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Engine Mechanical System - General Information - 2.4L: Specifications Kia Optima III

Mechanical

Specifications

Description		Specifications	Limit
General
Type		In-line, DOHC
Number of cylinders		4
Bore		88 mm (3.464 in)
Stroke		97 mm (3.819 in)
Total displacement		2359 cc (143.90 cu. in)
Compression ratio		11.3 ± 0.3 : 1
Firing order		1-3-4-2
Valve timing
Intake valve	Opens (ATDC/BTDC)	ATDC 7° ~ BTDC 38°
Intake valve	Closes (ABDC)	ABDC 67° ~ 22°
Exhaust valve	Opens (BBDC)	BBDC 44° ~ 4°
Exhaust valve	Closes (BTDC)	ATDC 0° ~ 40°
Valve clearance (Engine coolant temperature : 20°C (68°F))
Intake valve		0.17 ~ 0.23 mm (0.0067 ~ 0.0090 in.)	0.10 ~ 0.30 mm (0.0039 ~ 0.0118 in.)
Exhaust valve		0.27 ~ 0.33 mm (0.0106 ~ 0.0129 in.)	0.20 ~ 0.40 mm (0.0079 ~ 0.0157 in.)
Camshaft
Cam height	Intake	44.2 mm (1.7401 in.)
Cam height	Exhaust	45.0 mm (1.7716 in.)
Journal outer diameter	Intake	No. 1 : (1) 30 mm (1.1811 in.) No. 2, 3, 4, 5 : (2) 24 mm (0.9449 in.)
Journal outer diameter	Exhaust	No. 1 : (1) 36 mm (1.4173 in.) No. 2, 3, 4, 5 : (2) 24 mm (0.9449 in.)
Bearing oil clearance	Intake	No. 1 : 0.022 ~ 0.057 mm (0.00087 ~ 0.00224 in.) No. 2, 3, 4, 5 : 0.045 ~ 0.082 mm (0.00177 ~ 0.00323 in.)	No. 1 : 0.090 mm (0.00354 in.) No. 2, 3, 4, 5 : 0.120 mm (0.00472 in.)
Bearing oil clearance	Exhaust	No. 1 : 0 ~ 0.032 mm (0 ~ 0.00126 in.) No. 2, 3, 4, 5 : 0.045 ~ 0.082 mm (0.00177 ~ 0.00323 in.)
End play		0.04 ~ 0.16 mm (0.0016 ~ 0.0063 in.)	0.20 mm (0.0078 in.)
Valve
Valve length	Intake	113.18 mm (4.4559 in.)	112.93 mm (4.4461 in)
Valve length	Exhaust	105.84 mm (4.1669 in.)	105.59 mm (4.1571 in)
Stem outer diameter	Intake	5.465 ~ 5.480 mm (0.21516 ~ 0.21575 in.)
Stem outer diameter	Exhaust	5.458 ~ 5.470 mm (0.21488 ~ 0.21535 in.)
Face angle		45.25° ~ 45.75°
Thickness of valve head (margin)	Intake	1.02 mm (0.0401 in.)
Thickness of valve head (margin)	Exhaust	1.09 mm (0.0429 in.)
Valve stem to valve guide clearance	Intake	0.020 ~ 0.047 mm (0.00078 ~ 0.00185 in.)	0.070 mm (0.00275 in.)
Valve stem to valve guide clearance	Exhaust	0.030 ~ 0.054 mm (0.00118 ~ 0.00212 in.)	0.090 mm (0.00354 in.)
MLA outer diameter		31.964 ~ 31.980 mm (1.2584 ~ 1.2590 in.)
Tappet bore inner diameter		32.000 ~ 32.025 mm (1.2598 ~ 1.2608 in.)
MLA to tappet bore clearance		0.020 ~ 0.061 mm (0.00078 ~ 0.00240 in.)	0.070 mm (0.00275 in.)
Valve guide
Length	Intake	43.8 ~ 44.2 mm (1.7244 ~ 1.7401 in.)
Length	Exhaust	43.8 ~ 44.2 mm (1.7244 ~ 1.7401 in.)
Inner diameter	Intake	5.500 ~ 5.512 mm (0.21654 ~ 0.21701 in.)
Inner diameter	Exhaust	5.500 ~ 5.512 mm (0.21654 ~ 0.21701 in.)
Valve seat
Width of seat contact	Intake	1.16 ~ 1.46 mm (0.0457 ~ 0.0575 in.)
Width of seat contact	Exhaust	1.35 ~ 1.65 mm (0.0531 ~ 0.0649 in.)
Seat angle	Intake	44.75° ~ 45.10°
Seat angle	Exhaust	44.75° ~ 45.10°
Valve spring
Free length		47.44 mm (1.8677 in.)
Load		19.0 ± 0.6kg/35.0 mm (41.88 ± 1.32lb/1.3779 in 39.8 ± 1.2kg/26.0 mm (87.74 ± 2.64lb/1.0236 in.)
Out of squareness		Less than 1.5°
Cylinder head
Flatness of gasket surface		Less than 0.05 mm (0.0019 in.) for total area Less than 0.02 mm (0.0007 in.) for a section of 100 mm (3.9370 in.) x100 mm (3.9370 in.)
Flatness of manifold mounting surface	Intake	Less than 0.10 mm (0.0039 in.)
Flatness of manifold mounting surface	Exhaust	Less than 0.10 mm (0.0039 in.)
