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

REMOVAL

Remove the cylinder head, timing belt train, front case, flywheel, piston and crankshaft. For further details, refer to the respective headings.

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1. Visually check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects. Correct or replace the block if defective.
2. Measure cylinder bore with a cylinder gauge at three levels in directions of A and B shown in illustration. Level 1 : No. 1 piston ring position with piston at TDC Level 2 : Center of cylinder Level 3 : Bottom of cylinder
3. If cylinder bores show more the specified out-of-round or taper, or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed and fitted with oversize pistons and rings. Standard value Cylinder bore: 85.00-85.03 mm (3.3465-3.3476 in.) Out-of-roundness and taper of cylinder bore: Max. 0.01 mm (0.0004 in.)
4. If cylinder top ridge is worn in stages, cut away with ridge reamer.
5. Oversize piston is available in one size. Piston service size and mark mm (in.): 0.25 (0.010) O.S: 0.25
6. To rebore the cylinder to oversize, keep the specified clearance between the oversize piston and the bore, and make sure that all pistons used are of the same oversize. The standard measurement of the piston outside diameter is taken at a level 2 mm (0.08 in.) above the bottom of the piston skirt and across the thrust faces. Piston-to-cylinder wall clearance: 0.02-0.04 mm (0.0008-0.0012 in.)
7. Check for damage and cracks.
8. Check top surface for flatness. If excessive flatness is evident, grind to minimum limit or replace. Standard value Flatness of gasket surface : Max. 0.05 mm (0.0020 in.) Cylinder block (New) height : 284 mm (11.18 in.) Service limit Flatness of gasket surface : 0.1 mm (0.0039 in.) Overall height : -0.2 mm (-0.0079 in.) NOTE: The cylinder block gasket surface should be ground within -0.2 mm (-0.0079 in.) including the ground surface of cylinder head gasket surface.

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1. Oversize pistons to be used should be determined on the base of the largest bore cylinder. NOTE: Size mark is stamped on top of piston.
2. Measure outside diameter of piston to be used.
3. On the base of measured piston O.D., calculate boring finish dimension. Boring finish dimension = Piston O.D + 0.02-0.04 mm (0.0008-0.0016 in.) (clearance between O.D and cylinder) -0.02 mm (0.008 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size. NOTE: To prevent distortion that may result from temperature rise during honing, bore cylinders, working from No. 2 to No. 4 to No. 1 to No. 3.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check clearance between piston and cylinder. NOTE: When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.

Attach an engine hoist to the engine hooks, and raise just enough so that there is no pressure on the insulators.

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1. Remove the timing belt train, front case, flywheel cylinder head assembly and oil pan. For details, refer to respective procedures.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps. NOTE: Mark the main bearing caps to be reassembled in the original position and direction.
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order according to the cap number.

INSTALLATION

Fit O-ring in the groove provided at engine coolant inlet pipe end, wet the periphery of O-ring and insert engine coolant inlet pipe.

Note. Do not apply oils or greases to engine coolant pipe O-ring. Keep the engine coolant pipe connections free of sand, dust, etc. Insert engine coolant pipe to its end bottoms. While installing the engine coolant inlet pipe, always replace the O-ring with a new one.

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1. Drain the coolant and disconnect the radiator outlet hose and engine coolant by-pass hose from the engine coolant pump.
2. Remove the drive belt and engine coolant pump pulley.
3. Remove the timing belt covers and the timing belt tensioner.
4. Remove the engine coolant pump mounting bolts and then remove the alternator brace.
5. Remove the engine coolant pump assembly from the cylinder block.

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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. CAUTION: 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. On all vehicles, remove the radiator mounting bolt.
7. Remove the radiator together with the fan motor.
8. Remove the radiator fan motor and 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.

