Kia Optima DL3 Quiz

Engine Mechanical System

In this manual: Engine Mechanical System
General Information — 8Advanced Driver Assistance System (ADAS) — 21Maintenance — 27Engine Mechanical System — 45Engine Electrical System — 11Emission Control System — 11Engine Control System/Fuel System — 25Automatic Transmission — 20Drive Shaft and Axle — 7Suspension System — 22Steering — 7Restraints — 11Brake System — 22Body (Interior and Exterior) — 116Body Electrical System — 90Heating, Ventilation, and Air Conditioning — 32
20steps
~155min
5/5difficulty
7special tools
Done 0 of 20

Special Service Tools

Special Service Tools

Tool Name/Number Illustration Description
Front Crankshaft Oil Seal Installer
09231-2E000
Used to install the front crankshaft oil seal.
Rear Crankshaft Oil Seal Installer
09214-2E000 (Installer)
09231-H1100 (Handle)
Used to install the rear crankshaft oil seal.
Valve Spring Compressor and Retainer
09222-3K000 (Compressor)
09222-3K100 (Handle)
Used to remove/install intake or exhaust valve
Valve Stem Oil Seal Cap Installer
09222-2E000
Used to install the valve stem oil seal.
Flywheel/Drive Plate Stopper
09231-3N100
09231-2B100
Used to prevent the flywheel from rotating when removing/installing the crankshaft pulley bolt.
Flywheel/Drive Plate Stopper
09231-3D100
09231-2W100
Used to prevent the flywheel from rotating when removing/installing the crankshaft pulley bolt.
Oil Pan Remover
09215-3C000
Used to remove the oil pan.
Tensioner Stopper Pin
09240-2E100
Used to hold the compressed tensioner plunger.
Oil Filter Wrench
09263-2E000
Used to remove/install the oil filter.
Steel Ball Installer
0K221-2M100
Used to install the steel ball.
Radiator Cap Pressure Tester
0K253-G5100
Used to check the radiator cap sealing pressure and coolant leakage.

Compression Test

Compression Pressure Test

  1. Warm up and stop the engine.

    Allow the engine to warm up to normal operating temperature.

  2. Disconnect the injector connectors (A).

  3. Remove the spark plugs.

    (Refer to Engine Electrical System - Spark Plug)

  4. Check the compression pressure in the cylinder.

    1. Insert the compression gauge into the spark plug hole.

    2. Fully open the throttle valve.

    3. While cranking the engine, measure the compression pressure.

    4. Repeat steps (1) through (3) for each cylinder.

      Compression pressure:

      1275 kPa (13.0 kgf/cm², 185 psi)

      Minimum pressure:

      1128 kPa (11.5 kgf/cm², 164 psi)

      Difference between each cylinder:

      100 kPa (1.0 kgf/cm², 15 psi) or less

    5. If compression in one or more cylinders is low, add a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (1) through (3) for the cylinders with low compression.

      • If adding oil improves compression, the piston rings and/or cylinder bore are likely worn or damaged.

      • If the pressure remains low, a valve may be stuck or improperly seated, or there may be a leak past the cylinder head gasket.

  5. Install the remaining parts in the reverse order of removal.

  6. Some DTCs may remain after the inspection test and may need to be cleared manually using KDS.

Troubleshooting

Troubleshooting

Symptom Suspected Area Remedy
Engine misfire with abnormal internal low engine noise

  • Worn crankshaft bearings

  • Loose or out-of-specification engine flywheel

  • Replace the crankshaft and bearings if necessary.

  • Repair or replace the flywheel if necessary.
Worn piston rings
(Oil consumption may or may not cause engine misfire.)		 Inspect the cylinder for loss of compression.
Repair or replace if necessary.
Worn crankshaft thrust bearings Replace the crankshaft and bearings as necessary.
Engine misfire with abnormal valve train noise Stuck valves
(Carbon on valve stem)		 Repair or replace if necessary.
Excessively worn or misaligned timing chain Replace the timing chain and sprocket if necessary.
Worn camshaft lobes Replace the camshaft.
Engine misfire with coolant consumption

  • Faulty cylinder head gasket or other damage to the cylinder head and engine block cooling system

  • Coolant consumption may or may not cause engine overheating.

