3G 4G64 DOHC Head Swap

Parts List and Guide

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Kia Optima 2.4L Head Swap Parts List
Model Part Name Part Number Qty
Eclipse 2.4L Head Gasket MD332035 1
Eclipse 2.4L Timing Belt Pulley MD156604 1
Eclipse 2.4L Timing Belt Tensioner MD308086 1
Eclipse 2.4L Timing Belt Tensioner Pulley MD182537 1
Evo 8 Adjustable Cam Gear 1
Evo 8 Cam Gear MD322223 1
Evo 8 Cam Gear Bolt MF140285 2
Evo 8 Camshaft Seal MD153103 2
Evo 8 Coil Pack Boots MD623073 2
Evo 8 Dipstick MD343884 1
Evo 8 Dipstick Tube MD342319 1
Evo 8 EGR Valve MR560582 1
Evo 8 Exhaust Cam MN143620 1
Evo 8 Fuel Pressure Regulator MD320749 1
Evo 8 Fuel Rail MR561928 1
Evo 8 Intake Cam MN143619 1
Evo 8 Intake Manifold MN137746 1
Evo 8 intake manifold 10mm bolt MF241284 1
Evo 8 Intake Manifold 10mm nut MF430122 2
Evo 8 Intake Manifold Bolt MF241256 5
Evo 8 Intake Manifold Bracket MR560754 1
Evo 8 Intake Manifold Bracket Bolt MF140056 2
Evo 8 Intake Manifold Gasket MD310447 1
Evo 8 Lower Radiator Hose MN135593 1
Evo 8 Reluctor MD375814 1
Evo 8 Reluctor Bolt MD368730 1
Evo 8 Spark Plug Gaskets MD186785 4
Evo 8 Spark Plug Wire Set MD343245 1
Evo 8 Spark Plugs MD374841 4
Evo 8 Throttle Body MN128975 1
Evo 8 Throttle Body Gasket MD180361 1
Evo 8 Throttle Cable MN100169 1
Evo 8 Throttle Position sensor MD628074 1
Evo 8 Timing Belt MD326059 1
Evo 8 Timing Belt Front Cover MD334401 1
Evo 8 Timing Belt Rear Cover MD322517 1
Evo 8 Upper Timing Belt Cover MD373108 1
Evo 8 Valve Spring Seats MD113424 16
Evo 8 Valve Springs MN158946 16
Evo 8 Valve Stem Seals MD306079 16
Evo 8* Cylinder Head Rear Seal MD372348 1
Evo 8* Exhaust Valve MD184078 8
Evo 8* Intake Valve MD127840 8
Evo 8* Lash Adjuster MD377054 16
Evo 8* Lower Timing Belt Cover MN143079 1
Evo 8* Rocker Arm MD375091 16
 Evo 8* Valve Keepers MD016483 32
Evo 8* Valve Spring Retainers MN143698 16
Optima 2.4L Camshaft Sensor Housing 1
Optima 2.4L Head 1
Optima 2.4L Plug Cover 1
Optima 2.4L Rear Water Pipe 25461-38003 1
Optima 2.4L Thermostat 1
Optima 2.4L Thermostat Housing 1
Optima 2.4L Valve Cover 1
Optima 2.4L Valve Cover Gasket 1
Optima 2.4L Oil Cap 1

NOTES
This head swap was done on a 2002 Eclipse RS using a 2004 Kia Optima 2.4L Cylinder Head
All parts listed for an Optima must be from a 2001-2005 Kia Optima and not an Evo.
Evo 8 parts with an asterisk (*) are interchangeable with Optima parts.
Used Evo parts are much easier to get a hold of than Optima Parts.
Evo 8 parts can easily be found at Evolutionm.net and other Evo forums.
At least one adjustable cam gear is needed.
Either Kia or Evo upper and lower timing belt covers can be used. However, both upper and lower must c
 Purchased @
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Napa
Used
Used
Used
Used
Used
Used
Used
Used
Used
Used
Used
Used
Used
Used
Used
Used
 Used
Used
Used
Used
Used
Used
Used
Used
Used
Used
Used

a 2004 Kia Optima 2.4L Cylinder Head

Kia Optima and not an Evo.
Optima parts.
ptima Parts.
ther Evo forums.

