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Engine Mechanical (G4KC - Gsl 2.4L): Specifications Kia Optima II

Mechanical

SPECIFICATIONS

Description		Specifications	Limit
General
Type		In-line, Double Overhead Camshaft
Number of cylinders		4
Bore		88mm (3.464in)
Stroke		97mm (3.819in)
Total displacement		2359cc (143.90cu.in)
Compression ratio		10.5: 1
Firing order		1-3-4-2
Valve timing
Intake valve	Opens (ATDC/BBDC)	11°-34°
Intake valve	Closes (ABDC)	22°-67°
Exhaust valve	Opens (BBDC)	34°
Exhaust valve	Closes (ATDC)	10°
Cylinder head
Flatness of gasket surface		Less than 0.05mm (0.0020in)(0.02 mm(0.0008 in)/100 x 100)
Flatness of manifold mounting surface	Intake	Less than 0.10mm (0.0039in)
Flatness of manifold mounting surface	Exhaust	Less than 0.10mm (0.0039in)
Camshaft
Cam height	Intake	43.80mm (1.7244in)
Cam height	Exhaust	45.00mm (1.7716in)
Journal outer Diameter (Intake, Exhaust)		No.1: 30mm (1.1811 in) (Intake) No.2,3,4,5: 24mm (0.9449in) (Intake, Exhaust)
Journal outer Diameter (Intake, Exhaust)		No.1: 40mm (1.5748in) (Exhaust)
Bearing oil clearance	Intake	No.1: 0.020-0.057mm (0.00078-0.00224in)	0.09mm (0.0035in)
	Intake	No.2,3,4,5: 0.045-0.082mm (0.00177-0.00323in)	0.12mm (0.0047in)
	Exhaust	No.1,2,3,4,5: 0.045-0.082mm (0.00177-0.00323in)	0.12mm (0.0047in)
End play		0.1-0.22mm (0.0039-0.0086in)	0.24mm (0.0094in)
MLA
MLA outer Diameter		31.964-31.980 mm (1.2584-1.2591 in)
Cylinder head tappet bore inner diameter		32.000-32.025 mm (1.2598-1.2608 in)
MLA to tappet bore clearance		0.020-0.061 mm (0.0008-0.0024 in)	0.7mm (0.0276in)
Valve
Valve length	Intake	113.18mm (4.4559in)	112.93mm (4.4460in)
Valve length	Exhaust	105.89mm (4.1689in)	105.74mm (4.1629in)
Stem outer diameter	Intake	5.465-5.480mm (0.2151-0.2157in)
Stem outer diameter	Exhaust	5.458-5.470mm (0.2149-0.2153in)
Face angle		45.25°-45.75°
Thickness of valve head (margin)	Intake	1.02mm (0.0401 in)
Thickness of valve head (margin)	Exhaust	1.09mm (0.0429in)
Valve stem to valve guide clearance	Intake	0.020-0.047mm (0.00078-0.00185in)	0.07mm (0.00275in)
Valve stem to valve guide clearance	Exhaust	0.030-0.054mm (0.00118-0.00212in)	0.09mm (0.00354in)
Valve guide
Length		43.8-44.2mm (1.7244-1.7401in)
Inner diameter		5.500-5.512mm (0.2165-0.2170in)
Valve seat
Width of seat contact	Intake	1.16-1.46mm (0.0457-0.0575in)
Width of seat contact	Exhaust	1.35-1.65mm (0.0531-0.0649in)
Seat angle		44.75°-45.10°
Valve spring
Free length		47.44mm (1.8677in)
Load		19.0 ± 0.6kg/35.0mm (41.88±1.32lb/1.3779in)
Squareness		39.8 ± 1.2kg/26.0mm(87.74 ± 2.64lb/1.0236 in)
Out of squareness		Less than 1.5°
Valve clearance
