Kia Optima Hybrid manuals

Kia Optima Hybrid: Cylinder Block / Cylinder Block Repair procedures

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / Engine Mechanical System / Cylinder Block / Cylinder Block Repair procedures

Disassembly
   
•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
•
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
•
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
•
Turn the crankshaft pulley so that the No.1 piston is at top dead center.
   
Mark all wiring and hoses to avoid misconnection.
1.
Remove the engine and transaxle assembly from the vehicle. (Refer to Engine and transaxle assembly in this group)
2.
Remove the transaxle assembly. (Refer to AT group)
3.
Remove the torsion damper (A).

4.
Install the engine to an engine stand for disassembly.
5.
Remove the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group)
6.
Remove the timing chain. (Refer to Timing system in this group)
7.
Remove the cylinder head assembly. (Refer to Cylinder head in this group)
8.
Remove the balance shaft & oil pump assembly. (Refer to Lubrication system in this group)
9.
Remove the A/C compressor and bracket assembly. (Refer to HA group - "Electric A/C compressor")

10.
Remove the hybrid starter generator (HSG). (Refer to HT group - "Hybrid starter generator")
11.
Remove the water pump assembly. (Refer to Cooling system in this group)
12.
Remove the tensioner assembly integrated bracket (A).

13.
Remove the oil level gauge tube (A).

14.
Remove the knock sensor (A) and the oil pressure switch (OPS) (B).

15.
Remove the crankshaft position sensor (CKPS) (A) after removing the cover (B).

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 2 side rails and the spacer by hand.
   
Arrange the piston rings in the correct order only.
26.
Remove the snap rings and then disconnect the connecting rod from the piston.
Inspection
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~ 0.25mm (0.0039 ~ 0.0098in.)
Limit : 0.35mm (0.0138in.)

•
If out-of-tolerance, install a new connecting rod.
•
If still out-of-tolerance, replace the crankshaft.
2.
Check the connecting road bearing oil clearance.
(1)
Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2)
Remove 2 connecting rod cap bolts.
(3)
Remove the connecting rod cap and bearing half.
(4)
Clean the crank pin and bearing.
(5)
Place plastigage across the crank pin.
(6)
Reinstall the bearing half and cap, and torque the bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°
   
•
Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
•
Do not turn the crankshaft.
(7)
Remove 2 bolts, connecting rod cap and bearing half.
(8)
Measure the plastigage at its widest point.
Standard oil clearance
0.031 ~ 0.045mm (0.00122 ~ 0.00177in.)

(9)
If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
   
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10)
If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
   
•
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
•
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
Connecting Rod Identification Mark

Connecting Rod Specifications
Class
Mark
Inside Diameter
a
A
51.000 ~ 51.006mm
(2.00787 ~ 2.00811in.)
b
B
51.006 ~ 51.012mm
(2.00811 ~ 2.00834in.)
c
C
51.012 ~ 51.018mm
(2.00834 ~ 2.00858in.)

Crankshaft Pin Identification Mark

   
Conform to read stamping order as shown arrow direction from #1.
Crankshaft Specifications
Class
Mark
Outside Diameter Of Pin
I
1
47.966 ~ 47.972mm
(1.88842 ~ 1.88866in.)
II
2
47.960 ~ 47.966mm
(1.88819 ~ 1.88842in.)
III
3
47.954 ~ 47.960mm
(1.88795 ~ 1.88819in.)

Connecting Rod Bearing Identification Mark

Connecting Rod Bearing Specifications
Class
Mark
Thickness Of Bearing
AA
Blue
1.515 ~ 1.518mm
(0.05965 ~ 0.05976in.)
A
Black
1.512 ~ 1.515mm
(0.05953 ~ 0.05965in.)
B
None
1.509 ~ 1.512mm
(0.05941 ~ 0.05953in.)
C
Green
1.506 ~ 1.509mm
(0.05929 ~ 0.05941in.)
D
Yellow
1.503 ~ 1.506mm
(0.05917 ~ 0.05929in.)

(11)
Select a connecting rod bearing using the selection chart.
Selection Chart For Connecting Rod Bearings
Crankshaft Indentification Mark
Connecting Rod Identification Mark
Assembing Classification Of Bearing
I (1)
a (A)
D (Yellow)
b (B)
C (Green)
c (C)
B (None)
II (2)
a (A)
C (Green)
b (B)
B (None)
c (C)
A (Black)
III (3)
a (A)
B (None)
b (B)
A (Black)
c (C)
AA (Blue)

3.
Inspect the connecting rods.
(1)
When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
(2)
Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
(3)
Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.
Allowable bend of connecting rod :
0.05mm (0.0020 in.) or less for 100mm (3.94 in.)
Allowable twist of connecting rod :
0.10mm (0.0039 in.) or less for 100mm (3.94 in.)
Crankshaft
1.
Check the crankshaft bearing oil clearance.
(1)
To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
(2)
Clean each main journal and bearing half with a clean shop towel.
(3)
Place one strip of plastigage across each main journal.
(4)
Reinstall the bearings and caps, then torque the bolts.
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°
   
•
Always use new crankshaft main bearing cap bolts. Crankshaft main bearing cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
•
Do not turn the crankshaft.
(5)
Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance
0.020 ~ 0.038mm (0.00079 ~ 0.00150in.)

