Engine Cooling System - 2.4L: Maintenance Kia Optima III

Refilling And Bleeding

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1. Make sure the engine and radiator are cool to the touch.
2. Remove radiator cap (A).
3. Loosen the drain plug (A), and drain the coolant.
4. Tighten the radiator drain plug securely.
5. After draining engine coolant in the reservoir tank, clean the tank.
6. Fill the radiator with water through the radiator cap and tighten the cap. NOTE: To most effectively bleed the air, pour the water slowly and press on the upper/lower radiator hoses.
7. Start the engine and allow to come to normal operating temperature. Wait for the cooling fans to turn on several times. Accelerate the engine to aid in purging trapped air. Shut engine off.
8. Wait until the engine is cool.
9. Repeat steps 1 to 8 until the drained water runs clear.
10. Fill fluid mixture with coolant and water (5 : 5) (Tropical region - 4:6) slowly through the radiator cap. Push the upper/lower hoses of the radiator so as bleed air easily. NOTE: Use only genuine antifreeze/coolant. For best corrosion protection, the coolant concentration must be maintained year-round at 35% minimum. Coolant concentrations less than 35% may not provide sufficient protection against corrosion or freezing. Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended. CAUTION: Do not mix different brands of antifreeze/coolants. Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.
11. Start the engine and run until coolant circulates. When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
12. Repeat 11 until the cooling fan 3 ~ 5 times and bleed air sufficiently out of the cooling system.
13. Install the radiator cap and fill the reservoir tank to the "MAX (or F)" line with coolant.
14. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
15. Stop the engine and wait coolant gets cool.
16. Repeat 10 to 15 until the coolant level doesn't fall any more, bleed air out of the cooling system. NOTE: It takes time to bleed out all the air in the cooling system. Refill coolant when coolant gets cool completely, when recheck the coolant level in the reservoir tank for 2~3 days after replacing coolant. Coolant capacity: 6.8L (1.79 U.S.gal., 7.18 U.S.qt., 5.98 lmp.qt.)

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1. Disconnect the battery terminals. Refer to «BATTERY»(ref-429624-S21182795222011101500000) .
2. Remove the air cleaner assembly. Refer to «ENGINE AND TRANSAXLE ASSEMBLY»(ref-429618-S34645398012011101500000) .
3. Remove the battery and battery tray. Refer to «BATTERY»(ref-429624-S21182795222011101500000) .
4. Disconnect the fan motor connector (A)
5. Remove the radiator upper hose clip bolt (B).
6. Remove the cooling fan assembly (A). Tightening torque: 4.9 ~ 7.8 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.8 lb-ft)
7. Remove the under cover. Refer to «ENGINE AND TRANSAXLE ASSEMBLY»(ref-429618-S34645398012011101500000) .
8. Loosen the drain plug (A), and drain the engine coolant. Remove the radiator cap to help drain the coolant faster.
9. Disconnect the over flow hose (A) from the radiator.
10. Disconnect the radiator upper hose (A) and lower hose (B). NOTE: When installing radiator hoses, install as shown in illustrations.
11. Disconnect the ATF cooler hoses (A/T only). Refer to «AUTOMATIC TRANSAXLE»(ref-429639-S03792191982011101500000) .
12. Remove the radiator mounting brackets (A). Tightening torque: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
13. Separate the condenser from the radiator and then remove the radiator assembly (A).
14. Installation is the reverse order of removal.
15. Fill the radiator with coolant and check for leaks. NOTE: Bleed air from the cooling system. Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.) Turn off engine. Check the coolant level and add coolant if needed. This will allow trapped air to be removed from the cooling system. Put the radiator cap on tightly, then run engine again and check for leaks.

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1. Remove the radiator cap, wet its seal with engine coolant, and then install it on a pressure tester.
2. Apply a pressure of 93.16 ~ 122.58 kPa (0.95 ~ 1.25 kgf/cm 2 , 13.51 ~ 17.78 psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

Scheme 38

1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58 kPa (0.95 ~ 1.25 kgf/cm 2 , 13.51 ~ 17.78 psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap. NOTE: Check for engine oil in the coolant and/or coolant in the engine oil.

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1. Loosen the drain plug, and then drain the engine coolant. Remove the radiator cap to help drain the coolant faster.
2. Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise.
3. Remove the water pump pulley (A). Tightening torque: 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8~ 7.2 lb-ft)
4. Remove the water pump sub assembly (A) with the gasket. Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)
5. ULEV : Remove the exhaust manifold heat protector (A). Tightening torque: 7.8 ~ 11.8 N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft) SULEV : Using the SST (09392-2H100) (A), remove the front oxygen sensor (B) and the remove the exhaust manifold heat protector (C). Tightening torque Oxygen sensor: 39.2~ 49.0 N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2 lb-ft) Heat protector bolts: 7.8 ~ 11.8 N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)
6. Remove the water pump housing (A) with the gasket and the water inlet pipe (B). Tightening torque: Bolt (C) : 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft) Bolt (D, E) : 18.6 ~ 23.5 N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4 lb-ft)
7. Installation is reverse order of removal with a new water pump gasket.
8. Fill the engine coolant.
9. Start the engine and check for leaks.
10. Recheck the coolant level.