Kia Optima Hybrid: Engine Mechanical System / Specifications

Specifications
Description
Specifications
Limit
General
Type
In-line, DOHC
?
Number of cylinders
4
?
Bore
88mm (3.464in.)
?
Stroke
97mm (3.819in.)
?
Total displacement
2359cc (143.90cu.in)
?
Compression ratio
13.0 ± 0.3 : 1
?
Firing order
1-3-4-2
?
Valve timing
Intake valve
Opens
ATDC 10° ~ BTDC 35°
?
Closes
ABDC 100° ~ 55°
?
Exhaust valve
Opens
BBDC 44° ~ 4°
?
Closes
ATDC 0° ~ 40°
?
Valve clearance [Engine coolant temperature : 20°C (68°F)]
Intake valve
0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust valve
0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
Camshaft
Cam height
Intake
43.30mm (1.5748in.)
?
Exhaust
44.50mm (1.7520in.)
?
Journal outer diameter
Intake
No.1 : ?nbsp; 30mm (1.1811in.)
No.2,3,4,5 : ?nbsp; 24mm (0.9449in.)
?
Exhaust
No.1 : ?nbsp; 36mm (1.4173in.)
No.2,3,4,5 : ?nbsp; 24mm (0.9449in.)
?
Bearing oil clearance
Intake
No.1 : 0.022 ~ 0.057mm (0.00087 ~ 0.00224in.)
No.2,3,4,5 : 0.045 ~ 0.082mm (0.00177 ~ 0.00323in.)
No.1 : 0.090mm (0.00354in.)
No.2,3,4,5 : 0.120mm (0.00472in.)
Exhaust
No.1 : 0 ~ 0.032mm (0 ~ 0.00126in.)
No.2,3,4,5 : 0.045 ~ 0.082mm (0.00177 ~ 0.00323in.)
End play
0.04 ~ 0.16mm (0.0016 ~ 0.0063in.)
0.20mm (0.0078in.)
Valve
Valve length
Intake
113.18mm (4.4559in.)
112.93mm (4.4461in)
Exhaust
105.84mm (4.1669in.)
105.59mm (4.1571in)
Stem outer diameter
Intake
5.465 ~ 5.480mm (0.21516 ~ 0.21575in.)
?
Exhaust
5.458 ~ 5.470mm (0.21488 ~ 0.21535in.)
?
Face angle
45.25° ~ 45.75°
?
Thickness of valve head (margin)
Intake
1.02mm (0.0401in.)
?
Exhaust
1.09mm (0.0429in.)
?
Valve stem to valve guide clearance
Intake
0.020 ~ 0.047mm (0.00078 ~ 0.00185in.)
0.070mm (0.00275in.)
Exhaust
0.030 ~ 0.054mm (0.00118 ~ 0.00212in.)
0.090mm (0.00354in.)
MLA outer diameter
31.964 ~ 31.980mm (1.2584 ~ 1.2590in.)
?
Tappet bore inner diameter
32.000 ~ 32.025mm (1.2598 ~ 1.2608in.)
?
MLA to tappet bore clearance
0.020 ~ 0.061mm (0.00078 ~ 0.00240in.)
0.070mm (0.00275in.)
Valve guide
Length
Intake
43.8 ~ 44.2mm (1.7244 ~ 1.7401in.)
?
Exhaust
43.8 ~ 44.2mm (1.7244 ~ 1.7401in.)
?
Inner diameter
Intake
5.500 ~ 5.512mm (0.21654 ~ 0.21701in.)

Exhaust
5.500 ~ 5.512mm (0.21654 ~ 0.21701in.)

