Kia Optima Hybrid: Engine Mechanical System / Specifications

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / 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°	?
Intake valve	Closes	ABDC 100° ~ 55°	?
Exhaust valve	Opens	BBDC 44° ~ 4°	?
Exhaust valve	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.)	?
Cam height	Exhaust	44.50mm (1.7520in.)	?
Journal outer diameter	Intake	No.1 : ?nbsp; 30mm (1.1811in.) No.2,3,4,5 : ?nbsp; 24mm (0.9449in.)	?
Journal outer diameter	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.)
Bearing oil clearance	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)
Valve length	Exhaust	105.84mm (4.1669in.)	105.59mm (4.1571in)
Stem outer diameter	Intake	5.465 ~ 5.480mm (0.21516 ~ 0.21575in.)	?
Stem outer diameter	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.)	?
Thickness of valve head (margin)	Exhaust	1.09mm (0.0429in.)	?
Valve stem to valve guide clearance	Intake	0.020 ~ 0.047mm (0.00078 ~ 0.00185in.)	0.070mm (0.00275in.)
Valve stem to valve guide clearance	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.)	?
Length	Exhaust	43.8 ~ 44.2mm (1.7244 ~ 1.7401in.)	?
Inner diameter	Intake	5.500 ~ 5.512mm (0.21654 ~ 0.21701in.)
Inner diameter	Exhaust	5.500 ~ 5.512mm (0.21654 ~ 0.21701in.)
Valve seat
Width of seat contact	Intake	1.16 ~ 1.46mm (0.0457 ~ 0.0575in.)	?
Width of seat contact	Exhaust	1.35 ~ 1.65mm (0.0531 ~ 0.0649in.)	?
Seat angle	Intake	44.75° ~ 45.10°	?
Seat angle	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.)	?
Flatness of manifold mounting surface	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
Oil grade	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)	?
Radiator cap	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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