Cylinder Head Assembly: Installation

NOTE:

Thoroughly clean all parts to be assembled.
Always use a new cylinder 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.

Install the cylinder head gasket (A) on the cylinder block.
NOTE: Be careful of the installation direction.

Fig 1: Illustrating Head Gasket Direction
Courtesy of KIA MOTORS AMERICA, INC.
Place the cylinder head onto the block carefully in order to prevent damaging the gasket. If the gasket is damaged, fluid leakage could occur.
Install the cylinder head bolts.
1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
2. Using 8 mm and 10 mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in sequence. See Fig 2.
  1. Tightening torque:
  2. M10: 22.6-26.5 N.m (2.3-2.7 kg-m, 16.6-19.5 lb-ft) + (60°-65°) + (60°-65°)
  3. M12: 27.5-31.4 N.m (2.8-3.2 kg-m, 20.3-23.1 lb-ft) + (60°-65°) + (60°-65°)
  Fig 2: Cylinder Head Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.

NOTE:

Always use a new OCV (Oil Control Valve) filter gasket.
Keep the OCV filter clean.

Fig 3: Installing Oil Control Valve Filter

G00719063

Courtesy of KIA MOTORS AMERICA, INC.

Install the OCV (Oil Control Valve) filter (A).
Tightening torque: 40.2-50.0 N.m (4.1-5.1 kg-m, 29.7-36.9 lb-ft)
Install the OCV (Oil Control Valve) (A).
Tightening torque: 9.8-11.8 N.m (1.0-1.2 kg-m, 7.2-8.7 lb-ft)

Fig 4: Installing Oil Control Valve
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- Do not reuse the OCV (Oil Control Valve) when dropped.
- Keep the OCV clean.
- Do not hold the OCV (Oil Control Valve) sleeve during servicing.
- When the OCV is installed on the engine, be careful not to rotate the engine while holding the yoke.
Install the camshafts.
1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.
  
  Fig 5: Aligning Timing Chains
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install the camshaft (A) and bearing caps (B).
  Tightening torque: 13.7-14.7 N.m (1.4-1.5 kg-m, 10.1-10.8 lb-ft)
  
  Fig 6: Installing Camshaft Bearing Caps
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the timing chain auto tensioner (A).
  Tightening torque: 7.8-9.8 N.m (0.8-1.0 kg-m, 5.8-7.2 lb-ft)
  
  Fig 7: Installing Timing Chain Auto Tensioner
  Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the auto tensioner stopper pin (B).
Check and adjust valve clearance. See VALVE CLEARANCE INSPECTION & ADJUSTMENT .
Using the Service Tool (09221 - 21000), install the camshaft bearing oil seal.

Fig 8: Installing Camshaft Bearing Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Install the camshaft sprocket.

NOTE:

Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the groove.
When installing, make sure the cylinder head cover gasket is seated securely in the corners of the recesses with no gap.

Install the cylinder head cover.
1. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).
  
  Fig 9: Installing Cylinder Head Cover Gasket
  Courtesy of KIA MOTORS AMERICA, INC.
2. Apply liquid gasket to the head cover gasket at the corners of the recess.
  
  Fig 10: Applying Gasket Sealant
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Use liquid gasket, Loctite No. 5999.
  - Check that the mating surfaces are clean and dry before applying liquid gasket.
  - After assembly, wait at least 30 minutes before filling the engine with oil.
3. Install the cylinder head cover (A) with the 12 bolts (B). Uniformly tighten the bolts in several passes.
  Tightening torque: 7.8-9.8 N.m (0.8-1.0 kg-m, 5.8-7.2 lb-ft)
  
  Fig 11: Installing Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
Install the PCV (Positive Crankcase Ventilation) hose.
Install the timing belt. See TIMING BELT .
Install the intake manifold. See INTAKE AND EXHAUST SYSTEM .
Install the exhaust manifold. See INTAKE AND EXHAUST SYSTEM .
Install the spark plug cables.

Fig 12: Installing Spark Plug Cables
Courtesy of KIA MOTORS AMERICA, INC.
Install the power steering pump bracket (A) and bolts (B, C).
Tightening torque:

Bolt (B): 34.3-49.0 N.m (3.5-5.0 kg-m, 25.3-36.2 lb-ft)

Bolt (C): 11.8- 14.7 N.m (1.2-1.5 kg-m, 8.7-10.8 lb-ft)

Fig 13: Installing Power Steering Pump Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the power steering pump. See CHECKING POWER STEERING BELT TENSION .
Install the accelerator cable.
Install the brake booster hose (C).
Connect the hose (B) of the PCSV (Purge Control Solenoid Valve) side.
Connect the fuel inlet hose (A) of the delivery pipe side.

Fig 14: Connecting Fuel Hoses
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
1. Connect the PCSV (Purge Control Solenoid Valve) connector (A).
  
  Fig 15: Connecting Purge Control Solenoid Valve
  Courtesy of KIA MOTORS AMERICA, INC.
2. Connect the front heated oxygen sensor connector (A).
3. Connect the CKP (Crankshaft Position Sensor) connector (B).
4. Connect the oil pressure switch connector (C).
  
  Fig 16: Connecting Oil Pressure Switch Connector
  Courtesy of KIA MOTORS AMERICA, INC.
5. Connect the air conditioner compressor switch connector (F).
6. Connect the ground cables (D, E) to intake manifold and vehicle's body.
7. Connect the knock sensor connector (C)
8. Connect the fuel injector connectors (B)
9. Connect the CMP (Camshaft position sensor) connector (A).
  
  Fig 17: Connecting Engine Sensors & Grounds
  Courtesy of KIA MOTORS AMERICA, INC.
10. Connect the ISA (Idle Speed Actuator) connector (B).
11. Connect the TPS (Throttle Position Sensor) connector (A).
  
  Fig 18: Connecting ISA & TPS Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
12. Connect the ignition coil connector (D).
13. Connect the ECT (Engine Coolant Temperature Sensor) connector (C).
14. Connect the oil temperature sensor connector (B).
15. Connect the OCV (Oil Control Valve) connector (A).
  
  Fig 19: Connecting Oil Control Valve
  Courtesy of KIA MOTORS AMERICA, INC.
Install the heater hose (A).

Fig 20: Installing Heater Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the upper radiator hose (A) and lower radiator hose (B).

Fig 21: Installing Upper & Lower Radiator Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the intake air hose and air cleaner assembly.
1. Install the air cleaner lower cover (A) and bolts (B).
  Tightening torque: 7.8-9.8 N.m (0.8-1.0 kg-m, 5.8-7.2 lb-ft)
  
  Fig 22: Installing Air Cleaner Lower Cover
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install the air cleaner element.
3. Install the intake air hose (D) and air cleaner upper cover (C).
4. Install the breather hose (B) to intake air hose (D).
5. Connect the AFS (Air Flow Sensor) connector (A).
  
  Fig 23: Installing Intake Air Hose & AFS Connector
  Courtesy of KIA MOTORS AMERICA, INC.
Install the engine cover.
Tightening torque: 3.9-5.9 N.m (0.4-0.6 kg-m, 2.9-4.3 lb-ft)

Fig 24: Installing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the heat shield (B) and connect the battery terminals (A) to the battery.

Fig 25: Installing Heat Shield & Battery Terminals
Courtesy of KIA MOTORS AMERICA, INC.
Fill with engine coolant.
Start the engine and check for leaks.
Recheck engine coolant level and oil level.