Kia_Sephia_Rio_Spectra_Optima_1998-2006

Camshafts, Bearings, & Lifters

Print

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Ignition coils and high-tension cords
     
    Positive Crankcase Ventilation (PCV) valve and ventilation hoses
     

  4.  
  5. Position the engine so that No. 1 cylinder is at Top Dead Center (TDC).
  6.  
  7. Remove or disconnect the following:

    Timing belt
     
    Cylinder head cover
     
    Camshaft Position (CMP) sensor
     
    Camshaft sprockets
     

  8.  
  9. Loosen the camshaft bearing cap retaining bolts in several steps, following the proper sequence.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap mounting bolt removal sequence-1.8L engine

  10.  
  11. Remove or disconnect the following:
    NOTE
    The Hydraulic Lash Adjusters (HLA-s) must be installed in the location from which they were removed.



    Camshafts
     
    Camshaft oil seal using a seal removal tool
     

  12.  
  13. Mark the HLA-s to identify their original positions.
  14.  
  15. Remove the HLA-s from the cylinder head using a magnet, and store upside-down in a oil-filled container
  16.  

To install:

  1. Apply a coat of the clean engine oil to the sides of the HLA-s.
  2.  
  3. Install or connect the following:

    HLA-s into the cylinder head bore
     

  4.  
  5. Check that the HLA moves freely in its bore.
  6.  
  7. Lubricate the camshaft journals and lobes with clean engine oil.
  8.  
  9. Install or connect the following:

    Camshafts in the cylinder head making sure that the camshaft dowel pins point straight up

    Click image to see an enlarged view

    Fig. Camshaft bearing cap mounting bolt tightening sequence-1.8L engine

     
    Camshaft caps in their original positions. Loosely install the cap bolts.
     
    Camshaft cap bolts in 5-6 steps to 13-20 ft. lbs. (18-27 Nm) in the proper sequence
     

  10.  
  11. Oil the lip of the new camshaft oil seal and, using a seal installer. Drive the seal into the cylinder head until it is flush with the edge of the camshaft bearing cap.
  12.  
  13. Install or connect the following:

    Camshaft sprockets onto the camshaft. Be sure to align the I mark with the intake camshaft dowel pin and the E mark with the exhaust camshaft dowel pin, then tighten the retaining bolt to 36-44 ft. lbs. (49-61 Nm).
     
    CMP sensor
     
    Cylinder head cover
     
    Timing belt
     
    PCV and ventilation hoses
     
    Ignition coils and high-tension cords
     
    Negative battery cable
     

  14.  
  15. Check the engine fluid levels, start the vehicle and check for leaks.
  16.  

1.5L & 1.6L (VIN 5) Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the breather hose and Positive Crankcase Ventilation (PCV) hose.
  6.  
  7. Remove the water pump and crankshaft pulleys.
  8.  
  9. Remove the timing belt cover.
  10.  
  11. Loosen the timing bolt tensioner pulley and temporarily secure it.
  12.  
  13. Remove the timing belt from the camshaft sprocket.
  14.  
  15. Remove the center cover bolts and cover.
  16.  
  17. Remove the ignition coil.
  18.  
  19. Remove the cylinder head cover.
  20.  
  21. Remove the camshaft pulley (sprocket).

    Click image to see an enlarged view

    Fig. Remove the camshaft pulley (sprocket)-1.5L and 1.6L engines



    Click image to see an enlarged view

    Fig. Exploded view of the camshafts and related components-1.5L and 1.6L engines

  22.  
  23. Remove the cam carrier assembly and timing belt.
  24.  
  25. Remove the camshafts.
  26.  
  27. Remove the camshaft oil seal using a seal removal tool.
    NOTE
    The Hydraulic Lash Adjusters (HLA-s) must be installed in the location from which they were removed.

  28.  
  29. Mark the HLA-s to identify their original positions.
  30.  
  31. Remove the HLA-s from the cylinder head using a magnet, and store upside-down in a oil-filled container
  32.  