  • Inspect the cylinder head and cylinder block for damage to coolant passages and/or defective cylinder head gasket.

  • Repair or replace if necessary.
Engine misfire with excessive oil consumption Worn valves, valve guides, and/or valve stem seals Repair or replace if necessary.
Worn piston rings
(Oil consumption may or may not cause engine misfire)

  • Inspect the cylinder for loss of compression.

  • Repair or replace if necessary.
Engine noise at start-up that lasts only a few seconds
(Check and compare with a known good vehicle to determine normal condition.)		 Incorrect engine oil viscosity

  • Drain the oil.

  • Fill with engine oil of the correct viscosity.
Worn crankshaft thrust bearing

  • Inspect the thrust bearing and crankshaft.

  • Repair or replace if necessary.
Engine noise is louder regardless of engine speed Low oil pressure Repair or replace if necessary.
Broken valve spring Replace the valve spring.
Worn or dirty valve lifters Replace the valve lifters.
Stretched 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 if necessary.
Worn camshaft lobes

  • Inspect the camshaft lobes.

  • Replace the camshaft if necessary.
Worn valve guides or valve stems Inspect the valves and valve guides, then repair or replace as necessary.
Valve sticking (carbon deposits on the valve stem or valve seat may cause the valve to remain open.) Inspect the valves and valve guides, then repair or replace as necessary.
Worn drive belt, tensioner, idler, and bearing Replace as necessary.
Low engine noise regardless of crankshaft speed. Low oil pressure Repair or replace as required.
Loose or damaged flywheel Repair or replace the flywheel.
Damaged oil pan, contact with oil pump strainer

  • Inspect the oil pan.

  • Inspect the oil pump strainer.

  • Repair or replace if necessary.
Oil pump strainer loose, damaged, or clogged

  • Inspect the oil pump strainer.

  • Repair or replace if necessary.
Excessive piston-to-cylinder clearance

  • Inspect the piston, piston pin, and cylinder bore.

  • Repair or replace if necessary.
Excessive piston pin-to-piston clearance

  • Inspect the piston, piston pin, and connecting rod.

  • Repair or replace if necessary.
Excessive connecting rod bearing clearance Inspect the following components and repair or replace if necessary.

  • Connecting rod bearings.

  • Connecting rods.

  • Crankshaft thrust washers.
Excessive crankshaft bearing clearance Inspect the following components and repair or replace if necessary.

  • Crankshaft bearings.

  • Crankshaft main journals.

  • Cylinder block
Incorrect installation of piston, piston pin, and connecting rod

  • Make sure the piston pins and connecting rods are installed correctly.

  • Repair as necessary.
Engine noise under load Low oil pressure Repair or replace if necessary.
Excessive connecting rod bearing clearance Inspect the following components and repair or replace if necessary:

  • Connecting rod bearings

  • Connecting Rods

  • Crankshaft
Excessive crankshaft bearing clearance Inspect the following components and repair or replace if necessary:

  • Crankshaft Bearings

  • Crankshaft Main Journals

  • Cylinder block
Engine does not start.
Crankshaft does not rotate.		 Hydraulic lock of cylinder

  • Coolant/antifreeze in cylinder

  • Oil in cylinder

  • Fuel in cylinder

  1. Remove the spark plugs and check for liquid.

  2. Inspect for a broken head gasket.

  3. Inspect the cylinder block or cylinder head for cracks.

  4. Inspect the fuel injector and/or fuel pressure regulator for sticking.
Broken timing chain and/or timing chain sprocket

