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.
•
Be sure to read and follow the “General Safety Information
and Caution” before doing any work related with the high voltage
system.
Failure to follow the safety instructions may result in serious electrical injuries."
•
Be sure to shut off the high voltage circuit according to
the “High Voltage Shut-off Procedures” before doing any work related
with the high voltage system to avoid serious electrical injuries.
1.
Shut off the High Voltage circuit (Refer to “High Voltage Shutoff Procedure” in this group).
2.
Remove the engine cover.
3.
Remove the air duct and the air cleaner assembly. (Refer to Engine and transaxle assembly in this group)
4.
Remove the under covers. (Refer to Engine and transaxle assembly in this group)
5.
Remove the RH front wheel. (Refer to SS group - "Wheel")
6.
Loosen the drain plug, and drain the engine coolant. Remove
the radiator cap to help drain the coolant faster. (Refer to Cooling
system in this group)
7.
Disconnect the radiator upper hose and lower hose. (Refer to Cooling system in this group)
8.
Disconnect the wiring connectors and harness clamps, and
remove the wiring and protectors from the cylinder head and intake
manifold.
(1)
The intake oil control valve (OCV) connector (A).
(2)
The exhaust oil control valve (OCV) connector (A).
(3)
The oil pressure switch (OPS) connector (A), the A/C
compressor switch connector (B) and the hybrid starter generator (HSG)
sensor connector (C).
(4)
The injector connectors (A).
(5)
The ignition coil connectors (A).
(6)
The electronic throttle control (ETC) connector (A), the
manifold absolute pressure sensor (MAPS) & intake air temperature
sensor (IATS) connector (B), the knock sensor connector (C) and the
intake camshaft position sensor (CMPS) connector (D).
(7)
The engine coolant temperature sensor (ECTS) connector (A),
the condenser connector (B), the crankshaft position sensor(CKPS)
connector (C), the oxygen sensor connectors (D), the exhaust camshaft
position sensor(CMPS) connector (E) and the purge control solenoid
valve(PCSV) connector (F).
9.
Disconnect the heater hoses. (Refer to Engine and transaxle assembly in this group)
10.
Disconnect the fuel hose (A) and the purge control solenoid valve(PCSV) hose (B).
11.
Disconnect the water hoses (A).
12.
Remove the water temperature control assembly (A).
13.
Remove the timing chain. (Refer to Timing system in this group)
14.
Remove the intake and exhaust manifold. (Refer to Intake and exhaust system in this group)
15.
Remove the intake CVVT assembly (A) and exhaust CVVT assembly (B).
When removing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.
16.
Remove the camshaft.
(1)
Remove the front camshaft bearing cap (A) with the upper bearing (B).
(2)
Remove the camshaft bearing cap (A) in the sequence shown.
(3)
Remove the camshafts (A).
(4)
Remove the exhaust camshaft lower bearing (A).
17.
Remove the intake oil control valve (OCV) (A) using a torx wrench.
18.
Remove the exhaust oil control valve (OCV) (A) using a torx wrench.
19.
Remove the intake camshaft position sensor (CMPS) (A).
20.
Remove the exhaust camshaft position sensor (CMPS) (A) after removing the engine hanger and cam position sensor cover (B).
21.
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 (B).
Disassembly
Identify MLA(Mechanical Lash Adjuster), 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
contacting surface of the cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm (0.0019in.) for total area
Less than 0.02mm (0.0007in.) for a section of 100mm (3.9370in.) X 100mm (3.9370in.)
Flatness of manifold mounting surface (Intake/Exhaust)
Standard : Less than 0.10mm (0.0039in.)
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.
Clamp the camshaft using a vise. Be careful not to damage the cam lobes and journals in the vise.
(2)
Check that the CVVT is locked by turning it clockwise or counterclockwise. It must not rotate.
(3)
Intake CVVT : Seal one of the two advance holes in the camshaft journal with tape.
Exhaust CVVT : Seal one of the two retard holes in the camshaft journal with tape.
[Intake]
[Exhaust]
(4)
Intake CVVT : Apply approx. 150 kPa (1.5 kgf/cm?, 21 psi )
of compressed air into the unsealed advance hole to release the lock.
Exhaust CVVT : Apply approx. 150 kPa (1.5 kgf/cm?, 21 psi )
of compressed air into the unsealed retard hole to release the lock.
Cover the oil paths with a piece of cloth when applying compressed air to prevent oil from spraying.
(5)
Intake CVVT : With compressed air applied, rotate the CVVT
into the advance direction (counterclockwise) within its phasing range
and check that the CVVT turns smoothly.
Exhaust CVVT : With compressed air applied, rotate the CVVT
into the retard direction (clockwise) and check that the CVVT turns
smoothly.
CVVT phasing range
Intake : 22.5°±1° (from the most retarded position to the most advanced position)
Exhaust : 20°±1° (from the most advanced position to the most retarded position)
(6)
Intake CVVT : Rotate the CVVT into the most retarded position (clockwise) and then check that the CVVT is locked.
Exhaust CVVT : Rotate the CVVT into the most advanced position (counterclockwise) and then check that the CVVT is locked.
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.
Mode Control Actuator Description and Operation
Description
The mode control actuator is located at the heater unit.
It adjusts position of mode door by operating mode control
actuator based on signal of A/C control unit. Pressing mode select ...
High beam operation
To turn on the high beam headlights, push the lever away from you. Pull it back
for low beams.
The high beam indicator will light when the headlight high beams are switched
on.
To prevent the ...
Kia Optima: Cylinder Head Repair procedures
![[Exhaust]](images/books/2071/slmm10100n.gif)