To install:

  1. Apply a coat of the clean engine oil to the sides of the HLA-s.
  2.  
  3. Install the HLA-s into the cylinder head bore. Check that the HLA moves freely in its bore.
  4.  
  5. Lubricate the camshaft journals and lobes with clean engine oil.
  6.  
  7. Install the camshafts in the cylinder head making sure that the camshaft dowel pins point straight up.
  8.  
  9. Install the cam carrier assembly. Tighten the bolts, in several steps, to 8-11 ft. lbs. (11-15 Nm).
  10.  
  11. Install the camshaft oil seal, using a suitable seal installer.
  12.  
  13. Install the camshaft sprockets onto the camshaft. Be sure to align the I mark with the intake camshaft dowel pin and the E mark with the exhaust camshaft dowel pin, then tighten the retaining bolt to 36-44 ft. lbs. (49-61 Nm).
  14.  
  15. The remainder of installation is the reverse of the removal procedure.
  16.  
  17. Check the engine fluid levels, start the vehicle and check for leaks.
  18.  

1.6L (VIN 3) & 2.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
  6.  
  7. Disconnect the terminals from battery and remove the heat shield.
  8.  
  9. Remove the engine cover.
  10.  
  11. Drain the engine coolant.
  12.  
  13. Remove the radiator cap to speed draining.
  14.  
  15. Remove the intake air hose and air cleaner assembly.
  16.  
  17. Disconnect the AFS (Air Flow Sensor) connector.
  18.  
  19. Disconnect the breather hose from intake air hose.
  20.  
  21. Remove the intake air hose and air cleaner upper cover.
  22.  
  23. Remove the air cleaner element.
  24.  
  25. Remove the bolts and air cleaner lower cover.
  26.  
  27. Remove the upper radiator hose and lower radiator hose.
  28.  
  29. Remove the heater hoses.
  30.  
  31. Disconnect the accelerator cable by loosening the lock-nut, then slip the cable end out of the throttle linkage.
  32.  
  33. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
  34.  
  35. Disconnect the OCV (Oil Control Valve) connector.
  36.  
  37. Disconnect the oil temperature sensor connector.
  38.  
  39. Disconnect the ECT (Engine Coolant Temperature) sensor connector.
  40.  
  41. Disconnect the ignition coil connector.
  42.  
  43. Disconnect the TPS (Throttle Position Sensor) connector.
  44.  
  45. Disconnect the ISA (Idle Speed Actuator) connector.
  46.  
  47. Disconnect the CMP (Camshaft Position Sensor) connector.
  48.  
  49. Disconnect the four injector connectors.
  50.  
  51. Disconnect the knock sensor connector.
  52.  
  53. Disconnect the ground cables from the intake manifold and vehicle's body.
  54.  
  55. Disconnect the air conditioner compressor switch connector.
  56.  
  57. Disconnect the front heated oxygen sensor connector.
  58.  
  59. Disconnect the CKP (Crankshaft Position Sensor) connector.
  60.  
  61. Disconnect the oil pressure switch connector.
  62.  
  63. Disconnect the PCSV (Purge Control Solenoid Valve) connector.
  64.  
  65. Disconnect the fuel inlet hose of the delivery pipe side.
  66.  
  67. Disconnect the hose of the PCSV (Purge Control Solenoid Valve) side.
  68.  
  69. Remove the brake booster vacuum hose.
  70.  
  71. Remove the power steering pump drive belt.
  72.  
  73. Remove the power steering pump and use a wire to secure the pump to the vehicle so that it is out of the way.
  74.  
  75. Remove the bolts and power steering pump bracket.
  76.  
  77. Remove the spark plug cables.
  78.  
  79. Remove the exhaust manifold.
  80.  
  81. Remove the intake manifold.
  82.  
  83. Remove the timing belt.
  84.  
  85. Remove the PCV (Positive Crankcase Ventilation) hose.
  86.  
  87. Remove the cylinder head cover.
  88.  
  89. Remove the camshaft sprocket.
  90.  
  91. Insert a stopper pin or other device into timing chain auto tensioner and remove the auto tensioner.
  92.  
  93. Remove the camshaft bearing caps and camshafts.

    Click image to see an enlarged view

    Fig. Exploded view of the camshafts and related components-2.0L and 1.6L (VIN 3) engines

  94.  

To install:

  1. Install the camshafts.
  2.  
  3. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.

    Click image to see an enlarged view

    Fig. Camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket alignment-2.0L and 1.6L (VIN 3) engines

  4.  
  5. Install the camshaft and bearing caps. Tighten the bearing cap bolts to 10.5 ft. lbs. (14 Nm).
  6.  
  7. Install the timing chain auto tensioner. Tighten the bolts to 6 ft. lbs. (8.5 Nm).
  8.  
  9. Remove the auto tensioner stopper pin.
  10.  
  11. Check and adjust valve clearance.
  12.  
  13. Using the SST (09221 - 21000), install the camshaft bearing oil seal.
  14.  
  15. Install the camshaft sprocket.
  16.  
  17. Install the cylinder head cover.
  18.  
  19. Install the cylinder head cover gasket in the groove of the cylinder head cover. 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. Apply liquid gasket to the head cover gasket at the corners of the recess.
  20.  
  21. Install the cylinder head cover  with the 12 bolts. Tighten all cylinder head cover bolts temporarily to half of the standard torque, the re-tighten completely using the order specified in the illustration.

