Kia Sportage 2005-06

Camshaft, Bearings & Lifters

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Inspection



2.7L Engine
  1. Following proper procedures, remove the camshaft bearing caps and the camshafts. Inspect the cam lobes.
  2.  
  3. Using a micrometer, measure the cam lobe height. Cam height:  

    Intake: 43.95-44.15 mm (1.7303-1.7382 in.). 
     
    Exhaust: 43.95-44.15 mm (1.7303-1.7382 in.). 
     

  4.  
  5. If the cam lobe height is less than minimum, replace the camshaft.
  6.  
  7. Using a micrometer, measure the journal diameter. Standard value: 25.964-25.980 mm (1.0222-1.0228 in.). 
  8.  
  9. If the journal diameter is not as specified, check the oil clearance.
  10.  
  11. Check the bearings for flaking and scoring.  If the bearings are damaged, replace the bearing caps and cylinder head as a set.
  12.  
  13. Clean the bearing caps and camshaft journals. 
  14.  
  15. Place the camshafts on the cylinder head. 
  16.  
  17. Lay a strip of Plastigage® across each of the camshaft journal. 
  18.  
  19. Install the bearing caps. Tighten the bolts as described below. Remove the bearing caps. 
  20.  
  21. Measure the Plastigage® at its widest point. Bearing oil clearance:

    Standard value: 0.02-0.061 mm (0.0008-0.0024 in.) 
     
    Limit: 0.1 mm (0.0039 in.) 
     

  22.  
  23. If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 
  24.  
  25. Completely remove the Plastigage®. 
  26.  
  27. Using a dial indicator, measure the end play while moving the camshaft back and forth. Standard value: 0.1-0.15 mm (0.004-0.0059 in.) 
  28.  
  29. If the end play is greater than maximum, replace the camshaft.  If necessary, replace the bearing caps and cylinder head as a set. 
  30.  

2.0L Engine


Click image to see an enlarged view

Fig. Camshafts and related parts - 2.0L engine

  1. Following proper procedures, remove the camshaft bearing caps and the camshafts. Inspect the cam lobes.

    Click image to see an enlarged view

    Fig. Using a micrometer, measure the cam lobe height

  2.  
  3. Using a micrometer, measure the cam lobe height.

    Intake: 44.518-44.718mm (1.7527-1.7605in.)
     
    Exhaust: 44.418-44.618mm (1.7487-1.7566in.)
     

  4.  
  5. If the cam lobe height is less than minimum, replace the camshaft.
  6.  
  7. Inspect the camshaft journal clearance.
    1. Clean the bearing caps and camshaft journals.
    2.  
    3. Place the camshafts on the cylinder head.
    4.  
    5. Lay a strip of Plastigage® across each of the camshaft journals.

      Click image to see an enlarged view

      Fig. Lay a strip of Plastigage® across each of the camshaft journals

    6.  
    7. Install the bearing caps and tighten the bolts to 10 ft. lbs. (14 Nm).
      WARNING
      Do not turn the camshaft.

    8.  
    9. Remove the bearing caps.
    10.  
    11. Measure the Plastigage® at its widest point.

      Click image to see an enlarged view

      Fig. Measure the Plastigage® at its widest point

    12.  
    13. Bearing oil clearance:

      Standard: 0.020-0.061mm (0.0008-0.0024in)
       
      Limit: 0.1mm ( 0.0039in.)
       

    14.  

  8.  
  9. If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
  10.  
  11. Completely remove the Plastigage®.
  12.  
  13. Inspect the camshaft end play. Using a dial indicator, measure the end play while moving the camshaft back and forth. Camshaft end play should be 0.1-0.2mm (0.0039-0.0079in.) If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.

    Click image to see an enlarged view

    Fig. Using a dial indicator, measure the end play while moving the camshaft back and forth

  14.  
  15. Inspect the CVVT (Continuous Variable Valve Timing) assembly.
    1. Check that the CVVT (Continuous Variable Valve Timing) assembly will not turn.

