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Home › Kia › 2005 › Optima EX, 2.4 6 › Repair and Diagnosis › Engine Mechanical › Lubrication System › 2.4L 4-Cylinder Engine › Engine Block › Front Case › Installation

Front Case: Installation

  1. Apply engine oil to the gear and align the two timing marks.
    Fig 1: Installing Oil Pump Gears
    G00326759Courtesy of KIA MOTORS AMERICA, INC.
  2. Using the special tool, Crankshaft Front Oil Seal Installer (09214-32000), install the crankshaft front oil seal into the front case.
    Fig 2: Identifying Crankshaft Front Oil Seal Installer (09214-32100)
    G00326760Courtesy of KIA MOTORS AMERICA, INC.
  3. Set the special tool (09214-32100) on the front end of crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
    Fig 3: Identifying Crankshaft Front Oil Seal Guide (09214-32100)
    G00326761Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the front case assembly through a new front case gasket and temporarily tighten the flange bolts (other than those for tightening the filter bracket).
    Fig 4: Installing Front Case
    G00326762Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.

    Front case assembly

    Tightening torque

    All except : 20-27 Nm (200-270 kg.cm, 14-20 lb.ft)

    Fig 5: Identifying Front Case Bolts
    G00326763Courtesy of KIA MOTORS AMERICA, INC.
  6. Insert a screwdriver through plug hole in left side of cylinder block. Checking that the shaft is in position and tighten.
    Fig 6: Installing Shaft In Left Side Of Cylinder Block
    G00326764Courtesy of KIA MOTORS AMERICA, INC.
  7. Install a new O-ring to the groove of front case.
  8. Using a special tool, install the plug case and tighten to the specified torque.
    Fig 7: Identifying Plug Cap Wrench (09213-33000)
    G00326765Courtesy of KIA MOTORS AMERICA, INC.
  9. Apply sealant into the groove of the pan flange as shown in illustration.
    NOTE:
    • Apply sealant about 4 mm (0.16 in.) in thickness.
    • After application of sealant, do not exceed 15 minutes before installing the oil pan.
    Fig 8: Installing Oil Pan Bolts (1 Of 2)
    G00326766Courtesy of KIA MOTORS AMERICA, INC.
  10. Note the difference in bolt lengths at the location shown in illustration. Install the oil pan and tighten the bolts to the specified torque.

    Oil pan bolt tightening torque: 10-12 Nm (100-120 kg.cm, 7-9 lb.ft)

    Fig 9: Installing Oil Pan Bolts (2 Of 2)
    G00326767Courtesy of KIA MOTORS AMERICA, INC.
  11. Using the special tool, install the oil pressure switch after applying sealant to the threaded area.

    Sealant : Threebond 1104 or equivalent

    NOTE: Do not torque the oil pressure switch excessively.

    Tightening torque

    Oil pressure switch: 8-12 Nm (80-120 kg.cm, 6-8 lb.ft)

Fig 10: Installing Oil Pressure Switch
G00326768Courtesy of KIA MOTORS AMERICA, INC.
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