    Click image to see an enlarged view

    Fig. Cylinder head cover sequence-1.6L (VIN 3)

  22.  
  23. Install the PCV(Positive Crankcase Ventilation) hose.
  24.  
  25. Install the timing belt.
  26.  
  27. Install the intake manifold.
  28.  
  29. Install the exhaust manifold.
  30.  
  31. Install the spark plug cables.
  32.  
  33. Install the power steering pump bracket and bolts.
  34.  
  35. Install the power steering pump.
  36.  
  37. Connect the accelerator cable.
  38.  
  39. Install the brake booster hose.
  40.  
  41. Connect the hose of the PCSV side.
  42.  
  43. Connect the fuel inlet hose of the delivery pipe side. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
  44.  
  45. Connect the PCSV connector.
  46.  
  47. Connect the front heated oxygen sensor connector.
  48.  
  49. Connect the CKP connector.
  50.  
  51. Connect the oil pressure switch connector.
  52.  
  53. Connect the air conditioner compressor switch connector.
  54.  
  55. Connect the ground cables to intake manifold and vehicle's body.
  56.  
  57. Connect the knock sensor connector.
  58.  
  59. Connect the fuel injector connectors.
  60.  
  61. Connect the CMP connector.
  62.  
  63. Connect the ISA connector.
  64.  
  65. Connect the TPS connector.
  66.  
  67. Connect the ignition coil connector.
  68.  
  69. Connect the ECT connector.
  70.  
  71. Connect the oil temperature sensor connector.
  72.  
  73. Connect the OCV connector.
  74.  
  75. Install the heater hose.
  76.  
  77. Install the upper radiator hose and lower radiator hose.
  78.  
  79. Install the intake air hose and air cleaner assembly.
  80.  
  81. Install the air cleaner element.
  82.  
  83. Install the intake air hose and air cleaner upper cover.
  84.  
  85. Install the breather hose to intake air hose.
  86.  
  87. Connect the AFS connector.
  88.  
  89. Install the engine cover.
  90.  
  91. Install the heat shield and connect the battery terminals to the battery.
  92.  
  93. Fill with engine coolant.
  94.  
  95. Start the engine and check for leaks.
  96.  
  97. Recheck engine coolant level and oil level.
  98.  

1.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the ignition coils and high-tension cords.
  6.  
  7. Remove the Positive Crankcase Ventilation (PCV) valve and ventilation hoses.
  8.  
  9. Position the engine so that No. 1 cylinder is at Top Dead Center (TDC).
  10.  
  11. Remove the timing belt.
  12.  
  13. Remove the cylinder head cover.
  14.  
  15. Remove the Camshaft Position (CMP) sensor.
  16.  
  17. Remove the camshaft sprockets.
  18.  
  19. Loosen the camshaft bearing cap retaining bolts in several steps, following the proper sequence.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap mounting bolt removal sequence-1.8L engine

  20.  
  21. Remove the camshafts.
  22.  
  23. Remove the camshaft oil seal using a seal removal tool.
    NOTE
    The Hydraulic Lash Adjusters (HLA-s) must be installed in the location from which they were removed.

  24.  
  25. Mark the HLA-s to identify their original positions.
  26.  
  27. Remove the HLA-s from the cylinder head using a magnet, and store upside-down in a oil-filled container
  28.  

To install:

  1. Apply a coat of the clean engine oil to the sides of the HLA-s.
  2.  
  3. Install the HLA-s into the cylinder head bore.
  4.  
  5. Check that the HLA moves freely in its bore.
  6.  
  7. Lubricate the camshaft journals and lobes with clean engine oil.
  8.  
  9. Install the camshafts in the cylinder head making sure that the camshaft dowel pins point straight up.

