Kia Rio: Cylinder Head Assembly / Cylinder Head

Kia Rio 2017-2024 YB Service Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head

Components and components location

Components

1. Cylinder head assembly
2. Cylinder head gasket
3. Swing arm
4. HLA(Hydraulic Lash Adjuster)
5. Retainer lock

6. Retainer
7. Valve spring
8. Valve stem seal
9. Valve
10. Cylinder head bolt

Repair procedures

Removal

Engine removal is not required for this procedure.

•	Use fender covers to avoid damaging painted surfaces.

•	To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) 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.

•	Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1.	Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")

2.	Remove the battery. (Refer to Engine Electrical System - "Battery")

3.	Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

4.	Drain the coolant. (Refer to Cooling System - Coolant")

5.	Remove the air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")

6.	Disconnect the radiator upper hose (A).

7.	Disconnect the brake booster vacuum hose (A), and heater hoses (B).

8.	Disconnect the fuel hose (A), purge control solenoid valve (PCSV) hose (B).

9.	Remove the water temperature control assembly. (Refer to Cooling System - "Water Temperature Control Assembly")

10.	Remove the cylinder head cover. (Refer to Cylinder Head Assembly - "Cylinder Head Cover")

11.	Remove the intake manifold. (Refer to Intake and Exhaust System - "Intake Manifold")

12.	Remove the delivery pipe assembly. (Refer to Engine Control / Fuel System - "Delivery Pipe")

13.	Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")

14.	Remove the timing chain. (Refer to Timing System - "Timing Chain")

15.	Remove the cvvt & camshaft. (Refer to Cylinder Head Assembly - "CVVT & Camshaft" )

16.

Remove the vacuum pipe (A).

Tightening torque :

9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

17.

Remove the solenoid valve bracket (A).

Tightening torque :

18.6 - 23.5 N·m (1.9 - 2.4 kgf·m, 13.7 - 17.4 lb·ft)

18.	Remove the intake camshaft position sensor (CMPS). (Refer to Engine Control / Fuel System - "Camshaft Position Sensor")

19.	Remove the exhaust CVVT oil control valve (OCV).

20.	Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.

21.

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.

22.	Remove the cylinder head gasket (A).

Disassembly

1.	Remove the swing arm and the hydraulic lash adjuster assembly (A).

Remove the valves.

(1)	Using the SST (09222-3K000, 09222-3K100), press the valve spring and remove retainer lock.

(2)	Remove the spring retainer.

(3)	Remove the valve spring.

(4)	Remove the valve.

(5)

Using the pliers, remove the valve stem seal.

Do not reuse old valve stem seals.

Inspection

Cylinder Head

Inspect for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting 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 (0.0020 in)

Less than 0.02 mm (0.0008 in) / 100 x 100

Flatness of manifold gasket surface

Standard : Less than 0.1 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

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 (0.2165 -0.2170 in)

(2)

Using a micrometer, measure the diameter of the valve stem.

Valve stem outer diameter

Intake : 5.465 - 5.480 mm ( 0.2151 - 0.2157 in)

Exhaust : 5.448 - 5.460 mm (0.2144 - 0.2149 in)

(3)

Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.

Valve stem-to-guide clearance

Intake : 0.020 - 0.047 mm (0.00078 - 0.00185 in)

Exhaust : 0.040 - 0.064 mm (0.00157 - 0.00251 in)

Inspect valves.

(1)

Check the valve is ground to the correct valve face angle.

Valve face angle :

Intake/Exhaust : 45.25° - 45.75°

(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. If the margin thickness is less than minimum, replace the valve.

Margin

Intake : 1.35 - 1.65 mm (0.0531 - 0.0650 in)

Exhaust : 1.60 - 1.90 mm (0.0630 - 0.0748 in)

(4)

Check the valve length.

Length

Intake : 100.94 mm (3.9740 in)

Exhaust : 101.09 mm (3.9799 in)

(5)	Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.

Inspect 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 cylinder head.

(2)	Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head.

(3)

Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.

