Engine Mechanical (G6EA - Gsl 2.7L): Removal & Installation Kia Optima II

INSTALLATION

1. Install the water pump.
2. Install the air conditioning compressor. (Refer to «AIR CONDITIONING SYSTEM»(ref-266085) ).
3. Install the cylinder head.
4. Install the power steering pump. (Refer to «MECHANICAL POWER STEERING SYSTEM»(ref-266036) ).
5. Install the generator.
6. Install the intake manifold.
7. Install the exhaust manifold.
8. Install the timing belt.
9. Install the rear plate (A). Tightening torque 9.8-11.8 N.m (1.0-1.2 kgf.m, 7.2-8.7 lb-ft)
10. Install the drive plate (A). Tightening torque 71.6-75.5 N.m (7.3-7.7 kgf.m, 52.8-55.7 lb-ft)

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REMOVAL

Note. Mark all wiring and hoses to avoid misconnection. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

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1. Remove the air duct (A) and the battery (B) after disconnecting the terminals (C) from the battery.
2. Remove the engine cover (A).
3. Remove the intake air hose and air cleaner assembly. Disconnect the MAF connector (A). Disconnect the breather hose (B) from air cleaner hose. Remove the intake air hose and air cleaner assembly (C). Disconnect the PCM connectors (D).
4. Remove the upper radiator hose (A) and lower radiator hose (B).
5. Remove the fuel inlet hose (A) from the delivery pipe.
6. Disconnect the engine wiring harness connectors. Disconnect the No.1/No.2 knock sensor connectors (A, B), the oil pressure switch connector (C), the ignition coil harness (D) and the No.1 VIS (Variable Induction System) connector (E). Disconnect the bank 1 front/rear O2 sensor connectors (A). Disconnect the injection connectors (A, B, C), the ground lines (D), the condenser connector (E) and the Ignition coil connectors (F). Disconnect the injection harness connector (A), the No.2 VIS (Variable Induction System) connector (B), the No.1/No.2 OCV (Oil Control Valve) connectors (C, D) and the OTS (Oil Temperature Sensor) connector (E). Disconnect the MAPS (Manifold Absolute Pressure Sensor) connector (A), the ETC (Electronic Throttle Control) connector (B) and the PCSV (Purge Control Solenoid Valve) connector (C). Disconnect the generator connector (A) and the air conditioning compressor connector (B). Disconnect the bank 2 CMP sensor connector (A) and the ECT (Engine Coolant Temperature) sensor connector (B). Disconnect the bank 2 front/rear O2 sensor connectors (A, B) and the CKP sensor connector (C). Disconnect the bank 1 CMP sensor connector (A).
7. Remove the PCV (Purge Control Valve) hose (A).
8. Disconnect the brake vacuum hose (A).
9. Remove the heater hoses.
10. Remove the drive belt (A).
11. Remove the power steering pump. (Refer to «MECHANICAL POWER STEERING SYSTEM»(ref-266036) ).
12. Remove the exhaust manifold assembly. (Refer to ' «INTAKE AND EXHAUST SYSTEM»(ref-265992-S08664519142007092700000) ').
13. Remove the intake manifold assembly. (Refer to ' «INTAKE AND EXHAUST SYSTEM»(ref-265992-S08664519142007092700000) ').
14. Remove the timing belt. (Refer to ' «TIMING SYSTEM»(ref-265992-S34583168082007092700000) ').
15. Remove the ignition coils.
16. Remove the water temp. control assembly.
17. Remove the cylinder head cover (A).
18. Remove the camshaft bearing cap (A).
19. Remove the timing chain tensioner (A).
20. Remove the camshaft.
21. Remove the bank 1 timing belt rear cover (A).
22. Remove the bank 2 timing belt rear cover (A).
23. Remove the CKP sensor connector bracket (A).
24. Remove the cylinder head assembly. Remove the bolts in 2-3 steps as following orders. CAUTION: If the bolts are not removed as the order, the deformation of the head assembly can be occurred. Put the cylinder head assembly on a wooden block after removal from the cylinder block. CAUTION: Ensure that the surface between the cylinder head and the block is not damaged.

Note. Thoroughly clean all parts to be assembled. Always use a new head and manifold gasket. The cylinder head gasket is a metal gasket. Take care not to bend it. Rotate the crankshaft to set the No.1 cylinder piston at TDC.