  1. Inspect the timing chain and sprockets.

  2. Repair as necessary.
Material in cylinder

  • Broken valve

  • Piston material

  • Foreign material

  1. Inspect the cylinder for damaged components and/or foreign material.

  2. Repair or replace if necessary.
Seizure of crankshaft or connecting rod bearings

  1. Inspect the crankshaft and connecting rod bearings.

  2. Repair as necessary.
Bent or broken connecting rod

  1. Inspect the connecting rods.

  2. Repair as necessary.
Broken crankshaft

  1. Inspect the crankshaft.

  2. Repair as necessary.

Service Data

Service Data

Description Specifications Limit
General
Type In-line, DOHC
Number of cylinders 4
Bore 81.0 mm (3.1890 in)
Hone 97.0 mm (3.8189 in)
Total Displacement 1999 cc (121.99 cu in)
Compression ratio 10,3±0,2 : 1
Firing order 1 - 3 - 4 - 2
Valve Timing
Intake Valve Open BTDC 10° - BTDC 40°
Close 67° ABDC - 17° ABDC
Exhaust Valve Open BBDC 54° - BBDC 14°
Close BTDC 1° - BTDC 41°
Camshaft
Cam Lobe Height Intake 39.0 mm (1.5354 in)
exhaust 38.66 mm (1.5220 in)
Journal Outside Diameter Intake No. 1: 35.959–35.975 mm
(1.41571 - 1.41634 in)
No. 2, 3, 4, 5: 22.959 - 22.975 mm
(0.90390 - 0.90453 in)
exhaust No. 1: 35.959–35.975 mm
(1.41571 - 1.41634 in)
No. 2, 3, 4, 5: 22.959 - 22.975 mm
(0.90390 - 0.90453 in)
Bearing Oil Clearance Intake No. 1: 0.032–0.062 mm
(0.00126–0.00244 in)
No. 2, 3, 4, 5: 0.032 - 0.062 mm
(0.00126–0.00244 in)
exhaust No. 1: 0.032–0.062 mm
(0.00126–0.00244 in)
No. 2, 3, 4, 5: 0.032 - 0.062 mm
(0.00126–0.00244 in)
End of Playback 0.10–0.19 mm (0.0039–0.0075 in)
Valve
Valve Length Intake 102.22 mm (4.0244 in.) 101.97 mm (4.0146 in.)
exhaust 104.04 mm (4.0961 in.) 103.79 mm (4.0862 in.)
Stem Outer Diameter Intake 5.465–5.480 mm (0.21516–0.21575 in)
exhaust 5.458–5.470 mm (0.21488–0.21535 in)
Face Angle 45,25° - 45,75°
Valve Head Margin Thickness Intake 1.30 mm (0.0512 in.)
exhaust 1.26 mm (0.0496 in.)
Valve Stem-to-Guide Clearance Intake 0.020–0.047 mm (0.00079–0.00185 in)
exhaust 0.030–0.054 mm (0.00118–0.00213 in)
Valve Guide
Length Intake 43.8–44.2 mm (1.7244–1.7402 in)
exhaust 43.8–44.2 mm (1.7244–1.7402 in)
Inside diameters Intake 5.500–5.512 mm (0.21654–0.21701 in)
exhaust 5.500–5.512 mm (0.21654–0.21701 in)
Valve Seat
Seat Contact Width Intake 1.05–1.35 mm (0.0413–0.0532 in)
exhaust 1.35–1.65 mm (0.0532–0.0650 in)
Seat Angle Intake 44° 45' - 45° 6'
exhaust 44° 45' - 45° 6'
Valve Spring
Free Length 45.93 mm (1.8083 in.)
Load 19.6 ± 1.0 kg/37.0 mm
(43.21 ± 2.20 lb / 1.4567 in)
45.7 ± 1.8 kg/27.0 mm
(100.75 ± 3.97 lb / 1.0630 in)
Out-of-Square Less than 1.5°
Cylinder head cover
Gasket Surface Flatness Total area less than 0.05 mm (0.0020 in)
Less than 0.02 mm (0.0008 in) for each section
100 mm (3.9370 in) × 100 mm (3.9370 in)
Manifold Mounting Surface Flatness Intake Less than 0.10 mm (0.0039 in.)
exhaust Less than 0.10 mm (0.0039 in.)
Piston
Piston Outer Diameter 80.97–81.00 mm (3.1878–3.1890 in)
Piston-to-Cylinder Clearance 0.02–0.04 mm (0.0008–0.0016 in.)
Ring Groove Width No. 1 Ring 1.030–1.050 mm (0.04055–0.04134 in)
No. 2 Ring 1.230–1.250 mm (0.04843–0.04921 in)
Oil Ring 2.010–2.025 mm (0.07913–0.07972 in)
Piston Ring
Backlash No. 1 Ring 0.040–0.080 mm (0.00157–0.00315 in)
No. 2 Ring 0.040–0.080 mm (0.00157–0.00315 in)
Oil Ring 0.040–0.115 mm (0.00157–0.00453 in)
End Gap No. 1 Ring 0.15–0.30 mm (0.0059–0.0118 in)
No. 2 Ring 0.30–0.45 mm (0.0118–0.0177 in.)
Oil Ring 0.20–0.70 mm (0.0079–0.0276 in)
Piston pin
Piston Pin Outer Diameter 19.997–20.000 mm (0.78728–0.78740 in)
Piston Pin Bore Inner Diameter 20.004–20.009 mm (0.78756–0.78775 in)
Piston Pin Bore Clearance 0.004–0.012 mm (0.00016–0.00047 in)
Connecting Rod Small End Bore Inner Diameter 20.007–20.015 mm (0.78768–0.78799 in)
Piston Pin-to-Connecting Rod Bushing Oil Clearance 0.007–0.018 mm (0.00028–0.00070 in)
Connecting Rod
Connecting Rod Big End Inner Diameter 48.000–48.018 mm (1.88976–1.89047 in)
Connecting Rod Bearing Oil Clearance 0.024–0.042 mm (0.00094–0.00165 in)
Backlash 0.10–0.25 mm (0.0039–0.0098 in.)
Crankshaft
Main Journal Outer Diameter 54.942–54.960 mm (2.16307–2.16378 in)
Crankpin Outer Diameter 44.954–44.972 mm (1.76984–1.77055 in)
Main Bearing Oil Clearance 0.016–0.034 mm (0.00063–0.00134 in)
End of Playback 0.07–0.25 mm (0.0028–0.0098 in)
Cylinder block
Cylinder Bore Diameter 81.00–81.03 mm (3.1890–3.1902 in)
Gasket Surface Flatness Total area less than 0.05 mm (0.0020 in)
Less than 0.02 mm (0.0008 in) for each section 100 mm (3.9370 in) × 100 mm (3.9370 in)
Cooling System
Cooling Method Forced circulation with cooling fan
Coolant Capacity Approx. 6.3 L (1.66 US gal, 6.66 US qt, 5.54 liters)
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 125.52 - 154.94 kPa
(1.28–1.58 kgf/cm², 18.21–22.47 psi).
Vacuum Valve Opening Pressure 0–6.86 kPa (0–0.07 kgf/cm², 0–1.00 psi)

