Kia Optima Repair Manual 2001-2010

SKU: HY54050-010

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Kia Optima Repair Manual 2001-2010
Kia Optima Repair Manual 2001-2010
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Item Description

This DIY repair and service manual by Haynes, covers 2001-2010 Kia Optima cars, powered by 2.4L 4-cylinder engines, and 2.5L or 2.7L V6 engines.

Transmissions offered include a 4- or 5-speed automatic, or a 5-speed manual transaxle.

This manual will help you maintain your Optima in good repair by showing you how to perform basic scheduled maintenance, service components and systems such as brakes, steering and suspension, all the way to a complete engine rebuild.


Book Excerpt: 2001-2010 Kia Optima Repair Manual

PART B | V6 ENGINES

GENERAL INFORMATION

The DOHC (Dual Overhead Cam) 2.5L and 2.7L V6 engines have four valves per cylinder aluminum cylinder heads and a two-piece oil pan.

This part of Chapter 2 is devoted to in-vehicle repair procedures for the V6 engine. Information concerning engine removal and installation can be found in Part C of this Chapter.

The following repair procedures are based on the assumption that the engine is installed in the vehicle. If the engine has been removed from the vehicle and mounted on a stand, many of the steps outlined in this part of Chapter 2 will not apply.


REPAIR OPERATIONS POSSIBLE WITH THE ENGINE IN THE VEHICLE

Many major repair operations can be accomplished without removing the engine from the vehicle.

Clean the engine compartment and the exterior of the engine with some type of degreaser before any work is done. It will make the job easier and help keep dirt out of the internal areas of the engine.

Depending on the components involved, it may be helpful to remove the hood to improve access to the engine as repairs are performed (see Chapter 11 if necessary).

Cover the fenders to prevent damage to the paint. Special pads are available, but also an old bedspread or blanket will also work.

If vacuum, exhaust, oil or coolant leaks develop, indicating a need for gasket or seal replacement, the repairs can generally be made with the engine in the vehicle.

The intake and exhaust manifold gaskets, oil pan gasket, crankshaft oil seals and cylinder head gaskets are all accessible with the engine in place.


BRAKES
DISC BRAKE PADS | REPLACEMENT
(Refer to illustrations 3.5, 3.6a through 3.6n and 3.7a through 3.7m)

WARNING: Disc brake pads must be replaced on both front or rear wheels at the same time - never replace the pads on only one wheel.

Also, the dust created by the brake system is harmful to your health. Never blow it out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on the brakes.

Do not, under any circumstances, use petroleum-based solvents to clean brake parts. Use brake system cleaner, only!

  1. Remove the cap from the brake fluid reservoir.
  2. Loosen the wheel lug nuts, raise the front or rear of the vehicle and support it securely on jackstands. Block the wheels at the opposite end.
  3. Remove the wheels. Work on one brake assembly at a time, using the assembled brake for reference if necessary.
  4. Inspect the brake disc carefully as outlined in Section 5. If machining is necessary, follow the information in that Section to remove the disc, at which time the pads can be removed as well.
  5. Push the piston back into its bore to provide room for the new brake pads. A C-clamp can be used to accomplish this (see illustration).

    As the piston is depressed to the bottom of the caliper bore, the fluid in the master cylinder will rise. Make sure that it doesn't overflow. If necessary, siphon off some of the fluid.

  6. If you are replacing the front brake pads, follow the accompanying photos, beginning with illustration 3.6a. Be sure to stay in order and read the caption under each illustration.
  7. [continued]
Brake job photo from Haynes Manual

Subject: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Kia Optima service, maintenance, repair. ISBN-10: 1563929244 | ISBN-13: 9781563929243 | Haynes 54050

Specifications
  • Publisher: Haynes Manuals
  • Pages: 320 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.5 x 11 inches
  • ISBN: 978-1-56392-924-3
  • Years: 2001 - 2010
Table of Contents
TABLE of CONTENTS: Introduction: Vehicle identification numbers. Buying parts. Safety. Maintenance techniques. Chemical and lubricants, and more.
  • Tune-up and routine maintenance
  • 2.4L 4-cylinder engine: G4JS Sirius II, G4KC Theta
  • 2.5L V6 engine: G6BW Delta
  • 2.7L V6 engine: G6BA Delta, G6EA Mu
  • General engine overhaul procedures
  • Cooling, heating and air-conditioning systems
  • Fuel and exhaust systems
  • Engine electrical systems
  • Emissions control systems
  • Manual transaxle
  • Automatic transaxle
  • Driveline
  • Brakes, ABS
  • Suspension and steering systems
  • Body
  • Chassis electrical system
  • Wiring diagrams
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