Hybrid fleet operators battle sudden engine shutdown and cam phaser codes caused by sludge accumulation inside oil passages. This precision remanufactured Hyundai Kia G4KK Remanufactured Engine cures oil flow restrictions across the cylinder block. The 2.4L 4-Cylinder 16-Valve DOHC hybrid engine requires verification of round VVT oil holes to guarantee match with late Theta-2 HEV cylinder heads.

Die-cast aluminum block casting G4KK integrates cast iron cylinder liners align-honed to preserve bearing centerline roundness within 0.0003in. A forged steel crankshaft rides inside tri-metal rod and main bearings clearanced to 0.0012in. Aluminum cylinder head casting Theta-2 HEV 2.4L houses direct fuel injectors, sixteen sodium-cooled valves, and round VVT oil feed channels. Dry crated assembly weight measures 250 lbs with crated envelope dimensions of 36in length by 36in width by 36in height and a 4.6 quarts oil capacity.

Key Features of Hyundai Kia G4KK

Automotive service shops buy Hyundai Kia G4KK remanufactured engine units to restore hybrid drivetrain torque. Master technicians install this remanufactured G4KK long block replacement to cure phaser chatter.

- Block casting G4KK receives CNC deck milling to secure multi-layer steel head gaskets.
- Round VVT feed holes undergo pressure testing to ensure unrestricted lubrication to camshaft sprockets.
- Forged steel crankshaft journals receive micro-polishing to achieve an eight Ra finish across all journals.
- Tri-metal rod bearings maintain 0.0012in oil clearance to protect crankshaft throws under torque surges.
- Diamond plateau cylinder bore honing produces a crosshatch pattern that seats compression rings within 500 miles.
- Cylinder head casting Theta-2 HEV receives valve seat cutting to hold 0.001in valve seat runout.
- Threaded brass oil gallery plugs replace press-fit plugs to eliminate oil leaks within the block.

Dyno Load Precision Machining Tolerances

Dynamometer brake load verification confirms 159 HP at 5,500 RPM alongside 154 ft-lbs torque output at 4,500 RPM under continuous testing cycles. Line-honing operations maintain main journal alignment within 0.0003in TIR while rod bearing clearances measure 0.0012in. Computerized bore honing establishes 0.0011in piston-to-bore clearance to stop cold piston slap. Hot engine oil pressure stabilizes at 62 PSI at 3,000 RPM with engine coolant regulated at 192°F. Mechanical cylinder pressure tests confirm balanced compression between 185 PSI and 192 PSI across all four cylinders.

Vehicle Fitment Drivetrain Guide

This remanufactured engine fits 2011 to 2015 Hyundai Sonata Hybrid and 2011 to 2016 Kia Optima Hybrid sedans equipped with the 2.4L 2359cc L4 Atkinson engine, Theta-2 HEV head, and round VVT oil holes. It mates with 6-Speed Automatic hybrid transaxles. This long block does not fit initial 2011 square VVT hole blocks, conventional non-hybrid 2.4L G4KJ direct-injection models, non-hybrid MPI engines, or Kia Sorento SUV platforms.

Installation Protocol Service Requirements

Disconnect the high-voltage hybrid interlock plug and verify hybrid transaxle damper condition prior to installation. Never drop this Atkinson cycle long block into non-hybrid passenger cars or forced-induction track projects without specialized ECU mapping. Technicians must clean intake runners and fuel injection rails to avoid contamination.

- Pressure-prime the oil channels with full synthetic motor oil prior to starter rotation to coat camshaft bearing surfaces.
- Drain break-in engine oil and swap the oil filter at 500 miles to clear machining friction dust.
- Re-check variable valve timing solenoid resistance and scan hybrid battery state at 3,000 miles.

Warranty Terms Core Return Policy

Our comprehensive 3-Year Unlimited-Mile warranty safeguards internal long block components and machine shop labor against defects. We provide free prepaid freight pickup for your rebuildable engine core inside a 30-day window. The crated freight contains the long block core, pre-installed timing components, oil pan, and valve cover.