Kia Optima Hybrid: Engine Mechanical System / Specifications

Specifications

Description		Specifications	Limit
General
Type		In-line, DOHC	?
Number of cylinders		4	?
Bore		88 mm (3.464 in)	?
Hone		97 mm (3.819 in)	?
Total Displacement		2359 cc (143.90 cu in)	?
Compression ratio		13,0 ± 0,3 : 1	?
Firing order		1-3-4-2	?
Valve Timing
Intake Valve	Opens	BTDC 10° ~ BTDC 35°	?
Intake Valve	Closes	ABDC 100° ~ 55°	?
Exhaust Valve	Opens	BBDC 44° ~ 4°	?
Exhaust Valve	Closes	BTDC 0° ~ 40°	?
Valve Clearance [Engine Coolant Temperature: 20 °C]
Intake Valve		0.17 ~ 0.23 mm (0.0067 ~ 0.0090 in)
Exhaust Valve		0.27 ~ 0.33 mm (0.0106 ~ 0.0129 in)
Camshaft
Cam Lobe Height	Intake	43.30 mm (1.5748 in)	?
Cam Lobe Height	exhaust	44.50 mm (1.7520 in)	?
Journal Outside Diameter	Intake	No.1: 30 mm (1.1811 in) No.2, 3, 4, 5: 24 mm (0.9449 in)	?
Journal Outside Diameter	exhaust	No.1: 36 mm (1.4173 in) No.2, 3, 4, 5: 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 of Playback		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°	?
Valve Head Margin Thickness	Intake	1.02 mm (0.0401 in)	?
Valve Head Margin Thickness	exhaust	1.09 mm (0.0429 in)	?
Valve Stem-to-Guide Clearance	Intake	0.020 ~ 0.047 mm (0.00078 ~ 0.00185 in)	0.070 mm (0.00275 in)
Valve Stem-to-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 Inside 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
Seat Contact Width	Intake	1.16 ~ 1.46 mm (0.0457 ~ 0.0575 in)	?
Seat Contact Width	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		44.45 mm (1.7500 in)	?
Load		17.3 ± 0.6 kg/35.0 mm (38.14 ± 1.32 lb/1.3779 in) 33.0 ± 1.0 kg/26.5 mm (72.75 ± 2.20 lb/1.0433 in)	?
Out-of-Square		Less than 1.5°	?
Cylinder head cover
Gasket Surface Flatness		Total area less than 0.05 mm (0.0019 in) Less than 0.02 mm (0.0007 in) per section 100 mm (3.9370 in) x 100 mm (3.9370 in)	?
Manifold Mounting Surface Flatness	Intake	Less than 0.10 mm (0.0039 in.)	?
Manifold Mounting Surface Flatness	exhaust	Less than 0.10 mm (0.0039 in.)	?
Piston
Piston Outer Diameter		87.960 ~ 87.990 mm (3.46299 ~ 3.46417 in)	?
Piston-to-Cylinder Clearance		0.030 ~ 0.050 mm (0.00118 ~ 0.00197 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
Backlash	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	0.060 ~ 0.125 mm (0.00236 ~ 0.00492 in)	0.200 mm (0.00787 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 ~ 0.70 mm (0.0079 ~ 0.0275 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 Bore Inner Diameter		22.003 ~ 22.007 mm (0.86626 ~ 0.86642 in)	?
Piston Pin Bore Clearance		0.003 ~ 0.010 mm (0.00012 ~ 0.00039 in)	?
Connecting Rod Small End Bore Inner Diameter		22.005 ~ 22.011 mm (0.86634 ~ 0.86657 in)	?
Piston Pin-to-Connecting Rod 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)
Backlash		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)	?
Crankpin 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 of Playback		0.07 ~ 0.25 mm (0.0028 ~ 0.0098 in.)	0.30 mm (0.0118 in.)
Cylinder block
Cylinder Bore Diameter		88.00 ~ 88.03 mm (3.4645 ~ 3.4657 in.)	?
Gasket Surface Flatness		Total area less than 0.05 mm (0.0019 in) Less than 0.02 mm (0.0007 in) per section 100 mm (3.9370 in) x 100 mm (3.9370 in)	?
Engine Oil
Oil Capacity	General	5.8 L (1.53 U.S. gal, 6.13 U.S. qt, 5.10 Imp. qt)	When replacing a short engine or engine assembly
	Oil Baffle	4.4 L (1.16 U.S. gal, 4.65 U.S. qt, 3.9 L Imp. qt)	?
	Drain and Refill	4.8 L (1.27 U.S. gal, 5.07 U.S. qt, 4.22 Imp. qt)	Including oil filter
Oil Grade	Recommended	ILSAC GF-4 (API SM) or higher / 5W-20
Oil Grade	Allowable	ILSAC GF-3, GF-4 (API SL, SM) or higher. For SAE viscosity grades according to ambient temperature, refer to "Lubrication System".	Use only if the recommended engine oil is not available.
Oil Pressure (at 1000 rpm)		118 kPa (1.2 kgf/cm², 17.1 psi) or higher	Oil Temperature (oil pan): 110±2 °C
Cooling System
Cooling Method		Water-cooled, pressurized Forced circulation by water pump	?
Coolant Capacity		6.6~6.9 L (1.74~1.82 U.S. gal, 6.97~7.29 U.S. qt, 5.81~6.07 Imp. qt)
Thermostat	Type	Wax Pellet Type	?
	Opening temperature	88±1.5°C (190.4±34.7°F)	?
	Full Open Lift / Temperature	More than 8 mm (0.3 in.) / 100 °C	?
Radiator Cap	Main Valve Opening Pressure	93.16 ~ 122.58 kPa (0.95 ~ 1.25 kgf/cm², 13.51 ~ 17.78 psi)	?
Radiator Cap	Vacuum Valve Opening Pressure	0 ~ 6.86 kPa (0 ~ 0.07 kgf/cm², 0 ~ 0.99 psi)	?