Piston
Piston outer diameter		87.970 ~ 88.000 mm (3.46338 ~ 3.46456 in.)
Piston to cylinder clearance		0.020 ~ 0.040 mm (0.00079 ~ 0.00157 in.)
Ring groove width	No. 1 ring	1.235 ~ 1.250 mm (0.04862 ~ 0.04921 in.)	1.260 mm (0.04961 in.)
	No. 2 ring	1.230 ~ 1.250 mm (0.04843 ~ 0.04921 in.)	1.260 mm (0.04961 in.)
	Oil ring	2.010 ~ 2.025 mm (0.07913 ~ 0.07972 in.)	2.050 mm (0.08071 in.)
Piston ring
Side clearance	No. 1 ring	0.050 ~ 0.080 mm (0.00197 ~ 0.00315 in.)	0.100 mm (0.00394 in.)
	No. 2 ring	0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)	0.100 mm (0.00394 in.)
	Oil ring	0.020 ~ 0.055 mm (0.00079 ~ 0.00217 in.)	0.60 mm (0.0236 in.)
End gap	No. 1 ring	0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)	0.60 mm (0.0236 in.)
	No. 2 ring	0.37 ~ 0.52 mm (0.0145 ~ 0.0204 in.)	0.70 mm (0.0275 in.)
	Oil ring	0.20 ~ 0.50 mm (0.0079 ~ 0.0197 in.)	0.80 mm (0.0315 in.)
Piston pin
Piston pin outer diameter		21.997 ~ 22.000 mm (0.86602 ~ 0.86614 in.)
Piston pin hole inner diameter		22.003 ~ 22.007 mm (0.86626 ~ 0.86642 in.)
Piston pin hole clearance		0.003 ~ 0.010 mm (0.00012 ~ 0.00039 in.)
Connecting rod small end hole inner diameter		22.005 ~ 22.011 mm (0.86634 ~ 0.86657 in.)
Piston pin-to-connecting rod bushing oil clearance		0.005 ~ 0.014 mm (0.00020 ~ 0.00055 in.)
Connecting rod
Connecting rod big end inner diameter		51.000 ~ 51.018 mm (2.00787 ~ 2.00858 in.)
Connecting rod bearing oil clearance		0.031 ~ 0.045 mm (0.00122 ~ 0.00177 in.)	0.050 mm (0.00197 in.)
Side clearance		0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.)	0.35 mm (0.0138 in.)
Crankshaft
Main journal outer diameter		51.942 ~ 51.960 mm (2.04496 ~ 2.04567 in.)
Pin journal outer diameter		47.954 ~ 47.972 mm (1.88795 ~ 1.88866 in.)
Main bearing oil clearance		0.020 ~ 0.038 mm (0.00079 ~ 0.00150 in.)	0.100 mm (0.00394 in.)
End play		0.07 ~ 0.25 mm (0.0028 ~ 0.0098 in.)	0.30 mm (0.0118 in.)
Cylinder block
Cylinder bore		88.00 ~ 88.03 mm (3.4645 ~ 3.4657 in.)
Flatness of gasket surface		Less than 0.05 mm (0.0019 in.) for total area Less than 0.02 mm (0.0007 in.) for a section of 100 mm (3.9370 in.) x 100 mm (3.9370 in.)
Engine oil
Oil quantity	Total	5.5 L (1.45 U.S.gal., 5.81 U.S.qt., 4.84 lmp.qt.)	When replacing a short engine or block assembly
	Oil pan	4.2 L (1.11 U.S.gal., 4.44 U.S.qt., 3.70 lmp.qt.)
	Drain and refill	4.6 L (1.22 U.S.gal., 4.86 U.S.qt., 4.05 lmp.qt.)	Including oil filter
Oil grade	Recommendation	5W-20/GF4 & SM	If not available, refer to LUBRICATION SYSTEM . .
	Classification	API SL, SM or above ILSAC GF3, GF4 or above	Satisfy the requirement of the API or ILSAC classification.
	SAE viscosity grade	Recommended SAE viscosity number	Refer to LUBRICATION SYSTEM .
Oil pressure (at 1, 000 RPM)		147.09 kPa (1.5 kgf/cm 2 , 22.33 psi) or above	Oil temperature (oil pan): 110±2°C (230±35.6°F)
Cooling system
Cooling method		Forced circulation with cooling fan
Coolant quantity		6.8L (1.79 U.S.gal., 7.18 U.S.qt., 5.98 lmp.qt.)
Thermostat	Type	Wax pellet type
	Opening temperature	82±1.5°C (179.6±2.7°F)
	Full opening valve lift/temperature	More than 8 mm (0.3 in.) / 95°C (203°F)
Radiator cap	Main valve opening pressure	93.16 ~ 122.58 kPa (0.95 ~ 1.25kgf/cm 2 , 13.51 ~ 17.78 psi)
Radiator cap	Vacuum valve opening pressure	0 ~ 6.86 kPa (0 ~ 0.07kgf/cm 2 , 0 ~ 0.99 psi)

