Kia Optima: Installation
| 1. |
Install the balance shaft chain.
(Refer to Lubrication system in this group) |
| 2. |
Install the crankshaft chain
sprocket (B) and the timing chain oil jet (A).
Tightening torque:7.8 ~
9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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| 3. |
Set the crankshaft so that the
key (A) of crankshaft will be aligned with the mating surface of main bearing
cap. Put the intake and exhaust camshaft assembly so that the TDC marks
(B) of the intake and exhaust CVVT sprockets will be aligned with the top
surface of cylinder head. As a result of this, the piston of No.1 cylinder
is placed at the top dead center on compression stroke.
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| 4. |
Install the timing chain guide
(A).
Tightening torque:9.8 ~
11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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| 5. |
Install the timing chain. To
install the timing chain with no slack between each shaft (cam, crank),
follow the below procedure. Crankshaft sprocket (A) → Timing chain guide
(B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket (D).
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The timing marks of each sprocket should be matched with timing
marks (color link) of timing chain when installing the timing chain.
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| 6. |
Install the timing chain tensioner
arm (A).
Tightening torque:9.8 ~
11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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| 7. |
Install the timing chain auto
tensioner (B) and remove the stopper pin (A).
Tightening torque:9.8 ~
11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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| 8. |
After rotating crankshaft 2 revolutions
in regular direction (clockwise viewed from front), confirm that the TDC
marks (A) on the intake and exhaust CVVT sprockets aligned with the top
surface of cylinder head.
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| 9. |
Install the timing chain cover.
| (1) |
Using a gasket scraper,
remove all the old packing material from the gasket surfaces.
|
| (2) |
The sealant locations
on chain cover and on counter parts (cylinder head, cylinder block,
and ladder frame) must be free of engine oil and etc. |
| (3) |
Before assembling the
timing chain cover, liquid sealant Loctite 5900H or equivalent should
be applied on the gap between cylinder head and cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
Bead width: 3.0mm
(0.12in.)
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| (4) |
After applying liquid
sealant Loctite 5900H or equivalent on the timing chain cover.
The part must be assembled within 5 minutes after sealant was applied.
Continuous bead of sealant should be applied to prevent any path
of oil leakage.
Bead width: 3.0mm
(0.12in.)
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| (5) |
The dowel pins on the
cylinder block and holes on the timing chain cover should be used
as a reference in order to assemble the timing chain cover to be
in exact position.
Tightening torque:
Bolts A (M6×25) :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)Bolts B
(M8×28) :
18.6 ~ 22.5N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)
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The engine starting or pressure tests should not be performed
within 30 minutes after the timing chain cover was assembled.
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| 10. |
Install the engine support bracket
(A).
Tightening torque:M10 bolts
:
39.2 ~ 44.1N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 32.5lb-ft)M8 bolts :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
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| 11. |
Install the crankshaft front
oil seal (A) using SST (09214-3K000, 09231-H1100) (B).
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| 12. |
Install the drive belt tensioner
(A).
Tightening torque :53.9
~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)
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| 13. |
Install the idler (A), the water
pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner
pulley (D).
Tightening torque :Idler
(A) :
53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)Water pump pulley
(B) :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)Crankshaft pulley
(C) :
166.6 ~ 176.4N.m (17.0 ~ 18.0kgf.m, 122.9 ~ 130.1lb-ft)Drive
belt tensioner pulley (D) :
53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)
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Tensioner pulley bolt is left-handed screw. |
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Use the SST (Ring gear stopper, 09231-3K000) to remove the crankshaft
pulley bolt. Install the starter after installing the crankshaft
pulley. |
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| 14. |
Install the engine mounting support
bracket (B) and connect the ground line (A).
Tightening torque :78.5
~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
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| 15. |
Remove the jack from the ladder
frame. |
| 16. |
Install the oil pan.
| (1) |
Using a gasket scraper,
remove all the old sealant material from the gasket surfaces.
|
| (2) |
Before assembling the
oil pan, liquid sealant Loctite 5900H, Threebond 1217H or equivalent
should be applied on oil pan. The part must be assembled within
5 minutes after sealant was applied.
Bead width : 2.5mm
(0.010in.)
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• |
When
applying sealant gasket, sealant must not be protruded
into the inside of oil pan. |
|
• |
To prevent
leakage of oil, apply sealant gasket on the inner
threads of the bolt holes. |
|
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| (3) |
Install the oil pan (A).
Uniformly tighten the bolts in several passes.
Tightening torque
Bolts B (M9) :
30.4 ~ 34.3N.m (3.1 ~ 3.5kgf.m, 22.4 ~ 25.3lb-ft)Bolts
C (M6) :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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After assembly, wait at least 30 minutes before filling
the engine with oil. |
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Always use a new drain plug gasket. |
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| 17. |
Install the A/C compressor bracket
(A).
Tightening torque :19.6
~ 23.5N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)
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| 18. |
Install the A/C compressor lower
bolts (A).
Tightening torque :20.0
~ 33.0N.m (2.04 ~ 3.36kgf.m, 14.8 ~ 24.3lb-ft)
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| 19. |
Install the drive belt (A).