Cold (20°C[68°F])	Intake	0.17-0.23mm (0.0067-0.0090in)	0.10-0.30mm (0.0039-0.0118in)
Cold (20°C[68°F])	Exhaust	0.27-0.33mm (0.0106-0.0129in)	0.20-0.40mm (0.0078-0.0157in)
Cylinder block
Cylinder bore		88.00-88.03mm (3.4645-3.4657in)
Flatness of gasket surface		Less than 0.05mm (0.0020in)(0.02 mm(0.0008 in)/100 x100)
Piston
Piston outer diameter		87.975-88.005mm (3.4636-3.4648 in)
Piston to cylinder clearance		0.015-0.035mm (0.0028-0.0014in)
Ring groove width	No. 1 ring groove	1.22-1.24mm (0.0006-0.0488in)	1.26mm (0.0496in)
	No. 2 ring groove	1.22-1.24mm (0.0480-0.0488in)	1.26mm (0.0496in)
	Oil ring groove	2.01-2.03mm (0.0791-0.0799in)	2.05mm (0.0807in)
Piston ring
Side clearance	No. 1 ring	0.03-0.07mm (0.0012-0.0028 in)	0.1mm (0.004in)
	No. 2 ring	0.03-0.07mm (0.0012-0.0028 in)	0.1mm (0.004in)
	Oil ring	0.06-0.15mm (0.0024-0.0059in)	0.2mm (0.008in)
End gap	No. 1 ring	0.15-0.30mm (0.0059-0.0118in)	0.6mm (0.0236in)
	No. 2 ring	0.30-0.45mm (0.0118-0.0177in)	0.7mm (0.0275in)
	Oil ring	0.20-0.70mm (0.0078-0.0275in)	0.8mm (0.0315in)
Piston pin
Piston pin outer diameter		21.001-21.006mm (0.8268-0.8270 in)
Piston pin hole inner diameter		21.016-21.021mm (0.8274-0.8276 in)
Piston pin hole clearance		0.010-0.020mm (0.0004-0.0008 in)
Connecting rod small end inner diameter		20.974-20.985mm (0.8257-0.8262 in)
Piston pin press-fit load		2451.7-12258.3N(250-1250kg, 551.2-2755.8 lb)
Connecting rod
Connecting rod big end inner diameter		51.000-51.018mm (2.0079-2.0086 in)
Connecting rod bearing oil clearance		0.028-0.046mm (0.0011-0.0018 in)	0.05mm (0.0019in)
Side clearance		0.10-0.25mm (0.0039-0.0098 in)	0.35mm (0.0138in)
Crankshaft
Main journal outer diameter		51.942-51.960mm (2.0449-2.0456in)
Pin journal outer diameter		47.954-47.972mm (1.8879-1.8886in)
Main bearing oil clearance		0.026-0.049mm (0.0010-0.0019 in)	0.1mm (0.004in)
End play		00.07-0.25mm (0.0027-0.0098in)
Engine oil
Oil quantity (Total)		5.1 L (5.39 US qt, 4.49lmp qt)
Oil quantity (Excluding oil filter)		4.0 L (4.23 US qt, 3.52 lmp qt)
Oil quantity (Including oil filter)		4.3 L (4.54 US qt, 3.78 lmp qt)
Oil type		5W-20(SL/GF-3)
Cooling system
Cooling method		Forced circulation with cooling fan
Coolant quality		6.4-6.9 L (6.76288-7.29US qt, 5.63136-6.07lmp qt)
Thermostat	Type	Wax pellet type
	Opening temperature	82±1.5°C (179.6±34.7°F)
	Closing temperature	77°(176.9°F)
	Pull opening temperature	95°C (201°F)
Radiator cap	Main valve opening pressure	93.16-122.58kpa(0.95-1.25kg/cm 2 , 13.51-17.78psi)
Radiator cap	Vacuum valve opening pressure	6.86kpa (1psi, 0.07kg/cm 2 ) or less
Water temperature sensor
Type		Thermistor type
Resistance	20°C (68°F)	2.45 ± 0.14kohms
Resistance	80°C (176°F)	0.3222kohms

