Kia Optima: Disassembly
| • |
Use fender covers to
avoid damaging painted surfaces. |
| • |
To avoid damage, unplug
the wiring connectors carefully while holding the connector portion. |
|
| • |
Mark all wiring and hoses
to avoid misconnection. |
| • |
Turn the crankshaft pulley
so that the No.1 piston is at top dead center. |
| • |
Engine removal is required
for this procedure. |
|
|
In case of removing the high pressure fuel pump, high pressure fuel pipe,
delivery pipe, and injector, there may be injury caused by leakage of the
high pressure fuel. So don’t do any repair work right after engine stops. |
| 1. |
Remove the engine assembly from
the vehicle. (Refer to Engine and transaxle assembly in this group) |
| 2. |
Install the engine to an engine
stand for disassembly. |
| 3. |
Remove the intake manifold and
exhaust manifold. (Refer to Intake and exhaust system in this group)
|
| 4. |
Remove the timing chain. (Refer
to Timing system in this group) |
| 5. |
Remove the cylinder head assembly.
(Refer to Cylinder head in this group) |
| 6. |
Remove the drive plate (A) and
the adapter plate (B).
|
| 7. |
Remove the balance shaft & oil
pump assembly. (Refer to Lubrication system in this group) |
| 8. |
Remove the A/C compressor. (Refer
to HA group) |
| 9. |
Remove the alternator. (Refer
to EE group) |
| 10. |
Remove the water pump assembly.
(Refer to Cooling system in this group) |
| 11. |
Remove the tensioner assembly
integrated bracket (A).
|
| 12. |
Remove the oil level gauge tube
(A).
|
| 13. |
Remove the knock sensor (A).
|
| 14. |
Remove the oil pressure sensor
(A).
|
| 15. |
Remove the cover (B) and then
CKPS (Crankshaft position sensor) (A).
|
| 16. |
Remove the ladder frame (A).
|
| 17. |
Check the connecting rod end
play. |
| 18. |
Remove the connecting rod caps
and check oil clearance. |
| 19. |
Remove piston and connecting
rod assemblies.
| (1) |
Using a ridge reamer,
remove all the carbon from the top of the cylinder. |
| (2) |
Push the piston, connecting
rod assembly and upper bearing through the top of the cylinder block.
|
• |
Keep
the bearings, connecting rod and cap together.
|
|
• |
Arrange
the piston and connecting rod assemblies in the
correct order. |
|
|
|
| 20. |
Remove crankshaft bearing cap
and check oil clearance. |
| 21. |
Check the crankshaft end play. |
| 22. |
Lift the crankshaft (A) out of
the engine, being careful not to damage journals.
|
Arrange the main bearings and thrust bearings in the correct order. |
|
| 23. |
Remove the oil jet (A).
|
| 24. |
Check fit between piston and
piston pin. Try to move the piston back and forth on the piston pin. If
any movement is felt, replace the piston and pin as a set.
|
| 25. |
Remove piston rings.
| (1) |
Using a piston ring expander,
remove the 2 compression rings. |
| (2) |
Remove oil ring.
|
Arrange the piston rings in the correct order only. |
|
|
| 26. |
Disconnect connecting rod from
piston. Remove the snap ring at both ends of piston pin. And push the
piston pin to seperate and connecting rod
|
Connecting Rod
1.
Check the connecting rod end
play.Using a feeler gauge, measure the end play while moving the connecting
rod back and forth.
End play :Standard : 0.10~ ...
Inspection