n be used. However, both upper and lower must come from the same car.
Evo 8 Head Swap Parts List
Model Part Name Part Number Qty
Eclipse 2.4L Head Gasket MD332035 1
Eclipse 2.4L Timing Belt Pulley MD156604 1
Eclipse 2.4L Timing Belt Tensioner MD308086 1
Eclipse 2.4L Timing Belt Tensioner Pulley MD182537 1
Evo 8 Adjustable Cam Gear 1
Evo 8 Cam Gear Bolt MF140285 2
Evo 8 Cam Gears MD322223 1
Evo 8 Camshaft Seals MD153103 2
Evo 8 Camshaft Sensor Housing MD344722 1
Evo 8 Camshaft Sensor Housing Cover MD329502 1
Evo 8 Camshaft Sensor Housing Gasket MD329503 1
Evo 8 Coil Pack Boots MD623073 2
Evo 8 Cylinder Head Rear Seal MD372348 1
Evo 8 Dipstick MD343884 1
Evo 8 Dipstick Tube MD342319 1
Evo 8 EGR Valve MR560582 1
Evo 8 Exhaust Cam MN143620 1
Evo 8 Exhaust Valve MD184078 8
Evo 8 Fuel Pressure Regulator MD320749 1
Evo 8 Fuel Rail MR561928 1
Evo 8 Head MN155744 1
Evo 8 Intake Cam MN143619 1
Evo 8 Intake Manifold MN137746 1
Evo 8 Intake Manifold Bolt MF241256 5
Evo 8 intake manifold bolt big MF241284 1
Evo 8 Intake Manifold Bracket MR560754 1
Evo 8 Intake Manifold Bracket Bolt MF140056 2
Evo 8 Intake Manifold Gasket MD310447 1
Evo 8 Intake Manifold nut MF430122 2
Evo 8 Intake Valve MD127840 8
Evo 8 Lash Adjuster MD377054 16
Evo 8 Lower Radiator Hose MN135593 1
Evo 8 Lower Timing Belt Cover MN143079 1
Evo 8 Oil Cap MN163112 1
Evo 8 Plug Cover MD345681 1
Evo 8 Rear Water Pipe MN143306 1
Evo 8 Reluctor MD375814 1
Evo 8 Reluctor Bolt MD368730 1
Evo 8 Rocker Arm MD375091 16
Evo 8 Spark Plug Gaskets MD186785 4
Evo 8 Spark Plug Wire Set MD343245 1
Evo 8 Spark Plugs MD374841 4
Evo 8 Thermostat Housing MN143307 1
Evo 8 Throttle Body MN128975 1
Evo 8 Throttle Body Gasket MD180361 1
Evo 8 Throttle Cable MN100169 1
 Evo 8 Throttle Position sensor MD628074 1
Evo 8 Timing Belt MD326059 1
Evo 8 Timing Belt Front Cover MD334401 1
Evo 8 Timing Belt Rear Cover MD322517 1
Evo 8 Upper Timing Belt Cover MD373108 1
Evo 8 Valve Cover MN155455 1
Evo 8 Valve Cover Gasket MD340535 1
Evo 8 Valve Keepers MD016483 32
Evo 8 Valve Spring Retainers MN143698 16
Evo 8 Valve Spring Seats MD113424 16
Evo 8 Valve Springs MN158946 16
Evo 8 Valve Stem Seals MD306079 16

NOTES
Evo 8 parts can easily be found at Evolutionm.net and other Evo forums.
At least one adjustable cam gear is needed.
Throttle Position Sensor
TPS sensor clip needs to be rewired for the EVO sensor.

Dip Stick
Dip stick tube bracket must be modified to seat properly.
Pics coming soon

Radiator Hoses
Evo 8 lower radiator hose is used as upper radiator hose for swap
Stock 3G lower radiator hose stays

Thermostat Housing
Kia thermostat housing needs to be drilled and tapped for gauge cluster temp gauge
Evo 8 thermostat housing does not need to be modified

Misc Wiring
The wiring harness can be unwrapped and rerouted to allow sensor harnesses/clips to reach. The #2 cylinder coil pack is the o

Fuel Injectors
Stock 3G fuel injectors are shorter than Evo injectors. Stock spacers need to be replaced with washers and shorter fuel rail bo

EGR Valve
Coming Soon
2 cylinder coil pack is the only harness clip that has to be cut and extended.

ers and shorter fuel rail bolts are needed.

FASTENER TIGHTENING SPECIFICATIONS
Items

Generator and Ignition Coil

Auto-tensioner assembly bolt M8
Auto-tensioner assembly bolt M10
Center cover bolt
Crankshaft pulley bolt
Generator brace bolt (flange bolt)
Generator brace bolt (bolt, washer assembly)
Generator pivot nut
Idler pulley bolt
Ignition coil bolt
Oil dipstick guide bolt
Spark plugs
Water pump pulley bolt