GENERAL SPECIFICATION

TIGHTENING TORQUE

Item	Quantity	N.m	Kgf.m
Ladder frame bolts	10	23.52-27.44	2.4-2.8
Oil pump & balance shaft module bolts	4	16.66 + 60° + 60°	1.7 + 60° + 60°
Timing chain cover bolts (M8)	6	18.62-22.54	1.9-2.3
Timing chain cover bolts (M6)	7	7.84-9.8	0.8-1.0
Oil pan bolts (M6 x 10)	16	9.8-11.76	1.0-1.2
Oil pan bolts (M8 x 103)	2	26.46-30.38	2.7-3.1
Engine support bracket bolt (M10 x 40)	1	39.2-44.1	4.0-4.5
Engine support bracket bolts (M10 x 45)	2	39.2-44.1	4.0-4.5
Engine support bracket bolt (M8 x 30)	1	19.6-24.5	2.0-2.5
Camshaft bearing cap bolts (M6)	16	10.78-12.74	1.1-1.3
Camshaft bearing cap bolts (M8)	4	27.44-31.36	2.8-3.2
Cylinder head bolts	10	34.3 + 90° + 90°	3.5 + 90° +90°
Engine hanger bolts	2	19.6-26.46	2.0-2.7
Cylinder head cover bolts	18	7.84-9.8	0.8-1.0
Crankshaft pulley bolt	1	166.6-176.4	17-18
Flywheel bolts	7	117.6-127.4	12-13
Drive plate bolts	7	117.6-127.4	12-13
Timing chain tensioner bolts	2	9.8-11.76	1.0-1.2
Timing chain tensioner arm bolt	1	9.8-11.76	1.0-1.2
Timing chain guide bolts	3	9.8-11.76	1.0-1.2
OCV bolt	1	9.8-11.76	1.0-1.2
CVVT & camshaft sprocket bolt	1	53.9-63.7	5.5-6.5
Balance shaft chain tensioner arm bolt	1	9.8-11.76	1.0-1.2
Balance shaft chain guide bolts	2	9.8-11.76	1.0-1.2
Balance shaft chain tensioner bolts	2	9.8-11.76	1.0-1.2
Water pump bolts	5	19.6-26.46	2.0-2.7
A/C bracket bolts	4	19.6-33.0	2.0-3.36
P/S bracket bolts	2	44.1-53.9	4.5-5.5
Tensioner & idler bracket bolts	7	39.2-44.1	4.0-4.5
Water temp. control bolts	2	14.7-21.56	1.5-2.2
Water temp. control nut	1	19.6-26.46	2.0-2.7
Water inlet pipe bolts	2	19.6-26.46	2.0-2.7
Oil level gauge assembly bolt	1	7.84-11.76	0.8-1.2
Ignition coil bolts	4	3.92-5.88	0.4-0.6
Intake manifold bolts	3	18.62-27.44	1.9-2.8
Intake manifold nuts	2	18.62-27.44	1.9-2.8
Intake manifold stay bolts	4	18.62-27.44	1.9-2.8
Exhaust manifold heat protector bolts	4	18.62-27.44	1.9-2.8
Exhaust manifold nuts	7	39.2-44.1	4.0-4.5
Exhaust manifold stay bolts (M8)	2	18.62-27.44	1.9-2.8
Exhaust manifold stay bolt (M10)	1	42.2-53.9	4.3-5.5
Front muffler bolts	2	39.2-58.8	4.0-6.0
Engine cover nuts	2	3.92-5.88	0.4-0.6
Engine cover mounting bracket bolts	2	7.84-11.76	0.8-1.2
Crankshaft position sensor & cover bolt	1	3.92-5.88	0.4-0.6
Oxygen sensor	1	34.3-44.1	3.5-4.5
Knock sensor	1	16.66-25.48	1.7-2.6
Oil temperature sensor	1	19.6-39.2	2.0-4.0
Camshaft position sensor	1	3.92-5.88	0.4-0.6
Oil pressure switch	1	7.84-11.76	0.8-1.2
Main bearing cap bolts	10	26.46 + 45°	2.7 + 45°
Oil filter	1	11.76-15.68	1.2-1.6
Connecting rod bearing cap bolts	8	19.6 + 90°	2.0 + 90°
Engine mounting nut (M12 x 1.25 6T)	3	63.7-83.4	6.5-8.5
Engine mounting bolts (M12 x 1.25 10T)	1	63.7-83.4	6.5-8.5

TIGHTENING TORQUE SPECIFICATION

See also:
• DRIVESHAFT