" (.10 mm)
Exhaust Valve
Length1.988" (50.5 mm)
Valve Stem Guide-To-Oil Clearance
Standard.0020-.0033" (.051-.084 mm)
Service Limit.0059" (.150 mm)

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

ApplicationIn. (mm)
End Play.0004-.0008 (.010-.020)
Journal Diameter1.102 (27.99)
Lobe Height
Intake
Standard1.3904 (35.316)
Service Limit1.3707 (34.816)
Exhaust
Standard1.3859 (35.202)
Service Limit1.3662 (34.701)
Oil Clearance.0020-.0029 (.051-.074)

CAMSHAFT

COUNTERBALANCE SHAFT SPECIFICATIONS

ApplicationIn. (mm)
Right Counterbalance Shaft
Front Journal Diameter1.6519-1.6526 (41.958-41.976)
Rear Journal Diameter1.6122-1.6129 (40.950-40.968)
Oil Clearance
Front.0008-.0024 (.020-.060)
Rear.0020-.0036 (.051-.091)
Left Counterbalance Shaft
Front Journal Diameter.7270-.7276 (18.466-18.481)
Rear Journal Diameter1.6126-1.6132 (40.960-40.975)
Oil Clearance
Front.0008-.0021 (.020-.0053)
Rear.0017-.0033 (.043-.084)

COUNTERBALANCE SHAFT

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