(6)
If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
   
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(7)
If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
   
•
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
•
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
Crankshaft Bore Identification Mark

Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.
Cylinder Block Specifications
Calss
Mark
Inside Diameter
a
A
56.000 ~ 56.006mm
(2.20472 ~ 2.20496in.)
b
B
56.006 ~ 56.012mm
(2.20496 ~ 2.20519in.)
c
C
56.012 ~ 56.018mm
(2.20519 ~ 2.20543in.)

Crankshaft Journal Identification Mark

   
Conform to read stamping order as shown arrow direction from #1.
Crankshaft Specifications
Class
Mark
Outside Diameter Of Journal
I
1
51.954 ~ 51.960mm
(2.04543 ~ 2.04567in.)
II
2
51.948 ~ 51.954mm
(2.04519 ~ 2.04543in.)
III
3
51.942 ~ 51.948mm
(2.04496 ~ 2.04519in.)

Crankshaft Bearing Identification Mark

Crankshaft Bearing Specifications
Class
Mark
Thickness Of Bearing
AA
Blue
2.026 ~ 2.029mm
(0.07976 ~ 0.07988in.)
A
Black
2.023 ~ 2.026mm
(0.07965 ~ 0.07976in.)
B
None
2.020 ~ 2.023mm
(0.07953 ~ 0.07965in.)
C
Green
2.017 ~ 2.020mm
(0.07941 ~ 0.7953in.)
D
Yellow
2.014 ~ 2.017mm
(0.07929 ~ 0.07941in.)

(8)
Select a crankshaft bearing using the selection chart.
Selection Chart For Crankshaft Bearings
Crankshaft Identification Mark
Crankshaft Bore Identification Mark
Assembling Classification Of Bearing
I (1)
a (A)
D (Yellow)
b (B)
C (Green)
c (C)
B (None)
II (2)
a (A)
C (Green)
b (B)
B (None)
c (C)
A (Black)
III (3)
a (A)
B (None)
b (B)
A (Black)
c (C)
AA (Blue)

2.
Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
End play
Standard : 0.07 ~ 0.25mm (0.0028 ~ 0.0098in.)
Limit : 0.30mm (0.0118in.)

If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness
1.925 ~ 1.965mm (0.07579 ~ 0.07736in.)
3.
Inspect main journals and crank pins.
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
51.942 ~ 51.960mm (2.04496 ~ 2.04567in.)
Crank pin diameter :
47.954 ~ 47.972mm (1.88795 ~ 1.88866in.)

Cylinder Block
1.
Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2.
Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3.
Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard : Less than 0.05mm (0.0019in.) for all
Less than 0.02 (0.0007in.) for 100mm (3.9370in.) x 100mm (3.9370in.)

4.
Inspect cylinder bore diameter.
Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder block.
5.
Inspect cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter
88.00 ~ 88.03mm (3.4645 ~ 3.4657in.)

   
Measure position points (from the bottom of the cylinder block)
: 110.7mm(4.3582in.)/160mm(6.2992in.)/210mm(8.2677in.)
6.
Check the cylinder bore size code on the cylinder block.

Cylinder Bore Inner Diameter
Size Code
Cylinder Bore Inner Diameter
A
88.00 ~ 88.01mm
(3.4645~ 3.4649in.)
B
88.01 ~ 88.02mm
(3.4649~ 3.4653in.)
C
88.02 ~ 88.03mm
(3.4653~ 3.4657in.)

7.
Check the piston size code on the piston top face.

H5 : HEV 2.4L
A : Grade
II : Theta II
   
Stamp the grade mark of basic diameter with rubber stamp.
Piston Outer Diameter
Size Code
Piston Outer Diameter
A
87.960 ~ 87.970mm
(3.46299~ 3.46338in.)
B
87.970 ~ 87.980mm
(3.46338~ 3.46377in.)
C
87.980 ~ 87.990mm
(3.46377~ 3.46417in.)

8.
Select the piston related to cylinder bore class.
Clearance : 0.030 ~ 0.050mm (0.00118 ~ 0.00197in.)
Piston And Rings
1.
Clean piston
(1)
Using a gasket scraper, remove the carbon from the piston top.
(2)
Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3)
Using solvent and a brush, thoroughly clean the piston.
   
Do not use a wire brush.
2.
The standard measurement of the piston outside diameter is taken 17mm (0.67in.) from the bottom of the piston.
Standard diameter
87.960 ~ 87.990mm (3.46299 ~ 3.46417in.)

3.
Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.030 ~ 0.050mm (0.00118 ~ 0.00197in.)
4.
Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance
Standard
No.1 : 0.050 ~ 0.080mm (0.00197 ~ 0.00315in.)
No.2 : 0.040 ~ 0.080mm (0.00157 ~ 0.00315in.)
Oil ring : 0.060 ~ 0.125mm (0.00236 ~ 0.00492in.)
Limit
No.1 : 0.100mm (0.00394in.)
No.2 : 0.100mm (0.00394in.)
Oil ring : 0.200mm (0.00787in.)