Valve seat
Width of seat contact
Intake
1.16 ~ 1.46mm (0.0457 ~ 0.0575in.)
?
Exhaust
1.35 ~ 1.65mm (0.0531 ~ 0.0649in.)
?
Seat angle
Intake
44.75° ~ 45.10°
?
Exhaust
44.75° ~ 45.10°
?
Valve spring
Free length
44.45mm (1.7500in.)
?
Load
17.3 ± 0.6kg/35.0mm (38.14 ± 1.32lb/1.3779in.)
33.0 ± 1.0kg/26.5mm (72.75± 2.20lb/1.0433in.)
?
Out of squareness
Less than 1.5°
?
Cylinder head
Flatness of gasket surface
Less than 0.05mm (0.0019in.) for total area
Less than 0.02mm (0.0007in.) for a section of
100mm (3.9370in.)?100mm (3.9370in.)
?
Flatness of manifold mounting surface
Intake
Less than 0.10mm (0.0039in.)
?
Exhaust
Less than 0.10mm (0.0039in.)
?
Piston
Piston outer diameter
87.960 ~ 87.990mm (3.46299 ~ 3.46417in.)
?
Piston to cylinder clearance
0.030 ~ 0.050mm (0.00118 ~ 0.00197in.)
?
Ring groove width
No. 1 ring
1.235 ~ 1.250mm (0.04862 ~ 0.04921in.)
1.260mm (0.04961in.)
No. 2 ring
1.230 ~ 1.250mm (0.04843 ~ 0.04921in.)
1.260mm (0.04961in.)
Oil ring
2.010 ~ 2.025mm (0.07913 ~ 0.07972in.)
2.050mm (0.08071in.)
Piston ring
Side clearance
No. 1 ring
0.050 ~ 0.080mm (0.00197 ~ 0.00315in.)
0.100mm (0.00394in.)
No. 2 ring
0.040 ~ 0.080mm (0.00157 ~ 0.00315in.)
0.100mm (0.00394in.)
Oil ring
0.060 ~ 0.125mm (0.00236 ~ 0.00492in.)
0.200mm (0.00787in.)
End gap
No. 1 ring
0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
0.60mm (0.0236in.)
No. 2 ring
0.37 ~ 0.52mm (0.0145 ~ 0.0204in.)
0.70mm (0.0275in.)
Oil ring
0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)
0.80mm (0.0315in.)
Piston pin
Piston pin outer diameter
21.997 ~ 22.000mm (0.86602 ~ 0.86614in.)
?
Piston pin hole inner diameter
22.003 ~ 22.007mm (0.86626 ~ 0.86642in.)
?
Piston pin hole clearance
0.003 ~ 0.010mm (0.00012 ~ 0.00039in.)
?
Connecting rod small end hole inner diameter
22.005 ~ 22.011mm (0.86634 ~ 0.86657in.)
?
Piston pin-to-connecting rod clearance
0.005 ~ 0.014mm (0.00020 ~ 0.00055in.)
?
Connecting rod
Connecting rod big end inner diameter
51.000 ~ 51.018mm (2.00787 ~ 2.00858in.)
?
Connecting rod bearing oil clearance
0.031 ~ 0.045mm (0.00122 ~ 0.00177in.)
0.050mm ( 0.00197in.)
Side clearance
0.10 ~ 0.25mm (0.0039 ~ 0.0098in.)
0.35mm (0.0138in.)
Crankshaft
Main journal outer diameter
51.942 ~ 51.960mm (2.04496 ~ 2.04567in.)
?
Pin journal outer diameter
47.954 ~ 47.972mm (1.88795 ~ 1.88866in.)
?
Main bearing oil clearance
0.020 ~ 0.038mm (0.00079 ~ 0.00150in.)
0.100mm (0.00394in.)
End play
0.07 ~ 0.25mm (0.0028 ~ 0.0098in.)
0.30mm (0.0118in.)
Cylinder block
Cylinder bore
88.00 ~ 88.03mm (3.4645 ~ 3.4657in.)
?
Flatness of gasket surface
Less than 0.05mm (0.0019in.) for total area
Less than 0.02mm (0.0007in.) for a section of
100mm (3.9370in.)?100mm (3.9370in.)
?
Engine oil
Oil quantity
Total
5.8L (1.53U.S.gal., 6.13U.S.qt., 5.10lmp.qt.)
When replacing a short engine or block assembly
Oil pan
4.4L (1.16U.S.gal., 4.65U.S.qt., 3.87lmp.qt.)
?
Drain and refill
4.8L (1.27U.S.gal., 5.07U.S.qt., 4.22lmp.qt.)
Including oil filter
Oil grade
Recommended
ILSAC GF-4 (API SM) or above / 5W-20
Allowed
ILSAC GF-3, GF-4 (API SL, SM) or aboveFor information on SAE viscosity grades based on ambient temperatures, refer to the “Lubrication System”.
Usable only if the recommended engine oil is not available
Oil pressure (at 1,000rpm)
118kPa (1.2kgf/cm?, 17.1psi) or above
Oil temperature (oil pan): 110±2°C (230±35.6°F)
Cooling system
Cooling method
Water-cooled, pressurized.
Forced circulation with water pump
?
Coolant quantity
6.6~6.9 L (1.74~1.82 U.S.gal., 6.97~7.29 U.S.qt., 5.81~6.07 lmp.qt.)

Thermostat
Type
Wax pellet type
?
Opening temperature
88±1.5°C (190.4±34.7°F)
?
Full opening valve lift/temperature
More than 8mm (0.3in.) / 100°C (212°F)
?
Radiator cap
Main valve opening pressure
93.16 ~ 122.58kPa
(0.95 ~ 1.25kgf/cm?, 13.51 ~ 17.78psi)
?
Vacuum valve opening pressure
0 ~ 6.86 kPa
(0 ~ 0.07kgf/cm?, 0 ~ 0.99psi)
?

Tightening Torques
Item
Quantity
N.m
kgf.m
lb-ft
Engine mounting
Engine mounting bracket to body fixing bolt
4
58.8 ~ 73.5
6.0 ~ 7.5
43.4 ~ 54.2
Engine mounting insulator to engine mounting support bracket fixing nut
1
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Engine mounting support bracket to engine support bracket fixing bolt
1
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Engine mounting support bracket to engine support bracket fixing nut
2
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Transaxle mounting bracket to body fixing bolt
3
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Transaxle mounting bracket to body fixing nut
1
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Transaxle mounting support bracket fixing bolt
2
58.8 ~ 78.5
6.0 ~ 8.0
43.4 ~ 57.9
Transaxle mounting support bracket fixing nut
2
78.5 ~ 98.0
8.0 ~ 10.0
57.9 ~ 72.3
Transaxle mounting bracket to transaxle mounting support bracket fixing bolt
2
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
Roll rod bracket to sub frame fixing bolt 
2
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Roll rod bracket to transaxle fixing bolt & nut
1
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
Timing system
Idler 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
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 (LH/RH)
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 hanger 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 (LH/RH)
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Cylinder block
Tensioner assembly intergrated bracket 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 switch
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 sub 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 fitting bolt
3
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Water temperature control 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 pipe 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 asembly 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 stay 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 protector bolt
4
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Exhaust manifold stay bolt (M8)
2
18.6 ~ 27.5
1.9 ~ 2.8
13.7 ~ 20.3
Exhaust manifold stay 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

   
Torque-to-yield cylinder head, connecting rod cap and crankshaft main bearing cap bolts must be replaced once removed because the bolts are designed to be permanently elongated beyond the state of elasticity when torqued. If the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
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