Kia Carens: Cylinder Head Assembly / Cylinder Head Repair procedures
Engine removal is not required for this procedure.
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Use fender covers to avoid damaging painted surfaces.
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To avoid damaging the cylinder head, wait until the engine coolant
temperature drops below normal temperature before removing it.
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When handling a metal gasket, take care not to fold the gasket
or damage the contact surface of the gasket.
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To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
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Mark all wiring and hoses to avoid misconnection.
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| 1. |
Remove the engine cover.
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| 2. |
Disconnect the battery negative terminal.
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| 3. |
Remove the air duct and air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
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| 4. |
Disconnect the mounting bracket and then remove the battery.
(Refer to Engine Electrical System - "Battery")
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| 5. |
Disconnect the ECM connector and then remove the battery tray.
(Refer to Engine Electrical System - "Battery")
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| 6. |
Remove the engine room under cover.
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| 7. |
Loosen the drain plug and drain the coolant. Open the radiator cap to
make rapid draining.
(Refer to Cooling System - "Coolant")
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| 8. |
Remove the radiator upper hose and lower hose.
(Refer to Cooling System - Radiator Hose")
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| 9. |
Disconnect the compressor connector.
(Refer to Heating, Ventilation Air conditioning -"Compressor")
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| 10. |
Disconnect the alternator connector and the cable from the alternator
“B” terminal.
(Refer to Engine Electical System - "Alternator")
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| 11. |
Disconnect the water temprature sensor.
(Refer to Engine Control/Fuel System - "Engine Control System")
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| 12. |
The ETC (Electronic throttle control) connector and the MAPS (Manifold
absolute pressure sensor) & IATS (Intake air temperature sensor) connector.
(Refer to Engine Control/Fuel System - "ETC System")
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| 13. |
Disconnect the heater hose(A) and brake booster vacuum hose(B).
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| 14. |
Remove the vacuum pipe assembly(A).
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| 15. |
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
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| 16. |
Remove the timing chain cover.
(Refet to Timing System - "Timing Chain Cover")
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| 17. |
Remove the camshaft.
(Refer to Cylinder Head Assembly - "CVVT & Camshaft")
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| 18. |
Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
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| 19. |
Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
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| 20. |
Remove the delivery pipe assembly.
(Refer to Engine Control/Fuel System - "Delivery Pipe")
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| 21. |
Disconnect the bypass hose, and then remove the water temperature control
assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
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| 22. |
Remove the heater pipe.
(Refet to Cooling System - "Water Pipe")
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| 23. |
Remove the intake OCV(Oil Control Valve).
(Refer to Engine Control/Fuel System - "CVVT Oil Control Valve")
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| 24. |
Remove the cylinder head bolts, then remove the cylinder head.
| (1) |
Uniformly loosen and remove the 10 cylinder head bolts, in several
passes, in the sequence shown.
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Head warpage or cracking could result from removing
bolts in an incorrect order.
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| (2) |
Lift the cylinder head from the cylinder block and put the cylinder
head on wooden blocks.
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Be careful not to damage the contact surfaces of the
cylinder head and cylinder block.
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Identify MLA(Mechanical lash adjuster), valves, valve springs as they
are removed so that each item can be reinstalled in its original position.
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| 1. |
Remove the MLAs (A).
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When removing MLAs, mark all the MLAs for their rearrangement.
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| 2. |
Remove the valves.
| (1) |
Using the SST (09222 - 3K000, 09222 - 3K100), compress the valve
spring and remove the retainer lock.
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| (2) |
Remove the spring retainer.
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| (3) |
Remove the valve spring.
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| (5) |
Remove the valve stem seal.
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| (6) |
Using a magnetic pickup tool, remove the spring seat.
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Do not reuse the valve stem seals.
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| 1. |
Inspect for flatness.
Using a precision straight edge and filler gauge, measure the surface
the contacting the cylinder block and the manifolds for warpage.
If the flatness is greater than maximum, replace the cylinder head.
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Flatness of cylinder head gasket surface
Standard :
Less than 0.05mm (0.0020in) for total area
Less than 0.02mm (0.0008in) for a section of 100mm (3.9370in)
X 100mm (3.9370in)
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| 2. |
Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder
block surface for cracks. If cracked, replace the cylinder head.
