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Engine Mechanical System - General Information - Hev: Diagnosis Kia Optima III

Mechanical 8 illustrations ~455 words

Compression Pressure Inspection

Note. If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

CAUTIONEngine may start anytime the vehicle is in READY mode. 1. Warm up and stop engine.

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  1. Warm up and stop engine. Allow the engine to warm up to normal operating temperature.
  2. Remove the engine cover.
  3. Disconnect the injector connectors (A).
  4. Disconnect the ignition coil connectors (A).
  5. Remove ignition coils (A).
  6. Remove spark plugs. Using a 16mm plug wrench, remove the 4 spark plugs.
  7. Check cylinder compression pressure. Insert a compression gauge into the spark plug hole. If possible, place the gauge where it can be seen from inside the vehicle. Attach the GDS Connect the cable of GDS to the data link connector. Select the vehicle model and then the HCU system. Select the "Engine On Test". See the screens below. While cranking the engine, measure the compression pressure. With the Brake pedal depressed, press the Start/Stop Button (SSB) one time. If the engine cranks, let it crank about 8 to 10 cycles (until the gauge readings stabilizes) then press the SSB one time to stop the engine from cranking. If the engine does not crank on its own when the SSB is pressed, the GDS should be used to crank the engine. While in the "Engine On Test" follow the instruction on the screen. The "Engine On Test" will start the engine cranking. After the compression readings stabilize (8-10 cycles), press the SSB one time to stop the cranking. Repeat steps ( 1 ) through ( 3 ) for each cylinder. WARNING: Be sure ignition is in the OFF mode between each cylinder test. This measurement must be done while the engine is still near operating temperature. Compression pressure: 1, 283kPa (13.0kgf/cm 2 , 185psi) / 200 ~ 250rpm Minimum pressure: 1, 135kPa (11.5kgf/cm 2 , 164psi) Difference between each cylinder: 100kPa (1.0kgf/cm 2 , 15psi) or less If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps ( 1 ) through ( 3 ) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
  8. Reinstall spark plugs.
  9. Install ignition coils. Tightening torque: 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
  10. Connect the injector connectors and ignition coil connectors.
  11. Some DTC's may exist after the inspection test and may need to be manually cleared with GDS.

Troubleshooting

SymptionSuspect areaRemedy
Engine misfire with abnormal internal lower engine noises.Worn crankshaft bearings Loose or out of specification engine flywheelReplace the crankshaft and bearings as required. Repair or replace the flywheel as required.
Worn piston rings (Oil consumption may or may not cause the engine to misfire.)Inspect the cylinder for a loss of compression. Repair or replace as required.
Worn crankshaft thrust bearingsReplace the crankshaft and bearings as required
Engine misfire with abnormal valve train noise.Stuck valves. (Carbon buildup on the valve stem)Repair or replace as required
Excessive worn or mis-aligned timing chain Out of specification valve clearancesReplace the timing chain and sprocket as required.
Worn camshaft lobes.Replace the camshaft and valve lifters.
Engine misfire with coolant consumptionFaulty cylinder head gasket or other damage to the cylinder head and engine block cooling system. Coolant consumption may or may not cause the engine to overheat.Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket. Repair or replace as required.
Engine misfire with excessive oil consumptionWorn valves, guides and/or valve stem oil seals.Repair or replace as required.
Worn piston rings. (Oil consumption may or may not cause the engine to misfire)Inspect the cylinder for a loss of compression. Repair or replace as required.
Engine noise on start-up, but only lasting a few seconds. (Check and compare with known good vehicle to determine normal condition.)Incorrect oil viscosityDrain the oil. Install the correct viscosity oil.
Worn crankshaft thrust bearing.Inspect the thrust bearing and crankshaft. Repair or replace as required.
Upper engine noise, regardless of engine speed.Low oil pressureRepair or replace as required.
Broken valve spring.Replace the valve spring.
Worn or dirty valve lifters.Replace the valve lifters.
Stetched or broken timing chain and/or damaged sprocket teeth.Replace the timing chain and sprockets.
Worn timing chain tensioner, if applicable.Replace the timing chain tensioner as required.
Worn camshaft lobes.Inspect the camshaft lobes. Replace the timing camshaft and valve lifters as required.
Out of specification valve clearances Worn valve guides or valve stems.Inspect the valves and valve guides, then repair or replace as required.
Stuck valves. (Carbon on the valve stem or valve seat may cause the valve to stay open.Inspect the valves and valve guides, then repair or replace as required.
Worn drive belt, idler, tensioner and bearing.Replace as required
Lower engine noise, regardless of engine speedLow oil pressureRepair or replace as required
Loose or damaged flywheel.Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump screen.Inspect the oil pan. Inspect the oil pump screen. Repair or replace as required.
Oil pump screen loose, damaged or restricted.Inspect the oil pump screen. Repair or replace as required.
Excessive piston-to-cylinder bore clearance.Inspect the piston, piston pin and cylinder bore. Repair or replace as required.
Excessive piston pin-to-piston clearanceInspect the piston, piston pin and the connecting rod. Repair or replace as required.
Excessive connecting rod bearing clearanceInspect the following components and repair or replace as required. The connecting rod bearings. The connecting rods. The crankshaft pin journals.
Excessive crankshaft bearing clearanceInspect the following components, and repair or replace as required. The crankshaft bearings. The crankshaft main journals. The cylinder block
Incorrect piston, piston pin and connecting rod installationVerify the piston pins and connecting rods are installed correctly. Repair as required.
Engine noise under loadLow oil pressureRepair or replace as required.
Excessive connecting rod bearing clearanceInspect the following components and repair or replace as required: The connecting rod bearings. The connecting rods. The crankshaft
Excessive crankshaft bearing clearanceInspect the following components, and repair or replace as required. The crankshaft bearings. The crankshaft main journals. The cylinder block.
Engine will not crank-crankshaft will not rotateHydraulically locked cylinder Coolant/antifreeze in cylinder. Oil in cylinder. Fuel in cylinderRemove spark plugs and check for fluid. Inspect for broken head gasket. Inspect for cracked engine block or cylinder head. Inspect for a sticking fuel injector and/or leaking fuel regulator.
Broken timing chain and/or timing chain and/or timing chain gears.Inspect timing chain and gears. Repair as required.
Material in cylinder Broken valve Piston material Foreign materialInspect cylinder for damaged components and/or foreign materials. Repair or replace as required.
Seized crankshaft or connecting rod bearings.Inspect crankshaft and connecting rod bearing. Repair as required.
Bent or broken connecting rod.Inspect connecting rods. Repair as required.
Broken crankshaftInspect crankshaft. Repair as required.