Tightening Torque

Item	Quantity	N·m	kgf·m	lb-ft
Engine Mounting
Engine Mounting Bracket to Body Bolt	4	58,8 ~ 73,5	6,0 ~ 7,5	43,4 ~ 54,2
Engine Mount Insulator to Engine Mount Bracket Nut	1	88,3 ~ 107,9	9,0 ~ 11,0	65,1 ~ 79,6
Engine Mount Support Bracket to Engine Mount Bracket Bolt	1	88,3 ~ 107,9	9,0 ~ 11,0	65,1 ~ 79,6
Engine Mount Support Bracket to Engine Mount Bracket Nut	2	88,3 ~ 107,9	9,0 ~ 11,0	65,1 ~ 79,6
Transaxle Mounting Bracket to Body Bolt	3	49,0 ~ 63,7	5,0 ~ 6,5	36,2 ~ 47,0
Transmission Mounting Bracket to Body Nut	1	49,0 ~ 63,7	5,0 ~ 6,5	36,2 ~ 47,0
Transmission Mount Bracket Mounting Bolt	2	58,8 ~ 78,5	6,0 ~ 8,0	43,4 ~ 57,9
Transmission Mount Bracket Nut	2	78,5 ~ 98,0	8,0 ~ 10,0	57,9 ~ 72,3
Transaxle Mounting Bracket to Transaxle Support Bracket Bolt	2	107,9 ~ 127,5	11,0 ~ 13,0	79,6 ~ 94,0
Steering Rod Bracket to Subframe Bolt	2	49,0 ~ 63,7	5,0 ~ 6,5	36,2 ~ 47,0
Steering Rod Bracket to Transmission Mounting Bolt and Nut	1	107,9 ~ 127,5	11,0 ~ 13,0	79,6 ~ 94,0
SYNC System
Tension Bolt	1	53,9 ~ 63,7	5,5 ~ 6,5	39,7 ~ 47,0
Drive Belt Tensioner Pulley Bolt	2	53,9 ~ 63,7	5,5 ~ 6,5	39,7 ~ 47,0
Drive belt tensioner bolt	2	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
Engine Support Bracket Bolt (M10)	3	39,2 ~ 44,1	4,0 ~ 4,5	28,9 ~ 32,5
Engine Support Bracket Bolt (M8)	1	19,6 ~ 24,5	2,0 ~ 2,5	14,5 ~ 18,1
Timing Chain Cover Service Hole Bolt	1	11,8 ~ 14,7	1,2 ~ 1,5	8,7 ~ 10,8
Timing Chain Cover Bolt (M6×25)	7	7,8 ~ 9,8	0,8 ~ 1,0	5,8 ~ 7,2
Timing Chain Cover Bolt (M8×28)	7	18,6 ~ 22,5	1,9 ~ 2,3	13,7 ~ 16,6
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 cover
Ignition Coil Bolt	4	3,9 ~ 5,9	0,4 ~ 0,6	2,9 ~ 4,3
Cylinder Head Cover Bolt	18	[3,9~5,9] + [7,8~9,8]	[0,4~0,6] + [0,8~1,0]	[2,9~4,3] + [5,8~7,2]
CVVT bolt (left/right)	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 mounting bolt (front/rear)	2	27,5 ~ 31,4	2,8 ~ 3,2	20,3 ~ 23,1
Camshaft Position Sensor (CMPS) (LH/RH)	2	9,8 ~ 11,8	1,0 ~ 1,2	7,2 ~ 8,7