    Click image to see an enlarged view

    Fig. Proper alignment, prior to camshaft installation-1.8L engine



    Click image to see an enlarged view

    Fig. Camshaft bearing cap mounting bolt tightening sequence-1.8L engine

  10.  
  11. Install the camshaft caps in their original positions. Loosely install the cap bolts.
  12.  
  13. Install the camshaft cap bolts in 5-6 steps to 13-20 ft. lbs. (18-27 Nm) in the proper sequence.
  14.  
  15. Oil the lip of the new camshaft oil seal and, using a seal installer. Drive the seal into the cylinder head until it is flush with the edge of the camshaft bearing cap.
  16.  
  17. Install the camshaft sprockets onto the camshaft. Be sure to align the I mark with the intake camshaft dowel pin and the E mark with the exhaust camshaft dowel pin, then tighten the retaining bolt to 36-44 ft. lbs. (49-61 Nm).
  18.  
  19. Install the CMP sensor.
  20.  
  21. Install the cylinder head cover.
  22.  
  23. Install the timing belt.
  24.  
  25. Install the PCV and ventilation hoses.
  26.  
  27. Install the ignition coils and high-tension cords.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Check the engine fluid levels, start the vehicle and check for leaks.
  32.  

2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the breather hose from between the air cleaner and rocker arm cover.
  8.  
  9. Remove the air cleaner.
  10.  
  11. Remove the timing belt cover.
  12.  
  13. Remove the rocker arm cover and crank angle sensor.
  14.  
  15. Remove the camshaft sprocket bolts and sprockets.
    NOTE
    Keep all valvetrain components in order as you remove them. The components must be installed in their original locations.

  16.  
  17. Remove the bearing cap bolts, bearing caps, camshafts, rocker arms and valve adjusters.

    Click image to see an enlarged view

    Fig. Exploded view of the camshafts and related components-2.4L engine

  18.  

To install:

  1. Lubricate the camshaft journals and lobes with clean engine oil.
  2.  
  3. Install the camshafts on the cylinder head. The intake camshaft has a slit on its rear side to drive the Crankshaft Position (CKP) sensor.
  4.  
  5. Install the camshaft bearing caps. Make sure the cam can be easily turned by hand, then remove the bearing caps and install the rocker arms.
  6.  
  7. Install the camshafts and bearings caps. Torque the bearing caps, in sequence, to 14-15 ft. lbs. (19-21 Nm).

    Click image to see an enlarged view

    Fig. Camshaft bearing cap tightening sequence-2.4L engine

  8.  
  9. Install the camshaft oil seal.
  10.  
  11. Install the camshaft sprockets. Torque the bolts to 58-72 ft. lbs. (80-100 Nm).
  12.  
  13. Install the rocker cover.
  14.  
  15. Install the remaining components in the reverse of the removal procedure.
  16.  
  17. Fill the cooling system. Check the engine fluid levels, start the vehicle and check for leaks.
  18.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine cover and intake manifold.
  6.  
  7. Remove the breather hose and engine harness.
  8.  
  9. Remove the water pump pulley, crankshaft pulley, idler pulley and tensioner pulley.
  10.  
  11. Remove the timing belt cover.
  12.  
  13. Remove the timing belt tensioner pulley, loosen and secure temporarily.
  14.  
  15. Remove the timing belt from the camshaft sprocket.
  16.  
  17. Remove the spark plug cables.
  18.  
  19. Remove the cylinder head cover.
  20.  
  21. Remove the camshaft sprocket.
  22.  
  23. Remove the camshaft bearing cap bolts.
  24.  
  25. Remove the camshafts.
  26.  
  27. Remove the HLA-s from the cylinder head using a magnet, and store upside-down in a oil-filled container

    Click image to see an enlarged view

    Fig. Exploded view of the camshafts and related components-2.7L engine

  28.  

To install:

  1. Apply a coat of the clean engine oil to the sides of the HLA-s.
  2.  
  3. Install the HLA-s into the cylinder head bore.
  4.  
  5. Check that the HLA moves freely in its bore.
  6.  
  7. Lubricate the camshaft journals and lobes with clean engine oil.
  8.  
  9. Install the camshafts in the cylinder head making sure that the camshaft dowel pins point straight up.
  10.  
  11. Install the bearing caps. Check the marks on the caps for the Intake (I) and Exhaust (E) markings. Torque the bolts, working from the center outward to 10-11 ft. lbs. (14-15 Nm).
  12.  
  13. Install the remaining components in the reverse of the removal procedure.
  14.  
  15. Check the engine fluid levels, start the vehicle and check for leaks.
  16.  

 
label.common.footer.alt.autozoneLogo