Kia Optima: Reassembly
| • |
Thoroughly clean all
parts to assembled. |
| • |
Before installing the
parts, apply fresh engine oil to all sliding and rotating surfaces. |
| • |
Replace all gaskets,
O-rings and oil seals with new parts. |
|
| 1. |
Assemble the piston and connecting
rod.
| (1) |
The piston front mark
and the connecting rod front mark must face the timing chain side
of the engine.
|
| (2) |
Before pressing the piston
pin, apply a coat of lubricant oil to the piston pin outer and connecting
rod.
|
• |
Take
care that piston pin is not damaged during reassemble
. |
|
• |
When
replace the piston pin, check the piston pin outer
diameter and connecting rod small end inner diameter
as below. Piston pin outer diameter : 21.997 ~
22.000mm (0.8660 ~ 0.8661in)
Piston pin hole inner diameter : 22.003mm ~ 22.007mm
(0.8662 ~ 0.8664in)Connecting rod small end inner
diameter : 22.005 ~ 22.011mm (0.8663 ~ 0.8665in)
Interference : -0.014mm ~ -0.005mm (0.0006 ~ 0.0002in) |
|
|
| (3) |
Set the snap ring in
one side of piston pin hole and insert the piston pin into the piston
pin hole & the small end bore of connecting rod while meeting the
front mark of connecting rod & piston.
|
Be sure to keep the small end bore, pistonpin hole & piston
pin from being damaged and scratched when inserting the
piston pin. |
|
Assembling condition
Temperature : piston side 70 to 80C , connecting rod
& pin is to be normal room temperature.
|
|
| (4) |
After inserting the piston
pin, set the snap ring of the other side.
|
Set the snap ring so that it contacts completely with the
groove of the piston pin hole. The snap ring must not
be deformed from the installation tooling method.
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|
|
| 2. |
Install the piston rings.
| (1) |
Install the oil ring
with coil spring by hand. |
| (2) |
Using a piston ring expander,
install the 2 compression rings with the code mark facing upward. |
| (3) |
Position the piston rings
so that the ring ends are as shown.
|
|
| 3. |
Install the connecting rod bearings.
| (1) |
Align the bearing claw
with the groove of the connecting rod or connecting rod cap. |
| (2) |
Install the bearings(A)
in the connecting rod and connecting rod cap(B).
|
|
| 4. |
Install the main bearings.
|
Upper bearings have an oil groove of oil holes; Lower bearings do
not. |
| (1) |
Align the bearing claw
with the claw groove of the cylinder block, push in the 5 upper
bearings(A).
|
| (2) |
Align the bearing claw
with the claw groove of the main bearing cap, and push in the 5
lower bearings. |
|
| 5. |
Install the thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the
cylinder block with the oil grooves facing outward.
|
| 6. |
Install the oil jet (A).
Tightening torque24.5 ~
29.4Nm (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft)
|
|
| 7. |
Place the crankshaft(A) on the
cylinder block.
|
| 8. |
Place the main bearing caps on
cylinder block. |
| 9. |
Install the main bearing cap
bolts.
|
Always use new main bearing cap bolts. |
| •
|
The main bearing
cap bolts are tightened in 3 progressive steps. |
| •
|
If any of the
bearing cap bolts in broken or deformed, replace it. |
|
| (1) |
Apply a light coat of
engine oil on the threads and under the bearing cap bolts. |
| (2) |
Using the SST (09221-4A000),
install and uniformly tighten the 10 bearing cap bolts, in several
passes, in the sequence shown.
Tightening torque
14.7N.m (1.5kgf.m, 10.8lb-ft) + 27.5~31.4Nm (2.8~3.2kgf.m,
20.3~23.1lb-ft) + 120~125°
|
|
| (3) |
Check that the crankshaft
turns smoothly. |
|
| 10. |
Check crankshaft end play. |
| 11. |
Install piston and connecting
rod assemblies.