Liquid Gasket

Location Product
Mating surface of timing chain cover Threebond 1217H or equivalent
Front part of mating surface between camshaft holder and cylinder head
Front part of mating surface between cylinder block and cylinder head
Upper part of the mating surface between the timing chain cover and the camshaft holder
Front upper part of cylinder block
Front upper part of cylinder head gasket
Lower part of camshaft holder
Lower part of cylinder block
Mating surface of oil pan
Mating surface of oil pressure switch TRIPLE BOND 2403

Lubricants

Lubricants

Description Specifications Limit
Engine Oil
Oil Capacity General 4.5 L (1.19 U.S. gal, 4.76 U.S. qt, 3.96 L qt) When replacing a short engine or engine assembly
Oil Baffle 3.7 L (0.98 US gal, 3.91 US qt, 3.26 Imp qt)
Drain and Refill 4 L (1.06 US gal, 4.23 US qt, 3.52 Imp qt) Including oil filter
Oil Grade Specifications All (except Middle East, India, Libya, Algeria, Morocco, Tunisia, Sudan, Egypt, Iran):
- ILSAC GF-4 and API SM or higher / 5W-20
- ACEA A5 or higher / 5W-20
Middle East, India, Libya, Algeria, Morocco, Tunisia, Sudan, Egypt, Iran:
- ACEA A5 or higher / 5W-30
Oil Pressure (at 1000 rpm) 98.07 kPa (1.0 kgf/cm², 14.22 psi) or higher Oil Temperature (oil pan): 110±2 °C

