2.7L V6 Engine: Removal & Installation Kia Optima I рестайлинг

REMOVAL

Remove the timing belt, cylinder head assembly, drive plate, transaxle mounting plate, oil pan and the oil pump case.

For further details, refer to their respective procedures.

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1. Visually check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects. Repair or replace the block if defective.
2. Measure the cylinder bore with a cylinder gauge at the three levels indicated in the directions of A and B as 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 the cylinder bores show more than the specified out-of-round or taper, or if the cylinder walls are badly scuffed or scored, the cylinder block should be re-bored and honed. New oversize pistons and rings should be installed. Standard value Cylinder bore : [2.4L] 84.00-84.04 mm (3.3071-3.3087 in.) [2.7L] 86.7 mm (3.41 in) Out-of-roundness and taper of cylinder bore : Max. 0.02 mm (0.0008 in.)
4. If a ridge exists at the top of the cylinder, cut it away with a ridge reamer.
5. Oversize pistons are available in two sizes. Piston service size and mark mm (in.) 0.25 mm (0.010 in.) O.S. : 0.25 mm 0.50 mm (0.020 in.) O.S. : 0.50 mm
6. To rebore the cylinder to the 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 12 mm (0.47 in.) above the bottom of the piston skirt and across the thrust faces. Piston-to-cylinder wall clearance : 0.010-0.030 mm (0.0004-0.0012 in.)
7. Check for damage or cracks in the cylinders.
8. Check the top surface of the cylinder block for flatness. If the top surface exceeds limits, grind to the minimum limit or replace. Standard value Flatness of gasket surface : Max. 0.03 mm (0.0012 in.) Service limit Flatness of gasket surface : 0.05 mm (0.0002 in.) CAUTION: When the cylinder head is assembled, grinding less than 0.2 mm (0.008 in.) is permissible.

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1. Oversize pistons used should be determined on the base of the largest bore cylinder. NOTE: Size mark is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.
3. On the base of the measured O.D., calculate the boring finish dimension. Boring finish dimension = Piston O.D + 0.01 to 0.03 mm (0.0004 to 0.0012 in.) (clearance between piston and cylinder) - 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size. CAUTION: To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order sequence.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder. Standard : 0.01-0.03 mm (0.0004-0.0012 in.) NOTE: When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the oversize.

Attach a cable or chain to the engine hooks, and then lift engine enough so that there is no pressure on the insulators.

1. Remove the timing belt, cylinder head assembly, drive plate, transaxle mounting plate oil pan. For details, refer to their respective procedures.
2. Remove the oil seal case and the rear oil seal.
3. Remove the connecting rod caps. NOTE: Mark the main bearing caps to be able to reassemble in the original position and direction.
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order by 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. Using the drain plug, drain the coolant.
2. Remove the drive belt and engine coolant pump pulley.
3. Remove the timing belt covers, the timing belt tensioner and idler.
4. Remove the engine coolant pump mounting bolts.
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 material etc. do not enter after the hose is 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 and condenser fan motor from the radiator.

1. To install, reverse removal procedures.
2. Fill the radiator and reservoir tank with clean coolant mixture.
3. Run the engine until the coolant warms up enough so that the thermostat valve opens, and then stop the engine.
4. Remove the radiator cap and pour the coolant up to the filler neck of the radiator. Fill the reservoir tank to the upper level.
5. 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. Remove the four shroud mounting 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 in the reverse order of removal procedures.

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

1. Check that the flange of the thermostat is correctly seated in the socket of the thermostat housing.
2. Install the engine coolant inlet fitting. Tightening torque Engine coolant inlet fitting bolt : 17-20 Nm (170-200 kg.cm, 12-14 lb.ft)
3. Refill the coolant.

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1. Check for damage or cracking.
2. Using a straight edge and a feeler gauge, check for distortion on the cylinder head mating surface. Standard value : 0.15 mm (0.006 in.) or less Service limit: 0.3 mm (0.012 in.) or less CAUTION: Do not use the used exhaust manifold gasket.

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1. Remove the high pressure fuel hose as follows. Disconnect the fuel pump harness connector after removing the rear seat cushion. Start the engine and after it stalls, turn the ignition switch to the OFF position. Disconnect the battery negative (-) terminal. Connect the fuel pump harness connector.
2. Remove the air intake surge tank.
3. Disconnect the fuel return hose.
4. Remove the delivery pipe with the fuel injector. NOTE: Be careful not to drop the injector when removing the delivery pipe. CAUTION: Be aware that fuel may flow out when removing the injector.
5. Remove the intake manifold and gasket.

1. Install the intake manifold and delivery pipe according to the reverse order of removal. CAUTION: Do not use the used intake manifold gasket.

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1. Remove the air intake hose connected to the throttle body.
2. Remove the accelerator and cruise control cables.
3. Remove the engine coolant hose.
4. Remove the PCV. hose and brake booster vacuum hoses.
5. Disconnect the vacuum hose connections.
6. Remove the ISA, TPS and ATS connector.
7. Remove the surge tank stay.
8. Remove the air intake surge tank and surge tank gasket.

1. Temporarily install the front exhaust pipe, the catalytic converter assembly, the center exhaust pipe, and the main muffler in this order.
2. Install the rubber hangers so that they can be 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. Disconnect the air flow sensor connector.
2. Remove the air intake hose and air duct connected to the air cleaner.
3. Remove the three bolts attaching the air cleaner body.
4. Remove the air cleaner.
5. Remove the air flow sensor from the air cleaner hose. CAUTION: Do not pull the air flow sensor harness.

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1. Check the air intake hose, air cleaner cover for damage.
2. Check the air intake duct for damage.
3. Check the air cleaner element for restriction, contamination or damage. If the element is slightly restricted, remove dust and debris by blowing the inside of the element. Replace the element if it cannot be cleaned.

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1. Blow the air inside of air cleaner to remove dust and debris.
2. Install the air cleaner according to the reverse order of removal.

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