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Valve And Valve Spring
| 1. |
Inspect the valve stems and valve guides.
| (1) |
Using a caliper gauge, measure the inner diameter of valve guide.
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Valve guide inner diameter :
5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
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| (2) |
Using a micrometer, measure the outer diameter of valve stem.
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Valve stem outer diameter
Intake : 5.465 ~ 5.480mm (0.2152 ~ 0.2157in)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2154in)
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| (3) |
Subtract the valve stem outer diameter measurement from the
valve guide inner diameter measurement.
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Valve stem- to-guide clearance
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0019in)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in)
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If the clearance is greater than specification, replace the
valve or the cylinder head.
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| 2. |
Inspect the valves.
| (1) |
Check the valve is ground to the correct valve face angle.
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| (2) |
Check that the surface of valve for wear. If the valve face
is worn, replace the valve.
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| (3) |
Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
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Margin
Standard
Intake : 1.10mm (0.0433in)
Exhaust : 1.26mm (0.0496in)
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| (4) |
Check the length of valve.
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Valve length
Standard
Intake : 93.15mm (3.6673 in)
Exhaust : 92.60mm (3.6457 in)
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| (5) |
Check the surface of valve stem tip for wear. If the valve stem
tip is worn, replace the valve.
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| 3. |
Inspect the valve seats.
| (1) |
Check the valve seat for evidence of overheating and improper
contact with the valve face. If the valve seat is worn, replace
the cylinder head.
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| (2) |
Check the valve guide for wear. If the valve guide is worn,
replace the cylinder head.
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| 4. |
Inspect the valve springs.
| (1) |
Using a steel square, measure the out-of-square of valve spring.
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| (2) |
Using a vernier calipers, measure the free length of valve spring.
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Valve spring
Standard
Free height : 45.1mm (1.7756in)
Out of square : Less than 1.5°
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Thoroughly clean all parts to be assembled.
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Before installing the parts, apply fresh engine oil to all sliding
and rotating surface.
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Replace oil seals with new ones.
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| 1. |
Install the valves.
| (1) |
Install the spring seats.
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| (2) |
Using the SST (09222 - 2B100), push in a new oil seal.
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Do not reuse old valve stem oil seals.
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Incorrect installation of the seal could result
in oil leakage past the valve guides.
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Intake valve stem seals are different from exhaust ones
in type.
Do not reassembly ones in the other's places.
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| (3) |
Install the valve, valve spring and spring retainer, after applying
engine oil at the end of each valve.
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When installing valve springs, the enamel coated side
should face the valve spring retainer.
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| 2. |
Using the SST(09222 - 3K000, 09222 - 3K100), compress the spring and
install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly
in place before releasing the valve spring compressor.
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When installing the SST, use the torque, 1.2kgf.m or less.
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| 3. |
Lightly tap the end of each valve stem two or three times with the wooden
handle of a hammer to ensure proper seating of the valve and retainer
lock.
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| 4. |
Install the MLA(Mechanical lash adjuster)s.
Check that the MLA (A) rotates smoothly by hand.
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All the MLAs must be installed in its original position.
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Thoroughly clean all parts to be assembled.
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Always use a new cylinder head and manifold gasket.
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Always use a new cylinder head bolt.
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The cylinder head gasket is a metal gasket. Take care not to
bend it.
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Rotate the crankshaft, set the No.1 piston at TDC.
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| 1. |
Install the cylinder head assembly.
| (1) |
Before installing, remove the hardened sealant from the cylinder
block and cylinder head surface.
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| (2) |
Before installing the cylinder head gasket, apply sealant on
the upper surface of the cylinder block and reassemble the gasket
within five minutes.
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Refer to the illustration for applying sealant.
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Width : 2.0 ~ 3.0mm(0.0787~0.1181in.)
Position : 1.0 ~ 1.5mm(0.0394~0.0591in.)
Specification : TB 1217H or LOCTITE 5900H
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| (3) |
After installing the cylinder head gasket on the cylinder block,
apply sealant on the upper surface of the cylinder head gasket
and reassemble in five minutes.