ENGINE MECHANICAL SYSTEM SPECIFICATIONS

Tightening Torques

Item	Quantity	N.m	Kgf.m	Lb-ft
Engine mounting
Engine mounting bracket to body fixing bolt	4	58.8 ~ 73.5	6.0 ~ 7.5	43.4 ~ 54.2
Engine mounting insulator to engine mounting support bracket fixing nut	1	78.5 ~ 98.1	8.0 ~ 10.0	57.9 ~ 72.3
Engine mounting support bracket to engine support bracket fixing bolt	1	78.5 ~ 98.1	8.0 ~ 10.0	57.9 ~ 72.3
Engine mounting support bracket to engine support bracket fixing nut	2	78.5 ~ 98.1	8.0 ~ 10.0	57.9 ~ 72.3
Transaxle mounting bracket to body fixing bolt	3	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Transaxle mounting bracket to body fixing nut	1	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Transaxle mounting support bracket fixing bolt	2	58.8 ~ 78.5	6.0 ~ 8.0	43.4 ~ 57.9
Transaxle mounting support bracket fixing nut	2	78.5 ~ 98.0	8.0 ~ 10.0	57.9 ~ 72.3
Transaxle mounting bracket to transaxle mounting support bracket fixing bolt	2	88.3 ~ 107.9	9.0 ~ 11.0	65.1 ~ 79.6
Roll rod bracket to sub frame fixing bolt	2	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Roll rod bracket to roll rod support bracket fixing bolt & nut	1	88.3 ~ 107.9	9.0 ~ 11.0	65.1 ~ 79.6
Timing system
Idler bolt	2	53.9 ~ 63.7	5.5 ~ 6.5	39.7 ~ 47.0
Drive belt tensioner pulley bolt	1	53.9 ~ 63.7	5.5 ~ 6.5	39.7 ~ 47.0
Drive belt tensioner bolt	1	53.9 ~ 63.7	5.5 ~ 6.5	39.7 ~ 47.0
Crankshaft pulley bolt	1	166.6 ~ 176.4	17.0 ~ 18.0	122.9 ~ 130.1
Timing chain cover service hole bolt	1	11.8 ~ 14.7	1.2 ~ 1.5	8.7 ~ 10.8
Timing chain cover bolt (M6x25)	7	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Timing chain cover bolt (M8x28)	7	18.6 ~ 22.5	1.9 ~ 2.3	13.7 ~ 16.6
Engine support bracket bolt (M8x30)	1	19.6 ~ 24.5	2.0 ~ 2.5	14.5 ~ 18.1
Engine support bracket bolt (M10x40)	1	39.2 ~ 44.1	4.0 ~ 4.5	28.9 ~ 32.5
Engine support bracket bolt (M10x45)	2	39.2 ~ 44.1	4.0 ~ 4.5	28.9 ~ 32.5
Timing chain tensioner bolt	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Timing chain tensioner arm bolt	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Timing chain guide bolt	3	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Timing chain oil jet bolt	1	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Cylinder head
Engine cover mounting bolt	4	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Ignition coil bolt	4	3.9 ~ 5.9	0.4 ~ 0.6	2.9 ~ 4.3
Cylinder head cover bolt	20	(3.9~5.9) + (7.8~9.8)	(0.4~0.6) + (0.8~1.0)	(2.9~4.3) + (5.8~7.2)
High pressure fuel pipe nut	2	26.5 ~ 32.4	2.7 ~ 3.3	19.5 ~ 23.9
High pressure fuel pump bolt	2	12.7 ~ 14.7	1.3 ~ 1.5	9.4 ~ 10.8
High pressure fuel pump bracket bolt	3	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Injector & rail assembly bolt	3	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
CVVT bolt (LH/RH)	2	53.9 ~ 63.7	5.5 ~ 6.5	39.7 ~ 47.0
Camshaft bearing cap bolt (M6) (LH/RH)	16	(5.9) + (10.8~12.7)	(0.6) + (1.1~1.3)	(4.3) + (8.0~9.4)
Camshaft bearing cap bolt (M8)	4	(14.7) + (27.5 ~ 31.4)	(1.5) + (2.8~3.2)	(10.8) + (20.3~23.1)
Cylinder head bolt	10	(32.4~36.3) + (90~95°) + (90~95°)	(3.3~3.7) + (90~95°) + (90~95°)	(23.9~26.8) + (90~95°) + (90~95°)
Engine hanger bolt (Front/Rear)	2	27.5 ~ 31.4	2.8 ~ 3.2	20.3 ~ 23.1
Camshaft position sensor (LH/RH)	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Oil control valve (OCV) bolt (LH/RH)	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Cylinder block
Tensioner assembly integrated bracket bolt	5	39.2 ~ 44.1	4.0 ~ 4.5	28.9 ~ 32.5