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1. After putting the cylinder head gasket on the cylinder block, install the cylinder head. CAUTION: Ensure the LH/RH classification of the cylinder head gasket when installing.
2. Tighten the cylinder head bolts with the plain washers in several steps as following order. NOTE: In assembling washers, the marked surface should face upward. In installing the cylinder head bolts, apply engine oil on the thread of the bolts and the surface of the washers. Tightening torque 24.5 N.m (2.5 kgf.m, 18.1 lb-ft) + 60° + 45° NOTE: Using the SST (09221-4A000), tighten the bolts which need to be tightened with the angular tightening method.
3. Install the CVVT assembly and camshaft chain sprocket with the dowel pin in the CVVT installed to the intake camshaft. Ensure that the pin will not be installed in the hole for oil feeding. Tightening torque 66.7-78.5 N.m (6.8-8.0 kgf.m, 49.2-57.9 lb-ft) NOTE: After tightening the CVVT bolts, rotate the CVVT assembly housing counterclockwise by hand to seat the lock pin in the CVVT assembly in good position. CAUTION: Fix the hexagonal part of the camshaft in a vice when tightening the CVVT bolts. Do not fix the CVVT housing or sprocket in a vice.
4. Install the camshaft in the cylinder head assembly. Align the timing mark of the camshaft timing chain. LH CAMSHAFT CHAIN TIMING MARK RH CAMSHAFT CHAIN TIMING MARK CAUTION: Both timing marks should face upward in reassembly.
5. Install the timing chain tensioner. Insert the set pin by pressing the timing chain tensioner. Install the chain tensioner (A) in the cylinder head assembly. Remove the set pin from the tensioner after installing.
6. Install the camshaft bearing caps. Tightening torque Bearing cap bolt (A: 6x38) - 10.8-12.7 N.m (1.1-1.3 kgf.m, 8.0-9.4 lb-ft) Bearing cap bolt (B: 8x38) - 20.6-22.5 N.m (2.1-2.6 kgf.m, 15.2-18.8 lb-ft) NOTE: When installing the bearing caps, check the marks on them as shown below and install them in its proper position. A (LH/RH HEAD): L (LH), R (RH) B (Intake/Exhaust): I (Intake), E (Exhaust) C (Cap no.): 1, 2, 3 CAUTION: When installing the bearing caps, turn the crankshaft to place a piston in the middle of the block because interference between valves and pistons can occur.
7. Using the SST (09214-21000), install the camshaft oil seal. NOTE: Before installing, apply engine oil. The camshaft cap surface should adhere to the cylinder head assembly. Do not press an eccentric load.
8. Install the CKP sensor connector bracket (A).
9. Install the bank 2 timing belt rear cover (A).
10. Install the bank 1 timing belt rear cover (A). NOTE: The length of the bolt B is longer than that of the bolt C.
11. Install the timing belt. (Refer to ' «TIMING SYSTEM»(ref-265992-S34583168082007092700000) .').
12. Check and adjust the valve clearance.
13. Install the cylinder head cover. Remove oil, dust or sealant on the upper surface of the cylinder before assembling cylinder head cover. Assemble the cylinder head cover in five minutes after applying liquid gasket (LOCTITE 5900) on the camshaft cap and packing part. Tighten the cylinder head cover bolts as following order (A). Tightening torque 7.8-9.8 N.m (0.8-1.0 kgf.m, 5.8-7.2 lb-ft) NOTE: Do not start engine for thirty minutes after assembling the cylinder head cover. Do not reuse the cylinder head cover gasket.
14. Install the water temp. control assembly.
15. Install the intake manifold assembly.
16. Install the exhaust manifold assembly.
17. Install the power steering pump. (Refer to «MECHANICAL POWER STEERING SYSTEM»(ref-266036) ).
18. Install the drive belt (A).
19. Install the heater hose.
20. Connect the brake vacuum hose (A).
21. Install the PCV (Positive Crankcase Ventilation) hose (A).
22. Connect the engine wiring harness connectors. Connect the bank 1 CMP sensor connector (A). Connect the bank 2 front/rear O2 sensor connectors (A, B) and the CKP sensor connector (C). Connect the bank 2 CMP sensor connector (A) and the WTS (Water Temperature Sensor) connector (B). Connect the generator connector (A) and the air conditioning compressor connector (B). Connect the MAPS (Manifold Absolute Pressure Sensor) connector (A), the ETC (Electronic Throttle Control) connector (B) and the PCSV (Purge Control Solenoid Valve) connector (C). Connect the injection harness connector (A), the No.2 VIS (Variable Induction System) connector (B), the No.1/No.2 OCV (Oil Control Valve) connectors (C, D) and the OTS (Oil Temperature Sensor) connector (E). Connect the injection connectors (A, B, C), the ground lines (D), the condenser connector (E) and the Ignition coil connectors (F). Connect the bank 1 front/rear O2 sensor connectors (A). Connect the No.1/No.2 knock sensor connectors (A, B), the oil pressure switch connector (C), the ignition coil harness (D) and the No.1 VIS (Variable Induction System) connector (E).
23. Install the fuel inlet hose (A) from the delivery pipe.
24. Install the upper radiator hose (A) and lower radiator hose (B).
25. Install the intake air hose and air cleaner assembly. Connect the PCM connectors (D). Install the intake air hose and air cleaner assembly (C). Connect the breather hose (B) from air cleaner hose. Connect the MAF connector (A).
26. Install the engine cover (A). Tightening torque 7.8-11.8 N.m (0.8-1.2 kgf.m, 5.8-8.7 lb-ft)
27. Refill engine coolant.