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| 2. |
Place the cylinder head carefully not to damage the gasket.
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| 3. |
Install the cylinder head bolts with washers.
| (1) |
Tighten the 10 cylinder head bolts, in several passes, in the
sequence shown.
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Tightening torque :
29.4Nm (3.0kgf.m, 21.7lb-ft) + 90° + 90°
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Always use new cylinder head bolts.
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| 4. |
Install the oil control valve(OCV).
(Refer to Engine Control/Fuel System - "CVVT Oil Control Valve (OCV)")
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| 5. |
Install the heater pipe.
(Refer to Cooling System - "Water Pipe")
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| 6. |
Install the weter control assembly, and bypass hose.
(Refer to Cooling System - "Water Control Assembly")
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| 7. |
Install the delivery pipe assembly.
(Refer to Engine Control/Fuel System - "Delivery Pipe")
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| 8. |
Install the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
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| 9. |
Install the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
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| 10. |
Install the cam shaft.
(Refer to Cylinder Head Assembly - "CVVT & Camshaft")
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| 11. |
Install the timing chain.
(Refer to Timing System - "Timing Chain")
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| 12. |
Install the timing chain cover.
(Refer to Timing System - "Timing Chain Cover)
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| 13. |
Install the OCV(Oil Control Valve) adaptor.
(Refer to Engine Control/Fuel System - "CVVT Oil Control Valve")
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| 14. |
Install the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
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Do not reuse the disassembled gasket.
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| 15. |
Install the exhaust OCV (Oil control valve).
(Refer to Engine Control/Fuel System - "CVVT Oil Control Valve")
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| 16. |
Install the ignition coil.
(Refer to Engine Electrical System - "Igniton Coil")
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| 17. |
Install the high pressure fuel pump and the roller tappet.
(Refer to Engine Control/Fuel System - "High Pressure Fuel Pump")
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| 18. |
Install the vacuum pipe assembly (A).
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Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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| 19. |
Connect the brake booster vacuum hose (A) and heater hose (B).
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| 20. |
Connect the The ETC (Electronic throttle control) connector and the
MAPS (Manifold absolute pressure sensor).
(Refer to Engine Control/Fuel System - "Engine Control System components)
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| 21. |
Connect the ECTS (Engine coolant temperature sensor) connector.
(Refer to Engine Control/Fuel System - "Engine Control System")
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| 22. |
The A/C compressor switch connector, the alternator connector and the
cable from the alternator “B” terminal.
(Refer to Engine Electrical System - "Alternator)
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| 23. |
Connect the aircon compressor connector.
(Refer to Heating, Ventilation, Air Conditioning - "Compressor")
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| 24. |
Install the radoator upper hose and lower hose.
(Refer to Cooling System - "Radiator Hose")
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| 25. |
Install the engine room under cover.
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| 26. |
Install the ECM and then connect the ECM connector.
(Refer to Engine Electrical System - "Battery")
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| 28. |
Instal the air duct and air clean assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
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| 29. |
Install the battery assembly.
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| 30. |
Install the engine cover.
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Perform the following :
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Refill engine with engine oil.
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Refill a radiator and a reservoir tank with engine coolant.
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Inspect for fuel leakage.
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After assemble the fuel line, turn on the ignition switch (do
not operate the starter) so that the fuel pump runs for approximately
two seconds and fuel line pressurizes.
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Repeat this operation two or three times, then check for fuel
leakage at any point in the fuel line.
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Bleed air from the cooling system.
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Start engine and let it run until it warms up. (until the radiator
fan operates 3 or 4 times.)
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Turn Off the engine. Check the level in the radiator, add coolant
if needed. This will allow trapped air to be removed from the
cooling system.
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Put radiator cap on tightly, then run the engine again and check
for leaks.
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Components
1. Cylinder head assembly
2. MLA
3. Retainer lock
4. Retainer
5. Valve stem seal
6. Valve spring
7. Valve spring seat
8. OCV (Oi ...
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Cylinder Head Components and components location
Cylinder Block