Tightening Torque

Tightening torque

Item N·m kgf·m ft·lbf lb•inIb.in
Engine Mounting
Engine mount bracket and body mount insulator 68,6 - 88,3 7,0 - 9,0 50,6 - 65,1
Engine mount bracket and engine mount bracket bolt 88,3 - 107,9 9,0 - 11,0 65,1 - 79,6
Engine mount bracket and engine mount bracket nuts 88,3 - 107,9 9,0 - 11,0 65,1 - 79,6
Engine mount insulator and engine mount bracket support nut 88,3 - 107,9 9,0 - 11,0 65,1 - 79,6
Transaxle mount bracket and body mount bolts 68,6 - 88,3 7,0 - 9,0 50,6 - 65,1
Transaxle mount insulator and transaxle mount bracket support bolts 107,9 - 127,5 11,0 - 13,0 79,6 - 94,0
Steering tie rod bracket and subframe mounting bolts 49,0 - 63,7 5,0 - 6,5 36,1 - 47,0
Link Bracket to Link Support Bracket Mounting Bolt 107,9 - 127,5 11,0 - 13,0 79,6 - 94,0
Cylinder head cover
Engine Cover Mounting Bolt 7,8 - 9,8 0,8 - 1,0 5,8 - 7,2
Cylinder Head Cover Bolt [3,9–5,9] + [7,8–9,8] [0,4–0,6] + [0,8–1,0] [2,9–4,3] + [5,8–7,2] [34,5 - 52,1] + [69,0 - 86,7]
CVVT bolt (left/right) 64,7 - 76,5 6,6 - 7,8 47,7 - 56,4
Camshaft Bearing Cap Bolt (M6) 11,8 - 13,7 1,2 - 1,4 8,7 - 10,1
Camshaft bearing cap bolt (M8) 18,6 - 22,6 1,9 - 2,3 13,7 - 16,6
Camshaft bracket bolt 18,6 - 22,6 1,9 - 2,3 13,7 - 16,6
Cylinder head bolt [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) 34,3 - 39,2 3,5 - 4,0 25,3 - 28,9
Camshaft Position Sensor (Left/Right) 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Oil Control Valve (OCV) Bolt (Left/Right) 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Cylinder block
Drive plate bolt (transaxle) 117,7 - 127,5 12,0 - 13,0 86,8 - 93,9
Connecting Rod Bearing Cap Bolt [17,7–21,6] + [88–92°] [1,8–2,2] + [88–92°] [13,0–15,9] + [88–92°]
Oil Pan Lower Bolt 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Main Bearing Cap Bolt [27,5–31,4] + [120–125°] [2,8–3,2] + [120–125°] [20,3–23,1] + [120–125°]
Crankshaft Position Sensor Bolt 10,8 - 11,8 1,1 - 1,2 8,0 - 8,7
Knock sensor 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Lubrication System
Oil Drain Plug 34,3 - 44,1 3,5 - 4,5 25,3 - 32,5
Oil Filter 11,8 - 15,7 1,2 - 1,6 8,7 - 11,6
Oil Pan Bolt 11,8 - 13,7 1,2 - 1,4 8,7 - 10,1
Oil Filter Bolt 19,6 - 26,5 2,0 - 2,7 14,5 - 19,5
Oil screen nut 11,8 - 13,7 1,2 - 1,4 8,7 - 10,1
Oil pressure sensor 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Cooling System
Water Pump Pulley Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Water pump bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Water inlet fitting nut 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Water temperature control assembly bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Heater hose bolt 19,6 - 23,5 2,0 - 2,4 14,5 - 17,4
Intake and Exhaust System
Air Cleaner Mounting Bolt 7,8 - 9,8 0,8 - 1,0 5,8 - 7,2
Electronic Throttle Control (ETC) module bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Intake Manifold Mounting Bolt 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Intake manifold bolt 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Intake manifold nut 18,6 - 23,5 1,9 - 2,4 13,7 - 17,4
Exhaust Manifold Heat Shield Bolt 9,8 - 11,8 1,0 - 1,2 7,2 - 8,7
Exhaust Manifold Stud Bolt 39,2 - 49,0 4,0–5,0 28,9 - 36,2
Exhaust manifold nut 29,4 - 34,3 3,0 - 3,5 21,7 - 25,3
Muffler Nut 39,2 - 58,8 4,0–6,0 28,9 - 43,4

Test yourself

A quick Kia Optima DL3 quiz: every answer comes with an explanation and a link to the manual page.