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1. Remove the engine cover (A).
2. Remove the front right wheel and tire.
3. Remove the right side cover.
4. Remove the drive belt (A), the idler (B) and the tensioner (C). NOTE: In removing the drive belt, fix a tool in the auto tensioner pulley bolt and turn the bolt counter clockwise.
5. Remove the timing belt upper cover (A).
6. Align the groove of the pulley with the timing mark of the timing belt cover by turning the crankshaft pulley clockwise. Check if the timing mark of the camshaft sprocket is aligned with that of the cylinder head cover. (No.1 cylinder piston at TDC)
7. Remove the engine mounting bracket. Sustain the engine oil pan with a jack. CAUTION: Put a wooden or rubber block between the jack and the engine oil pan. Remove the engine mounting bracket (A).
8. Remove the crankshaft damper pulley (A).
9. Remove the timing belt lower cover (A).
10. Remove the engine support bracket (A). NOTE: After removal, a small amount of engine coolant may drain from point (B).
11. Remove the timing belt auto tensioner (A).
12. Remove the timing belt (A). NOTE: Mark the direction of rotation on the timing belt.
13. Remove the tensioner arm assembly (A) and the idler (B).
14. Remove the crankshaft sprocket.

Note. Mark all wiring and hoses to avoid misconnection.

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1. Remove the air duct (A) and the battery (B) after disconnecting the terminals (C) from the battery.
2. Remove the engine cover (A).
3. Remove the intake air hose and air cleaner assembly. Disconnect the MAF connector (A). Disconnect the breather hose (B) from air cleaner hose. Remove the intake air hose and air cleaner assembly (C). Disconnect the PCM connectors (D).
4. Remove the battery tray (A) while recovering refrigerant.
5. Remove the upper radiator hose (A) and lower radiator hose (B).
6. Remove the transaxle oil cooler hoses (A/T vehicles only).
7. Remove the fuel inlet hose (A) from the delivery pipe.
8. Disconnect the engine wiring harness connectors. Disconnect the No.1/No.2 knock sensor connectors (A, B), the oil pressure switch connector (C), the ignition coil harness (D) and the No.1 VIS (Variable Induction System) connector (E). Disconnect the bank 1 front/rear O2 sensor connectors (A). Disconnect the injection connectors (A, B, C), the ground lines (D), the condenser connector (E) and the Ignition coil connectors (F). Disconnect the injection harness connector (A), the No.2 VIS (Variable Induction System) connector (B), the No.1/No.2 OCV (Oil Control Valve) connectors (C, D) and the OTS (Oil Temperature Sensor) connector (E). Disconnect the MAPS (Manifold Absolute Pressure Sensor) connector (A), the ETC (Electronic Throttle Control) connector (B) and the PCSV (Purge Control Solenoid Valve) connector (C). Disconnect the generator connector (A) and the air conditioning compressor connector (B). Disconnect the bank 2 CMP sensor connector (A) and the WTS (Water Temperature Sensor) connector (B). Disconnect the bank 2 front/rear O2 sensor connectors (A, B) and the CKP sensor connector (C). Disconnect the bank 1 CMP sensor connector (A).
9. Disconnect ground lines (A, B) from the engine and the transaxle assembly.
10. Disconnect the battery wirings (A, B) from the engine room fuse & relay box (C).
11. Remove the heater hoses.
12. Disconnect the brake vacuum hose (A).
13. Disconnect the transaxle wiring harness connectors. (Refer to «AUTOMATIC TRANSAXLE SYSTEM»(ref-266022) ).
14. After draining or gathering power steering fluid, disconnect the power steering hose (A).
15. Remove the steering column shaft joint bolt. (Refer to «STEERING COLUMN AND SHAFT»(ref-266035) ).
16. Disconnect the air conditioning compressor hoses. (Refer to «AIR CONDITIONING SYSTEM»(ref-266085) ).
17. Remove the front wheels and tires. (Refer to «TIRES/WHEELS»(ref-266033) ).
18. Lifting the vehicle, remove the under cover.
19. Drain the engine coolant, engine oil and transaxle fluid. Remove the radiator cap to speed coolant draining.
20. Remove the brake caliper. (Refer to «BRAKE SYSTEM»(ref-266047) ).
21. Disconnect the ABS connectors. (Refer to «ABS (ANTI-LOCK BRAKE SYSTEM)»(ref-266015) ).
22. Disconnect the stabilizer bar link from the struts. (Refer to «FRONT SUSPENSION SYSTEM»(ref-266031) ).
23. Remove the knuckles from the struts. (Refer to «FRONT SUSPENSION SYSTEM»(ref-266031) ).
24. Remove the front muffler (A).
25. Disconnect the power steering return hose (A).
26. Remove the engine mounting bracket (A).
27. Remove the transaxle mounting bracket (A).
28. Supporting the engine and transaxle assembly with a jack, remove the assembly from the vehicle by loosening the subframe mounting bolts and lifting up the vehicle slowly. NOTE: When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

Installation is in the reverse order of removal.

Perform the following

1. Adjust the shift cable.
2. Refill the engine with engine oil.
3. Refill the transaxle with fluid.
4. Refill the radiator with engine coolant.
5. Bleed air from the cooling system with the heater valve open.
6. Clean the battery posts and cable terminals with "sandpaper" "assemble" them, then apply grease to prevent corrosion.
7. Inspect for fuel leakage. After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.