If the clearance is greater than maximum, replace the piston.
5.
Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits, If the bore is over the service limit, the cylinder block must be replaced.
Piston ring end gap
Standard
No.1 : 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
No.2 : 0.37 ~ 0.52mm (0.0145 ~ 0.0204in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)
Limit
No.1 : 0.60mm (0.0236in.)
No.2 : 0.70mm (0.0275in.)
Oil ring : 0.80mm (0.0315in.)

Piston Pins
1.
Measure the diameter of the piston pin.
Piston pin diameter
21.997 ~ 22.000mm (0.86602 ~ 0.86614in.)

2.
Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance
0.003 ~ 0.010mm (0.00012 ~ 0.00039in.)
3.
Check the clearance between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod clearance
0.005 ~ 0.014mm (0.00020 ~ 0.00055in.)
Reassembly
   
•
Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
•
Always use new crankshaft main bearing cap bolts. Crankshaft main bearing cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
•
Replace all gaskets, O-rings and oil seals with new parts.
•
Thoroughly clean all parts to be assembled.
•
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
1.
Assemble the piston and connecting rod.
(1)
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 pressing process.
•
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 (0.86602 ~ 0.86614in.)
Connecting rod small end inner diameter :
22.005 ~ 22.011mm (0.86634 ~ 0.86657in.)
(2)
The piston front mark and the connecting rod front mark (A) must face the timing chain side of the engine.

2.
Install the piston rings.
(1)
Install the oil ring spacer and 2 side rails 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).

   
Be careful not to change the position of bearing caps.
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 torque:
24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7 lb-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.
   
•
The main bearing cap bolts are tightened in 3 progressive steps.
•
If any of the bearing cap bolts is broken ordeformed, replace it.
•
Always use new crankshaft main bearing cap bolts. Crankshaft main bearing cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
(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°
   
•
Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
   
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 torque
Step 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) 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 torque
CKPS (A) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
M6 Bolt (C) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
M8 Bolt (D) : 18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

16.
Install OPS (Oil pressure switch).
(1)
Apply adhesive to 2 or 3 threads.
Adhesive : MS 721-39(B) or equivalent.
(2)
Install the oil pressure switch (B).
Tightening torque
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
17.
Install knock sensor (A).
Tightening torque
18.6 ~ 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 torque
39.2 ~ 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 HSG (Hybrid starter generator). (Refer to HT group - "Hybrid starter generator")
22.
Install the A/C compressor and bracket assembly. (Refer to HA group - "Electric A/C compressor")

23.
Install the balance shaft & oil pump assembly. (Refer to Lubrication system in this group)
24.
Install the cylinder head assembly. (Refer to Cylinder head in this group)
25.
Install the timing chain. (Refer to Timing system in this group)
26.
Install the intake manifold and exhaust manifold.
(Refer to Intake and exhaust system in this group)
27.
Remove the engine from the engine stand.
28.
Install the torsion damper (A).
Tightening torque :
117.7 ~ 127.5N.m (12.0 ~ 13.0kgf.m, 86.8 ~ 93.9lb-ft)

   
•
Always use new bolts.
•
Apply sealant to the screw part (10mm (0.39in) from the end of the bolt) when reusing the bolts.
Sealant: Three bond 2403, Loctite 200 or 204
•
Install and uniformly tighten the 7 bolts, in several passes.
29.
Install the transaxle assembly. (Refer to AT group - "Automatic transaxle")
30.
Install the engine and transaxle assembly on the vehicle. (Refer to Engine and transaxle assembly in this group)
31.
Installation is in the reverse order of removal.
Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.
   
•
Adjust a shift cable.
•
Refill engine with engine oil.
•
Refill a transaxle with fluid.
•
Refill an engine radiator and a reservoir tank with coolant.
•
Refill an inverter radiator and a reservoir tank with coolant.
•
Clean battery posts and cable terminals and assemble.
•
Inspect for fuel leakage.
–
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 fuel line pressurizes.
–
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
•
Bleed air from the hybrid motor cooling system. (Refer to HT group - "Coolant")
•
Bleed air from the engine cooling system.
–
Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
–
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.
Cylinder Block Components and Components Location

Components 1. Piston ring2. Piston3. Connecting rod 4. Connecting rod upper bearing5. Piston pin6. Connecting rod lower bearing7. Connecting rod bearing cap8. Ladder frame9. Oil filter bracket10. Crankshaft ...

Cooling System

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Other information:

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Electric Parking Brake (EPB) Description and Operation


Description Description of EPB The EPB is an electronic parking brake. The EPB is different from existing parking systems which operated with the brake pedal or the lever type. The EPB system sends the signal to the ECU when a driver operates the EPB switch. The ECU operates the EPB actuator composed ...

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: General Safety Information and Caution


Safety Precaution     Since hybrid vehicles contain a high voltage battery, if the high voltage system or vehicles are handled incorrectly, this might lead to a serious accidents like electric shock and electric leakage.     • Be sure to shut off the high voltage by removing the ...

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