Oil Control Valve (OCV) Bolt (Left/Right)	2	9,8 ~ 11,8	1,0 ~ 1,2	7,2 ~ 8,7
Cylinder block
Integrated Tensioner Bracket Assembly Bolt	7	39,2 ~ 44,1	4,0 ~ 4,5	28,9 ~ 32,5
Torsional Damper 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 (CKPS) Bolt	1	9,8 ~ 11,8	1,0 ~ 1,2	7,2 ~ 8,7
CKPS Cover Bolt (M6)	1	9,8 ~ 11,8	1,0 ~ 1,2	7,2 ~ 8,7
CKPS Cover Bolt (M8)	1	18,6 ~ 23,5	1,9 ~ 2,4	13,7 ~ 17,4
Knock Sensor Bolt	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 (M9–181.5)	4	[22,6~26,5] + [88~92°]	[2,3~2,7] + [88~92°]	[16,6~19,5] + [88~92°]
Balance Shaft Module (BSM) Bolt (M9–95)	2	[22,6~26,5] + [43~47°]	[2,3~2,7] + [43~47°]	[16,6~19,5] + [43~47°]
Oil pressure sensor	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 Assembly Bolt	5	18,6 ~ 23,5	1,9 ~ 2,4	13,7 ~ 17,4
Water Pump Cover Bolt	5	18,6 ~ 23,5	1,9 ~ 2,4	13,7 ~ 17,4
Water Inlet Bolt	3	7,8 ~ 11,8	0,8 ~ 1,2	5,8 ~ 8,7
Thermostat 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 Bolt	1	18,6 ~ 23,5	1,9 ~ 2,4	13,7 ~ 17,4
Intake and Exhaust System
Air intake hose clamp bolt	2	2,9 ~ 4,9	0,3 ~ 0,5	2,2 ~ 3,6
Air Cleaner Mounting 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 Mounting 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	44,1 ~ 49,0	4,5 ~ 5,0	32,5 ~ 36,2
Exhaust Manifold Heat Shield Bolt	4	7,8 ~ 11,8	0,8 ~ 1,2	5,8 ~ 8,7
Exhaust Manifold Mounting Bolt (M8)	2	18,6 ~ 27,5	1,9 ~ 2,8	13,7 ~ 20,3
Exhaust Manifold Mounting Bolt (M10)	2	51,9 ~ 57,8	5,3 ~ 5,9	38,3 ~ 42,6
Exhaust manifold nut	7	49,0 ~ 53,9	5,0 ~ 5,5	36,2 ~ 39,7
Catalytic Converter / Muffler Nut	8	39,2 ~ 58,8	4,0 ~ 6,0	28,9 ~ 43,4

Cylinder head, connecting rod caps and crankshaft main bearing cap bolts must be replaced after removal, as the bolts are designed to stretch permanently beyond their elastic limit. If the bolts are removed and reused, they may break or fail to maintain clamp load.

Specifications

Specifications

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