|
Before installing the pistons, apply a coat of engine oil to the
ring grooves and cylinder bores. |
| (1) |
Remove the connecting
rod caps, and slip short sections of rubber hose over the threaded
ends of the connecting rod bolts. |
| (2) |
Install the ring compressor,
check that the bearing is securely in place, then position the piston
in the cylinder, and tap it in using the wooden handle of a hammer. |
| (3) |
Stop after the ring compressor
pops free, and check the connecting rod-to-check journal alignment
before pushing the piston into place. |
| (4) |
Apply engine oil to the
bolt threads. Using the SST (09221-4A000), install the rod caps
with bearings, and torque the bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°
|
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Always use new connecting rod cap bolts. |
|
Maintain downward force on the ring compressor to prevent
the rings from expanding before entering the cylinder bore. |
|
|
| 12. |
Apply liquid gasket to the mating
surface of cylinder block and ladder frame.
| •
|
When assembling
ladder frame, the liquid sealant Loctite 5900H, Threebond
1217H or equivalent should be applied ladder frame. |
| •
|
The part must
be assembled within 5 minutes after sealant was applied. |
| •
|
Apply sealant
to the inner threads of the bolt holes. |
|
|
| 13. |
Install ladder frame(A) with
10 bolts, in several passes, in sequence shown.
Tightening torqueStep 1
: 8.8 ~ 9.8N.m (0.9 ~ 1.0kgf.m, 6.5 ~ 7.2lb-ft)
Step 2 : 17.7 ~20.6N.m (1.8 ~ 2.1kgf.m, 13.0 ~ 15.2lb-ft)Step
3 : 27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)
|
| (1) |
Tighten the bolts in
order number as shown with the 3 steps. |
| (2) |
Loosen the bolts as reverse
tightening order. |
| (3) |
Tighten the bolts in
order number as shown with the 3 steps. |
|
| 14. |
Install rear oil seal.
| (1) |
Apply engine oil to a
new oil seal lip. |
| (2) |
Using SST(09231-H1100,
09214-3K100) (B) and a hammer, tap in the oil seal (A) until its
surface is flush with the rear oil seal retainer edge.
|
|
| 15. |
Install CKPS (Crankshaft position
sensor) (A) and sensor cover (B).
Tightening torque9.8 ~
11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
|
|
| 16. |
Install oil pressure switch.
| (1) |
Apply adhesive to 2 or
3 threads. Adhesive : MS 721-39(B) or equivalent.
|
| (2) |
Install the oil pressure
switch (A).
Tightening torque
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
|
|
|
| 17. |
Install knock sensor(A).
Tightening torque18.6 ~
23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
|
|
| 18. |
Install oil level gauge assembly.
| (1) |
Install a new O-ring
on the oil level gauge. |
| (2) |
Apply engine oil on the
O-ring. |
| (3) |
Install the oil level
gauge assembly(A) with the bolt.
Tightening torque
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
|
|
|
| 19. |
Install tensioner assembly integrated
bracket(A).
Tightening torque39.2 ~
44.1N.m (4.0 ~ 4.5kgf.m, 28.9 ~ 32.5lb-ft)
|
|
| 20. |
Install the water pump. (Refer
to Cooling system in this group) |
| 21. |
Install the alternator. (Refer
to EE group) |
| 22. |
Install the balance shaft & oil
pump assembly. (Refer to Lubrication system in this group) |
| 23. |
Install the cylinder head assembly.
(Refer to Cylinder head in this group) |
| 24. |
Install the timing chain. (Refer
to Timing system in this group) |
| 25. |
Install the intake manifold and
exhaust manifold.
(Refer to Intake and exhaust system in this group)
|
| 26. |
Remove the engine from the engine
stand. |
| 27. |
AT : Install the drive plate
(A) and the adapter plate (B) (AT).
Tightening torque :117.7
~ 127.5N.m (12.0 ~ 13.0kgf.m, 86.8 ~ 93.9lb-ft)
|
MT : Install the flywheel.
Tightening torque :117.7
~ 127.5N.m (12.0 ~ 13.0kgf.m, 86.8 ~ 93.9lb-ft)
|
| •
|
Always use new
drive plate (or flywheel) bolts. |
| •
|
Apply sealant
to the screw part (10mm from the end of the bolt) when reusing
the drive plate bolts.
Sealant: Three
bond 2403, Loctite 200 or 204
|
|
| •
|
Install and uniformly
tighten the 7 bolts, in several passes. |
|
|
| 28. |
Install the engine assembly on
the vehicle. (Refer to Engine and transaxle assembly in this group)
Add all fluids to their normal operating levels. |
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
Cooling System