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1. Disconnect the ground cable from battery cable.
2. Disconnect the connectors from the fan motor and the harness from shroud.
3. For vehicles with automatic transaxle, remove the oil cooler hose from the shroud.
4. On all vehicles, remove the shroud mounting four bolts.
5. Remove the shroud with the fan motor.
6. Remove the fan mounting clip and detach the fan from fan motor.
7. Remove the three screws and detach the fan motor.

Installation is the reverse order of removal procedures.

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1. Drain the coolant to the thermostat level or below.
2. Remove the Engine coolant outlet fitting and gasket.
3. Remove the thermostat.

1. Check to ensure that the flange of the thermostat is correctly seated in the socket of the thermostat housing. If the thermostat is installed in the wrong direction, the bottom of the thermostat will touch the rib inside the intake manifold, making it impossible to seat flange in position.
2. Install a new gasket and engine coolant outlet fitting. Tightening torque Engine coolant outlet fitting bolt : 10-15 Nm (100-150 kg.cm, 7-11 lb.ft)
3. Refill the coolant.

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1. Remove the timing belt. Refer to «TIMING BELT»(ref-174553-S14381114022005040600000) .
2. Remove all the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil screen and gasket.
5. Remove the relief plunger and gasket, and then take off the relief spring and relief valve from the oil filter bracket.
6. Remove the oil pressure switch.
7. Remove the oil filter bracket and gasket.
8. Using the special tool, remove the plug cap from the oil pump portion of front case.
9. Remove the left side of cylinder block plug and insert a screwdriver with an 8 mm (0.32 in.) diameter shaft into plug hole. The screwdriver shaft must be inserted more than 60 mm (2.4 in.)
10. Remove the oil pump driven gear and left counter balance shaft retaining bolt.
11. Remove the front case mounting bolts and remove the front case assembly and gasket. Remove the two counter balance shafts from the cylinder block.
12. Remove the oil pump cover from the front case.
13. Remove the oil pump gears from the front case.

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1. Assemble the oil pump gear to the front case and rotate it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact surface between the front case and gear surface of the oil pump cover.
3. With the drive and driven gears installed into the front case, measure the tip clearance of the gears. [Standard value] Drive gear: 0.160-0.205 mm (0.0063-0.0081 in.) Driven gear: 0.180-0.205 mm (0.0071-0.0081 in.) [Limit] Drive gear : 0.25 mm (0.0098 in.) Driven gear : 0.25 mm (0.0098 in.)
4. Check the side clearance.

[Standard value]

Drive gear: 0.08-0.14 mm (0.0031-0.0055 in.)

Driven gear: 0.06-0.12 mm (0.0024-0.0047 in.)

[Limit]

Drive gear: 0.25 mm (0.0098 in.)

Driven gear : 0.25 mm (0.0098 in.)

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1. Apply engine oil to the gears and align the two timing marks.
2. Using the special tool, Crankshaft Front Oil Seal Installer (09214-32000), install the crankshaft front oil seal into the front case.
3. Set the special tool (09214-32100) on the front end of crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
4. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).
5. Install the front case assembly with a new gasket, and tighten the bolts to the specified torque. Front case assembly Tightening torque All except: 20-27 Nm (200-270 kg.cm, 14-20 lb.ft)
6. Insert a screwdriver through plug hole in left side of cylinder block. After checking that the shaft is in position, tighten.
7. Install a new O-ring to the groove of front case.
8. Using a special tool, install the case plug and tighten to the specified torque.
9. Apply sealant into the groove of the oil pan flange as shown in illustration. NOTE: Apply sealant about 4 mm (0.16 in.) in thickness. After application of sealant, do not exceed 15 minutes before installing the oil pan.
10. Note the difference in bolt lengths at the location shown in illustration. Install the oil pan and tighten the bolts to the specified torque. Tightening torque Oil pan bolt: 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)
11. Using the special tool, install the oil pressure switch after applying sealant to the threaded area. Sealant: Threebond 1104 or equivalent NOTE: Do not torque the oil pressure switch excessively. Tightening torque Oil pressure switch : 8-12 Nm (80-120 kg.cm, 6-8 lb.ft)

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1. To install, reverse removal procedure.
2. Make sure that the injector is not dropped, when installing the delivery pipe.

