2.4L 4-CYLINDER Engine: Diagnosis Kia Optima I рестайлинг

RADIATOR CAP PRESSURE TEST

Note. Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an improper indication.

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1. Use an adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving. Main valve opening pressure : 96.1-124.5 kPa (0.98-1.27 kg/m 2 , 13.94-18.06 psi) Main valve closing pressure : 83.4 kPa (0.85 kg/cm 2 , 12.1 psi)
3. Check that the pressure level is maintained at or above the limit.
4. Replace the radiator cap if the reading does not remain at or above the limit.

SPECIFIC GRAVITY TEST

1. Measure the specific gravity of the coolant with a hydrometer.
2. Measure the coolant temperature, and calculate the concentration from the relation between the specific gravity and temperature, using the following illustration for reference.

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Example

The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20°C (68°F).

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INSPECTION

Check journals for wear or seizure. If excessive wear or seizure is evident, check the bearing carefully. If necessary, replace the counter balance shaft bearings.

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1. Check the clutch disc contacting surface of the flywheel for damage and wear. Replace the flywheel if excessively damaged or worn.
2. Check the clutch disc contacting surface of the flywheel for runout. Limit Flywheel run-out : 0.13 mm (0.0051 in.)
3. Check the ring gear for damage, cracks and wear, and replace if necessary.

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1. Use the special tools (09234-33001), to disassemble and reassemble the piston and connecting rod.
2. Place the proper insert in the fork of the tool. Position the insert between the connecting rod and the piston.
3. Insert the proper tool for removal through the hole in the arch of the tool. NOTE: Center the piston, rod and pin assembly with the removal arbor.
4. Press the piston pin out of the connecting rod.
5. Install proper pin guide (as shown in illustration) through piston and into connecting rod. Hand tap pin guide into piston for proper retention. Drop piston pin into the other side of the piston. NOTE: The pin guide centers the connecting rod in the piston. When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork of the tool, the pin guide will also center this assembly in the tool. If a pin guide that is too small is used, the piston assembly will not be located centrally in the tool, and damage may occur to the fork and/or the insert of the tool.
6. Install the piston assembly onto the fork assembly of tool. The tool will support connecting rod at the piston pin. Be sure the piston assembly is slid onto the fork until the pin guide contacts the fork insert.
7. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the specified alpha numeric setting from the application chart shown in illustration is obtained. Turn knurled nut to lock numbered sleeve on shaft.
8. Insert the installing arbor through the hole in the arch of the tool. Press the piston pin into the connecting rod until the sleeve on the installing arbor contacts the top of the tool arch. The pin guide will fall out of the connecting rod as the piston pin is pressed in. CAUTION: Do not exceed 5000 pounds of force when stopping the installing arbor sleeve against the arch.

Check the engine coolant pipe and hoses for cracks, damage, and restrictions. Replace if necessary.

1. Check the engine coolant pump for cracks, damage or wear, and replace the engine coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the engine coolant pump assembly if necessary.
3. Check the seal unit for leaks, and replace the engine coolant pump assembly if necessary.
4. Check for engine coolant leakage. If the engine coolant leaks from hole "A" seal unit is defective. Replace engine coolant pump assembly.

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1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.
2. Install the new O-ring onto the groove on the front end of the engine coolant pipe, then wet the O-ring with engine coolant. NOTE: Do not apply oil or grease.
3. Install new Engine coolant pump gasket and Engine coolant pump assembly. Tighten the bolts to specified torque. Tightening torque Engine coolant pump bolt: 20-27 Nm (200-270 kg.cm, 14-20 lb.ft)
4. Install the timing belt tensioner and timing belt. Adjust the timing belt tension, and then install the timing belt covers.
5. Install the engine coolant pump pulley and drive belt, and then adjust the belt tension.
6. Refill the coolant.
7. Run the engine and check for leaks.

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1. To install, reverse removal procedure.
2. Check for foreign material between radiator fins.
3. Check the radiator fins for damage and straighten if necessary.
4. Check the radiator for corrosion, damage, rust or scale.
5. Check the radiator hoses for cracks, damage or deterioration.
6. Check the reserve tank for damage.
7. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration.

1. Heat the thermostat as shown in the illustration.
2. Check that the valve operates properly.
3. Check to determine the temperature at which the valve begins to open.

Valve opening temperature

80.5-83.5°C (176.9-182.3°F)

Full opening temperature : 95°C (203°F)

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1. Check the mufflers and pipes for corrosion and damage.
2. Check the rubber hanger and hangers for deterioration and cracks.

1. Check the cylinder head for cracks, damage and coolant leakage. If cracked, replace the cylinder head.
2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to them to make certain that the passages are not clogged.
3. Check the cylinder head gasket surface for flatness by using a straight edge in the direction of A, B, etc. as shown in illustration. If flatness exceeds service limit in any direction, either replace the cylinder head, or lightly machine the cylinder head gasket surface.

Flatness of cylinder head gasket surface

[Standard dimension]: Less than 0.05 mm (0.002 in.)

[Limit] : 0.2 mm (0.008 in.)

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1. Install the cylinder head bolts as shown in the illustration. NOTE: Check and measure the length of bolt. Maximum length : 99.4 +/- 0.35 mm (3.9 in.)
2. Tighten the bolts according to the following procedure shown in illustration.

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1. Using 12 mm socket, remove the retainer lock. Next, remove the spring retainer, valve spring, spring seat and valve. NOTE: Keep these parts so that they can be reinstalled in their original positions.
2. Remove the valve stem seals with pliers, and discard. NOTE: Do not reuse the valve stem seals.

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1. Using a wire brush, clean the valve thoroughly.
2. Check each valve for wear, damage and distortion of head and stem at location B. Repair or correct if necessary. If stem end A is pitted or worn, resurface as necessary. This correction must be limited to a minimum. Also resurface the valve face. Replace the valve if the margin has decreased to less than the service limit.

Margin

[Standard dimension]

Intake : 1.0 mm (0.040 in.)

Exhaust : 1.5 mm (0.059 in.)

[Limit]

Intake : 0.7 mm (0.028 in.)

Exhaust : 1.0 mm (0.040 in.)

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