Eliminate catastrophic bottom-end rod knock with this Kia Optima G4KD Remanufactured Engine long block assembly. Engineered for 2.0L 4-Cylinder 16-Valve DOHC installations, this unit cures factory cylinder wall scoring defects. A critical trade-off requires complete oil gallery pre-lubrication before starting to prevent bearing scuffing during the initial dry cranking sequence in your bay.

High-pressure die-cast aluminum cylinder block features casting designation G4KD with cast iron cylinder liners. The dual overhead camshaft cylinder head features continuous variable valve timing on the intake camshaft. Total crated envelope dimensions measure 36in length by 36in width by 36in height with an engine weight of 260 lbs. Rotating assembly components include a micro-polished forged steel crankshaft, crack-split forged connecting rods, hypereutectic pistons, and a 4.3-quart stamped steel oil pan.

Key Features of Kia G4KD

Commercial fleets buy Kia G4KD remanufactured engine assemblies to restore optimal vehicle fuel economy and pass state exhaust emissions testing. This precision long block solves common Theta II piston scuffing problems through CNC cylinder machining.

- Precision CNC deck surfacing creates an Ra 20 finish to seal multi-layer steel head gaskets
- Diamond plateau cylinder honing optimizes oil retention to prevent severe piston skirt friction
- Micro-polished forged steel crankshaft journals maintain 0.0003in TIR runout to safeguard rod bearings
- Align-honed main bearing journals restore true axial center to support high oil film strength
- Premium multi-layer steel head gaskets provide tight cylinder bore sealing under combustion thermal stress
- Upgraded intake CVVT cam phasers ensure accurate valve timing for responsive engine acceleration
- Remanufactured 16-Valve cylinder heads feature multi-angle valve seat cuts holding 0.001in concentricity

Dyno Load Precision Machining Tolerances

Dynamometer testing confirms 156 HP at 6,200 RPM alongside 144 ft-lbs of continuous torque at 4,600 RPM under operational conditions. Machine shop tolerances mandate crankshaft journal runout within 0.0003in TIR and hold connecting rod bearing oil clearances at 0.0013in. Plateau-honed cylinder walls produce balanced compression readings between 180 PSI and 185 PSI across all 4 chambers. Hot engine oil pressure sustains 55 PSI at 3,000 RPM, while regulated coolant operating temperatures maintain 192°F under full thermal dyno testing.

Vehicle Fitment Drivetrain Guide

This remanufactured long block fits 2010 to 2011 Kia Forte, Optima, and Sportage models equipped with the naturally aspirated 2.0L 1998cc Theta II G4KD 4-Cylinder engine. Compatible with front-wheel drive and all-wheel drive drivetrains paired with 6-Speed Manual or 6-Speed Automatic transmissions. Note: this long block does not fit turbocharged G4KF or 2.4L G4KE models, and it will not fit 2012 or newer direct-injected GDI G4NC vehicle chassis configurations.

Installation Protocol Service Schedules

Ensure variable valve timing solenoids and throttle harness connectors click into place before applying ignition power. Flush oil cooler lines and replace the intake manifold to remove trapped metal debris from prior engine failure. Never run this naturally aspirated long block in aftermarket turbo systems exceeding 5 PSI of boost without low-compression forged internal components.

- Fill engine crankcase with 4.3 quarts of SAE 5W-20 break-in oil before initial engine spin
- Drain break-in oil and install a new spin-on oil filter at the 500-mile mark
- Schedule recurring full synthetic oil and filter service every 3,000 miles or 5,000 miles

Warranty Terms Core Return Policy

We provide a 3-Year Unlimited-Mile parts warranty to support professional installers and vehicle owners. Our freight team handles prepaid return shipping for your rebuildable core within an authorized 30-day window. Each crate includes the complete long block, timing components, oil pan, valve cover, and technical installation guides.