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1. Temporarily install the front exhaust pipe (rear catalytic converter assembly), the center exhaust pipe, and the main muffler, in order.
2. Install the rubber hangers so that they are identical (left and right) in length.
3. Tighten the parts securely, and then confirm that there is no interference with any body components.

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1. Remove the air intake hose and air duct connected to the air cleaner, and the resonator.
2. Remove the three bolts attaching the air cleaner mounting brackets.
3. Detach the air cleaner.

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1. Check the air cleaner body, cover, or packing for distortion, corrosion or damage.
2. Check the air duct for damage.
3. Check the air cleaner element for restriction, contamination or damage. If the element is slightly restricted, remove the dust and other contaminants by blowing to the inside through the element.
4. Check the air cleaner housing for restriction, contamination or damage.
5. Check the resonator for damage.

Install the air cleaner according to the reverse order of removal.

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1. Remove the cylinder head bolts as shown in the illustration.

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Note. Clean each part before assembly. Apply engine oil to sliding and rotating parts.

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1. After installing the spring seat, fit the stem seal onto the valve guide. Fit the seal in by lightly tapping the Special Tool, Valve Stem Oil Seal Installer. The seal is installed in the specified position by means of the special tool. Incorrect installation of the seal will adversely affect the lip I.D. and eccentricity, resulting in oil leakage down the valve guides. When installing, therefore, be careful not to twist the seal. Do not reuse old stem seals.
2. Apply engine oil to each valve. Insert the valves into the valve guides. Avoid inserting the valve into the seal by force. After inserting, check that the valve moves smoothly.
3. Install springs and spring retainers. Valve springs should be installed with the enamel coated side toward the valve spring retainer.
4. Using the special tool, Valve Spring Compressor (09221-29100), 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.
5. Clean all gasket surfaces of the cylinder block and cylinder head.
6. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.

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1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt.
2. Remove the timing belt cover.
3. Turn the crankshaft clockwise and align the timing marks so as to bring the No. 1 cylinder to compression top-dead-center position. At this time the timing marks of the camshaft sprocket and the timing marks of the rocker cover should coincide, and the dowel pin of the camshaft sprocket should be at the upper side. Remove the auto tensioner. CAUTION: Rotate the crankshaft clockwise.
4. Remove the timing belt. NOTE: If the timing belt is reused, make an arrow mark indicating the turning direction (of the front of the engine) to make sure that the belt is reinstalled in the same direction as before.
5. Remove the camshaft sprockets. NOTE: Be careful not to damage the cylinder head with the wrench.
6. When the oil pump sprocket nut is removed, first remove the plug at left side of the cylinder block and insert a screwdriver to check the left counter balance shaft in position. Screwdriver used for this purpose should have a shaft 8 mm (0.3 in.) in diameter which can be inserted more than 60 mm (2.36 in.)
7. Remove the oil pump sprocket retaining nut and remove the oil pump sprocket.
8. Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand.
9. Next, remove tensioner "B" and remove timing belt "B". CAUTION: After timing belt "B" has been removed, do not attempt to loosen bolt while holding sprocket with pliers, etc.
10. Remove the crankshaft sprocket "B" from crankshaft.

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1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation and check for play or noise. Replace as necessary.

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1. Check the auto tensioner for leak and replace as necessary.
2. Check the rod end for wear or damage and replace as necessary.
3. Measure the rod protrusion. If it is out of specification, replace the auto tensioner. Standard value : 14.5 mm (0.57 in.)
4. Using a soft-jawed vise push in the auto tensioner rod. If the rod can be easily retracted, replace the auto tensioner. You should feel a great deal of resistance when pushing the rod in. CAUTION: Clamp the auto tensioner in the vise so that it can be level. Use soft jaws in the vise to avoid damaging the auto tensioner.

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