Vacuum Pipe and Hose

Solenoid valve assembly bolt
Vacuum pipe and hose assembly bolt

Timing Belt
Auto-tensioner bolt
Camshaft sprocket bolt
Counterbalance shaft sprocket bolt
Crankshaft angle sensors bolt
Crankshaft bolt
Engine support bracket bolt
Idler pulley
Oil pump sprocket nut
PCV valve
Power steering pump bracket bolt
Rocker cover bolt
Tensioner arm bolt
Tensioner B bolt
Tensioner pulley bolt
Timing belt cover bolt (flange bolt)
Timing belt cover bolt (bolt, washer assembly)

Fuel System
EGR valve bolt
Fuel pressure regulator bolt
Fuel rail bolt
Throttle body bolt

Intake Manifold
Air control valve bracket bolt
Bracket bolt
Engine hanger bolt
Intake manifold bolt M8
Intake manifold bolt, nut M10
Intake manifold stay bolt
MDP sensor bolt

Exhaust Manifold
Exhaust manifold nut M8
Exhaust manifold nut M10

Water Pump and Water Hose

Engine coolant temperature gauge unit
Engine coolant temperature sensor
Knock sensor bolt
Thermostat housing bolt
Water inlet pipe bolt M6
Water inlet pipe bolt M8
Water outlet fitting bolt
Water pump bolt

Rocker Arms and Camshafts

Bearing cap bolt
Camshaft position sensing cylinder bolt
Camshaft position sensor bolt
Camshaft position sensor support bolt
Cover bolt
Oil delivery body bolt

Cylinder Head
Cylinder head bolt
G SPECIFICATIONS
Specifications

24 ± 4 (18 ± 2 ft-lb)
44 ± 10 (33 ± 6 ft-lb)
3.0 ± 0.5 (27 ± 3 in-lb)
25 ± 4 (19 ± 2 ft-lb)
23 ± 3 (17 ± 2 ft-lb)
22 ± 4 (17 ± 2 ft-lb)
44 ± 10 (33 ± 6 ft-lb)
79 ± 5 (58 ± 3 ft-lb)
10 ± 2 (89 ± 17 in-lb)
13 ± 1 (115 ± 8 in-lb)
25 ± 5 (19 ± 3 ft-lb)
8.8 ± 1.0 (78 ± 8 in-lb)

9.0 ± 1.0 (80 ± 8 in-lb)

11 ± 1 (98 ± 8 in-lb)

24 ± 3 (18 ± 1 ft-lb)
88 ± 10 (65 ± 7 ft-lb)
45 ± 3 (33 ± 2 ft-lb)
8.8 ± 1.0 (78 ± 8 in-lb)
167 (123 ft-lb)
49 ± 5 (36 ± 3 ft-lb)
35 ± 6 (26 ± 4 ft-lb)
54 ± 4 (40 ± 2 ft-lb)
10 ± 2 (89 ± 17 in-lb)
49 ± 9 (36 ± 6 ft-lb)
3.5 ± 0.5 (31 ± 4 in-lb)
21 ± 4 (16 ± 2 ft-lb)
19 ± 3 (14 ± 2 ft-lb)
48 ± 6 (35 ± 4 ft-lb)
11 ± 1 (98 ± 8 in-lb)
9.0 ± 1.0 (80 ± 8 in-lb)

20 ± 2 (15 ± 1 ft-lb)
8.8 ± 2.0 (79 ± 16 in-lb)
12 ± 1 (107 ± 8 in-lb)
19 ± 3 (14 ± 2 ft-lb)

23 ± 4 (17 ± 2 ft-lb)
11 ± 1 (98 ± 8 in-lb)
22 ± 4 (17 ± 2 ft-lb)
20 ± 2 (15 ± 1 ft-lb)
36 ± 6 (26 ± 4 ft-lb)
31 ± 3 (23 ± 2 ft-lb)
5.0 ± 1.0 (45 ± 8 in-lb)

29 ± 3 (21 ± 2 ft-lb)
49 ± 5 (36 ± 3 ft-lb)

10.8 ± 1.0 (96 ± 8 in-lb)

29 ± 10 (22 ± 6 ft-lb)
23 ± 2 (17 ± 2 ft-lb)
23 ± 4 (17 ± 2 ft-lb)
5.0 ± 1.0 (45 ± 8 in-lb)
13 ± 2 (115 ± 17 in-lb)
10 ± 1 (89 ± 8 in-lb)
14 ± 1 (124 ± 8 in-lb)

20 ± 1 (15 ± 1 ft-lb)
22 ± 4 (17 ± 2 ft-lb)
8.8 ± 1.0 (78 ± 8 in-lb)
14 ± 1 (124 ± 8 in-lb)
10 ± 2 (89 ± 17 in-lb)
11 ± 1 (98 ± 8 in-lb)

78 ± 2 (58 ± 1 ft-lb) → back off→ 20 ± 2 (15 ± 1 ft-lb) → 90° + 90°