Kia Sportage: Cylinder Head Assembly / Cylinder Head Repair procedures

Kia Sportage QL (2015-2019) Service Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head Repair procedures

Removal
  
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.
  
Use fender covers to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  
Mark all wiring and hoses to avoid misconnection.
1.
Remove the Battery tray. -
(Refer to Engine Electrical System - “Battery”)
2.
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - “Air Cleaner”)
3.
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - “Engine Room Under Cover”)
4.
Drain the engine coolant.
(Refer to Cooling System - "Coolant")
5.
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
6.
Remove the timing chain.
(Refer to Timing System - “Timing Chain”)
7.
Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
8.
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
9.
Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
10.
Remove the high pressure fuel pump bracket.
(Refer to Engine Control/Fuel System - "High Pressure Fuel Pump")
11.
Remove the delivery pipe.
(Refer to Engine Control / Fuel System - "Delivery Pipe")
12.
Remove the camshaft.
(Refer to Cylinder Head Assembly - "Camshaft" )
13.
Remove the exhaust oil control valve (OCV) (A) using a torx wrench.

14.
Remove the intake camshaft position sensor (CMPS) (A).

15.
Remove the exhaust camshaft position sensor (CMPS) (A) after removing the engine hanger (B).

16.
Remove the cylinder head.
(1)
Using triple square wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers.

  
Head warpage or cracking could result from removing bolts in an incorrect order.
(2)
Lift the cylinder head (A) from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

  
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
(3)
Remove the cylinder head gasket (A).

Disassembly
  
Identify mechanical lash adjuster (MLA), valves, valve springs as they are removed so that each item can be reinstalled in its original position.
1.
Remove the MLAs (A).

2.
Remove the valves.
(1)
Using SST (09222-3K000, 09222-3K100), compress the valve spring and remove retainer lock.

(2)
Remove the spring retainer.
(3)
Remove the valve spring.
(4)
Remove the valve.
(5)
Using needle-nose pliers, remove the valve stem seal.
  
Do not reuse old valve stem seals.
Inspection
Cylinder Head
1.
Inspect for flatness.
Using a precision straight edge and feeler 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.
Flatness of cylinder head gasket surface
Standard : Less than 0.05 mm (0.0019 in.) for total area
Less than 0.02 mm (0.0007 in.) for a section of 100 mm (3.9370 in.) X 100 mm (3.9370 in.)
Flatness of manifold mounting surface (Intake/Exhaust)
Standard : Less than 0.10 mm (0.0039 in.)

2.
Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
Valve And Valve Spring
1.
Inspect valve stems and valve guides.
(1)
Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide inner diameter
Intake / Exhaust :
5.500 - 5.512 mm (0.21654 - 0.21701 in.)

(2)
Using a micrometer, measure the diameter of the valve stem.
Valve stem outer diameter
Intake : 5.465 - 5.480 mm (0.21516 - 0.21575 in.)
Exhaust : 5.458 - 5.470 mm (0.214988 - 0.21535 in.)

(3)
Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake : 0.020 - 0.047 mm (0.00078 - 0.00185 in.)
Exhaust : 0.030 - 0.054 mm (0.00118 - 0.00212 in.)
If the clearance is greater than maximum, replace the valve or cylinder head.
2.
Inspect the valves.
(1)
Check the valve is ground to the correct valve face angle.
(2)
Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3)
Check the valve head margin thickness.
Valve head thickness (Margin)
[Standard]
Intake : 1.02 mm(0.0401 in.)
Exhaust : 1.09 mm(0.0429 in.)

If the margin thickness is less than minimum, replace the valve.
(4)
Check the valve length.
Valve length
[Standard]
Intake : 113.18 mm (4.4559 in.)
Exhaust : 105.84 mm (4.1669 in.)
[Limit]
Intake : 112.93 mm (4.4461 in.)
Exhaust : 105.59 mm (4.1571 in.)
(5)
Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3.
Inspect the valve seats
(1)
Check the valve seat for evidence of overheating and improper contact with the valve face. Replace the cylinder head if necessary.
(2)
Check the valve guide for wear. If the valve guide is worn, replace the cylinder head.
4.
Inspect the valve springs.
(1)
Using a steel square, measure the out-of-square of the valve spring.
(2)
Using a vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 47.44 mm (1.8677 in.)
Out-of-square : Less than 1.5°

If the free length is not as specified, replace the valve spring.
MLA (Mechanical Lash Adjuster)
1.
Inspect the MLA.
Using a micrometer, measure the MLA outside diameter.
MLA outer diameter :
31.964 - 31.980 mm (1.2584 - 1.2590 in.)
2.
Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore inner diameter :
32.000 - 32.025 mm (1.2598 - 1.2608 in.)
3.
Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.
MLA to tappet bore clearance
[Standard] : 0.020 - 0.061 mm (0.00078 - 0.00240 in.)
Reassembly
  
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1.
Install valves.
(1)
Using SST (09222-4A000), push in a new oil seal.
  
Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.

(2)
Install the valve, valve spring and spring retainer.
  
Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer.
(3)
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.

(4)
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.
2.
Install the MLAs after applying engine oil.
Check that the MLA rotates smoothly by hand.

  
MLA can be reinstalled in its original position.
However, the valve lash clearances must be rechecked and adjusted accordingly before the cylinder head is installed onto the cylinder block.
Refer to General information in EM section for Valve Clearance checking and adjustment procedure.
Installation
  
Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Thoroughly clean all parts to be assembled.
Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No.1 piston at TDC.
1.
Install the cylinder head gasket.
(1)
The sealant locations on cylinder head gasket and cylinder block must be free of engine oil and etc.
(2)
Apply liquid gasket (Loctite 5900H or equivalent) on the cylinder block top surface before assembling the cylinder head gasket.
Bead width : 2.0 - 3.0 mm (0.08 - 0.12 in.)

(3)
Install the cylinder head gasket (A) on the cylinder block.

  
Be careful of the installation direction.
(4)
Apply liquid gasket (Loctite 5900H or equivalent) on the cylinder head gasket top surface after assembling the cylinder head gasket.
Bead width : 2.0 - 3.0 mm (0.08 - 0.12 in.)

  
After applying liquid gasket, assemble the cylinder head in 5 minutes.
2.
Place the cylinder head (A) carefully in order not to damage the gasket with the bottom part of the end.

  
Remove the extruded sealant after assembling the cylinder head assembly.
3.
Install cylinder head bolts.
(1)
Do not apply engine oil on the cylinder head bolts.
(2)
Using the SST (09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque :
32.4 - 36.3 N·m (3.3 - 3.7 kgf·m, 23.9 - 26.8 lb·ft) + 90 - 95° + 90 - 95°

  
Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
4.
Install the order parts in the reverse order of removal.
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