Crankshaft pulley → A/C pulley → Alternator pulley → Idler #1 pulley → Idler
#2 pulley → Water pump pulley → Tensioner pulley.
Rotate the drive belt tensioner arm (B) counterclockwise moving the tensioner
pulley bolt with wrench. After putting the belt on the tensioner pulley,
release the tensioner pulley slowly.
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| 20. |
Install cylinder head cover.
| (1) |
The hardening sealant
located on the upper area between timing chain cover and cylinder
head should be removed before assembling cylinder head cover.
|
| (2) |
After applying sealant,
it should be assembled within 5 minutes.
Bead width : 2.5mm
(0.10in.)
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| (3) |
Install the cylinder
head cover (A) by tightening the bolts as following method.
Tightening torque
1st step: 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
2nd step: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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|
• |
Do not
reuse cylinder head cover gasket. |
|
• |
The firing
and/or blow out test should not be performed within
30 minutes after the cylinder head cover was assembled.
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| 21. |
Install the front engine hanger
(B) and then connect the PCV (Positive crankcase ventilation) hose (A).
Tightening torque :27.5
~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)
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| 22. |
Install the high pressure fuel
pump (A) and the roller tappet (B). (Refer to FL group)
Tightening torque :12.7
~ 14.7N.m (1.3 ~ 1.5kgf.m, 9.4 ~ 10.8lb-ft)
|
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Before installing the high pressure fuel pump, position the roller
tappet in the lowest position (BDC) by rotating the crankshaft.
Otherwise the installation bolts may be broken because of tension
of the pump spring. |
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Do not use already used bolt again. |
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When tightening the installation bolts of the high pressure fuel
pump, tighten in turn the bolts in small step (0.5 turns) after
tightening them with hand-screwed torque. |
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Note that internal damage may occur when the component is dropped.
In this case, use it after inspecting. |
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Apply engine oil to the O-ring (A) of the high pressure fuel pump,
the roller tappet (B), and the protrusion (C). Also apply engine
oil to the groove where the protrusion is installed. |
|
| 23. |
Install the high pressure pipe
(A). (Refer to FL group)
Tightening torque :Bolt
: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Nuts : 26.5 ~ 32.4N.m (2.7 ~ 3.3kgf.m, 19.5 ~ 23.9lb-ft)
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Do not reuse the high pressure pipe. |
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| 24. |
Connect PCSV (Purge control solenoid
valve) connector (A) and tighten the vacuum pipe assembly mounting bolts
and nut.
|
| 25. |
Connect the fuel hose (A) and
PCSV (Purge control solenoid valve) hose (B).
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| 26. |
Install the ignition coils (A).
Tightening torque :3.9
~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
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| 27. |
Connect the ignition coil connectors
(A) and fuel pump connector (B) after installing the wiring protector.
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| 28. |
Connect the exhaust OCV (Oil
control valve) connector (A) and the oxygen sensor connector (B).
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| 29. |
Install the under covers (A,B).
Tightening torque :7.8
~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
|
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When installing the cover (B), install the cover with the mounting
bracket. |
|
| 30. |
Install the intercooner inlet
pipe & hose assembly (C) ans then connect the recirculation valve connector
(A) and the vacuum hose (B).
Tightening torquePipe mounting
bolt:
14.7 ~ 19.6 N.m (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)
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| 31. |
Install the intercooler inlet
hose (A).
Tightening torque:4.9 ~
6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)
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| 32. |
Install the RH front wheel. |
| 33. |
Install the air cleaner assembly.
| (1) |
Install the air cleaner
assembly (E) and then connect the air intake hose (D).
Tightening torque
Hose clamp bolt :
2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Air cleaner assembly bolts :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
|
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| (2) |
Connect the breather
hose (A), the recirculation hose (B) and the brake booster vacuum
hose (C).
|
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| 34. |
Install the air duct (B).
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| 35. |
Connect the battery negative
terminal (A).
Tightening torque:4.0 ~
6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
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| 36. |
Install the engine cover. |
| 37. |
Add all the necessary fluids
and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.
| •
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Refill engine
with engine oil. |
| •
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Refill a transaxle
with fluid. |
| •
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Refill a radiator
and a reservoir tank with engine coolant. |
| •
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Clean battery
posts and cable terminals and assemble. |
| •
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Inspect for fuel
leakage. |
| -
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After assemble
the fuel line, turn on the ignition switch (do not operate
the starter) so that the fuel pump runs for approximately
two seconds and fuelline pressurizes. |
| -
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Repeat this operation
two or three times, then check for fuel leakage at any point
in the fuel line. |
| •
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Refill radiator
and reservoir tank with engine coolant. |
| •
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Bleed air from
the cooling system. |
| -
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Start engine
and let it run until it warms up. (until the radiator fan
operates 3 or 4 times.) |
| -
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Turn Off the
engine. Check the level in the radiator, add coolant if
needed. This will allow trapped air to be removed from the
cooling system. |
| -
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Put radiator
cap on tightly, then run the engine again and check for
leaks |
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Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1.
Check the camshaft sprocket and
crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
...
Inspection