Flywheel bolt	7	117.7 ~ 127.5	12.0 ~ 13.0	86.8 ~ 93.9
Drive plate bolt	7	117.7 ~ 127.5	12.0 ~ 13.0	86.8 ~ 93.9
Oil filter bracket bolt	4	21.6 ~ 26.5	2.2 ~ 2.7	15.9 ~ 19.5
Ladder frame bolt	10	(8.8~9.8) + (17.7~20.6) + (27.5~31.4)	(0.9~0.1) + (1.8~2.1) + (2.8~3.2)	(6.5~7.2) + (13.0~15.2) + (20.3~23.1)
Connecting rod bearing cap bolt	8	(17.7~21.6) + (88~92°)	(1.8~2.2) + (88~92°)	(13.0~15.9) + (88~92°)
Main bearing cap bolt	10	(14.7) + (27.5~31.4) + (120~125°)	(1.5) + (2.8~3.2) + (120~125°)	(10.8) + (20.3~23.1) + (120~125°)
Piston cooling oil jet bolt	4	24.5 ~ 29.4	2.5 ~ 3.0	18.1 ~ 21.7
Crankshaft position sensor bolt	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Crankshaft position sensor cover bolt (M6)	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Crankshaft position sensor cover bolt (M8)	1	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Knock sensor	1	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Lubrication system
Oil drain plug	1	34.3 ~ 44.1	3.5 ~ 4.5	25.3 ~ 32.5
Oil filter	1	11.8 ~ 15.7	1.2 ~ 1.6	8.7 ~ 11.6
Oil level gauge assembly bolt	1	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
A/C compressor bracket bolt	4	19.6 ~ 23.5	2.0 ~ 2.4	14.5 ~ 17.4
Oil pan bolt (M6)	16	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Oil pan bolt (M9)	2	30.4 ~ 34.3	3.1 ~ 3.5	22.4 ~ 25.3
BSM chain tensioner arm bolt	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
BSM chain guide bolt	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
BSM chain tensioner bolt	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Balance shaft module (BSM) bolt (M9X181.5)	4	(22.6~26.5) + (88~92°)	(2.3~2.7) + (88~92°)	(16.6~19.5) + (88~92°)
Balance shaft module (BSM) bolt (M9X95)	2	(22.6~26.5) + (43~47°)	(2.3~2.7) + (43~47°)	(16.6~19.5) + (43~47°)
Oil pressure switch	1	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
Cooling system
Water pump pulley bolt	3	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Water pump bolt	5	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Water pump housing bolt	5	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Water inlet fitting bolt	3	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
Water temperature control assembly nut	1	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Water temperature control assembly bolt	2	14.7 ~ 19.6	1.5 ~ 2.0	10.8 ~ 14.5
Water inlet pipe bolt	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Intake and exhaust system
Air intake hose clamp bolt	2	2.9 ~ 4.9	0.3 ~ 0.5	2.2 ~ 3.6
Air cleaner assembly bolt	2	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Electronic throttle control (ETC) module bolt	4	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Intake manifold stay bolt	4	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Intake manifold bolt	3	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Intake manifold nut	2	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Oxygen sensor (Front/Rear)	2	39.2 ~49.0	4.0 ~ 5.0	28.9 ~ 36.2
Exhaust manifold heat protector bolt	ULEV:3 SULEV:4	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
Exhaust manifold stay bolt (M8)	2	18.6 ~ 27.5	1.9 ~ 2.8	13.7 ~ 20.3
Exhaust manifold stay bolt (M10)	ULEV:1 SULEV:2	51.9 ~ 57.8	5.3 ~ 5.9	38.3 ~ 42.6
Exhaust manifold nut	ULEV:8 SULEV:7	49.0 ~ 53.9	5.0 ~ 5.5	36.2 ~ 39.7
Catalytic converter / muffler nut	6	39.2 ~ 58.8	4.0 ~ 6.0	28.9 ~ 43.4

TIGHTENING TORQUES