Valve seat contact width :

Intake : 0.85 - 1.15 mm ( 0.0334 - 0.0452 in)

Exhaust : 1.35 - 1.65 mm (0.0531 - 0.0649 in)

Valve seat angle :

Intake / Exhaust : 44.75° - 45.10°

Inspect valve springs.

(1)	Using a steel square, measure the out-of-square of the valve spring.

(2)

Using vernier calipers, measure the free length of the valve spring.

Valve spring

Free height : 47.9mm (1.8858in)

Out-of-square : 1.5° (MAX)

HLA (Hydraulic Lash Adjuster)

With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.

Problem	Possible cause	Action
1. Temporary noise when starting a cold engine	Normal	This noise will disappear after the oil in the engine reaches the normal pressure.
2. Continuous noise when the engine is started after parking more than 48 hours.	Oil leakage of the high pressure chamber on the HLA, allowing air to get in.	Noise will disappear within 15 minutes when engine runs at 2000-3000 rpm.If it doesn’t disappear, refer to step 7 below.
3. Continuous noise when the engine is first started after rebuilding cylinder head.	Insufficient oil in cylinder head oil gallery.
4. Continuous noise when the engine is started after excessively cranking the engine by the starter motor or band.	Oil leakage of the high-pressure chamber in the HLA, allowing air to get in.Insufficient oil in the HLA.
5. Continuous noise when the engine is running after changing the HLA.		Do not run engine at a speed higher than 3000 rpm, as this may damage the HLA.
6. Continuous noise during idle after high engine speed.	Engine oil level too high or too low.	Check oil level.Drain or add oil as necessary.
	Excessive amount of air in the oil at high engine speed.	Check oil supply system.
	Deteriorated oil.	Check oil quality.If deteriorated, replace with specified type.
7. Noise continues for more than 15 minutes.	Low oil pressure.	Check oil pressure and oil supply system of each part of engine.
7. Noise continues for more than 15 minutes.	Faulty HLA.	Remove the cylinder head cover and press HLA down by hand.If it moves, replace the HLA. Be careful with the hot HLAS.

Reassembly

•	Thoroughly clean all parts to be assembled.

•	Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.

Install the valves.

(1)

Using the SST (09222-03100), push in a new valve stem 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 cone shape side is upward retainer side.

(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.

Install the swing arm and the hydraulic lash adjuster assembly (A).

(1)	Until installing HLA shall be held upright so that engine oil in HLA should not spill and assured that dust does not adhere to HLA.

(2)

HLA shall be inserted tenderly to the cylinder head not to spill engine oil from HLA. In case of spilling, air vent shall be done in accordance with the air bent procedure.

Stroke HLA in engine oil 4-5 times by pushing its cap while pushing the ball down slightly by hard steel wire.

(Take care not to severely push hard steel wire down since ball is several grams.)

After installed on engine, lash adjuster might give out unusual noise. If air is mingled then apply slow racing (Approx. one minute for 1 racing) from idle to 3000rpm and is removed from adjuster.

Installation

•	Thoroughly clean all parts to be assembled.

•	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.

•	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.

(1)	The sealant locations on cylinder head gasket, cylinder block and timing chain lower case must be free of engine oil and etc.

(2)

Apply sealant TB1217 or LT5900 on the cylinder block top surface (Refer to below illustration) before assembling the cylinder head gasket.

Bead width : 2.0 - 3.0 mm (0.0787 - 0.1181 in)

(3)

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

Be careful of the installation direction.

(4)

Apply sealant TB1217 or LT5900 on the cylinder head gasket top surface (Refer to below illustration) after assembling the cylinder head gasket.

Bead width : 2.0 - 3.0 mm (0.0787 - 0.1181 in)

(5)	Remove the extruded sealant after assembling the cylinder head assembly.

Install the cylinder head assembly.

(1)	Place the cylinder head assembly (A) quietly in order not to damage the gasket with the bottom part of the end.

(2)

Tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.

Tightening torque :

12.7 - 16.7 N·m (1.3 - 1.7 kgf·m, 9.4 - 12.3 lb·ft) + 90 - 95° + 120 - 125°

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.

3.	Install the other parts in the reverse order of removal.

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