      Click image to see an enlarged view

      Fig. Apply vinyl tape to all the parts except the one indicated by the arrow

    2.  
    3. Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration.
    4.  
    5. To release the CVVT lock pin, wrap some tape around the tip of an air pressure adapter and apply low air pressure (about 14 psi) to the exposed camshaft port.
      NOTE
      Wrap a shop towel or rag around the CVVT because residual oil may leak out of the unit when applying air pressure.

    6.  
    7. With low air pressure applied, turn the CVVT to the ADVANCE direction as indicated in the illustration. With the low air pressure applied, the CVVT should turn to the ADVANCE side. If too much air leaks when applying the low air pressure, the CVVT lock pin may not release and the CVVT may not turn.

      Click image to see an enlarged view

      Fig. Allow the CVVT assembly to move in the ADVANCE and RETARD directions to ensure there is no binding and that it moves freely

    8.  
    9. Allow the CVVT assembly to move in the ADVANCE and RETARD directions to ensure there is no binding and that it moves freely. It should move smoothly in the range about 20°.
    10.  
    11. Turn the CVVT by hand and make sure it locks in the maximum retard angle position.
    12.  

  16.  
  17. If CVVT does not perform as specified, replace the CVVT assembly.
  18.  

Bearing Replacement



2.0L Engine

The 2.0L engine do not use camshaft bearing inserts. If measured camshaft journal oil clearance exceeds limit, or if the bearing caps are damaged, replace the bearing caps and cylinder head as a set.

2.7L Engine

The 2.7L engine do not use camshaft bearing inserts. If measured camshaft journal oil clearance exceeds limit, or if the bearing caps are damaged, replace the bearing caps and cylinder head as a set.

Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Use Fender cover 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.


    NOTE
    Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

  2.  
  3. Remove the air duct.
  4.  
  5. Disconnect the terminals from battery.
  6.  
  7. Remove the engine cover.
  8.  
  9. Drain the engine coolant. Remove the radiator cap to speed draining.
  10.  
  11. Remove the intake air hose and air cleaner assembly.
  12.  
  13. Remove the upper radiator hose and lower radiator hose.
  14.  
  15. Remove the heater hoses.
  16.  
  17. Remove the accelerator cable by loosening the lock-nut, then slip the cable end out of the throttle linkage.
  18.  
  19. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
  20.  
  21. Disconnect the fuel inlet hose of the delivery pipe side.
  22.  
  23. Disconnect the hose of the PCSV (Purge Control Solenoid Valve) side.
  24.  
  25. Remove the brake booster vacuum hose.
  26.  
  27. Remove the power steering pump drive belt.
  28.  
  29. Remove the power steering pump and fix the pump to vehicle with a wire.
  30.  
  31. Remove the bolts and power steering pump bracket.
  32.  
  33. Remove the spark plug cables.
  34.  
  35. Remove the timing belt.
  36.  
  37. Remove the PCV (Positive Crankcase Ventilation) hose.
  38.  
  39. Remove the cylinder head cover.
  40.  
  41. Remove the camshaft sprocket.
  42.  
  43. Insert a stopper pin or other device into timing chain auto tensioner and remove the auto tensioner.

    Click image to see an enlarged view

    Fig. Camshafts and related parts - 2.0L engine



    Click image to see an enlarged view

    Fig. Insert a stopper pin or other device into timing chain auto tensioner - 2.0L engine

  44.  
  45. Remove the camshaft bearing caps and camshafts.
  46.  

To install:

  1. 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. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown - 2.0L engine

  2.  
  3. Install the camshaft and bearing caps. Tighten to 10.1-10.8 ft. lbs. (13.7-14.7 Nm)
  4.  
  5. Install the timing chain auto tensioner. Tighten to 5.8-7.2 ft. lbs. (7.8-9.8 Nm)
  6.  
  7. Remove the auto tensioner stopper pin.
  8.  
  9. Check and adjust valve clearance.

    Click image to see an enlarged view

    Fig. Installing the camshaft bearing oil seal - 2.0L engine

  10.  
  11. Using seal driver, install the camshaft bearing oil seal.
  12.  
  13. Install the camshaft sprocket. Tighten to 72-87 ft. lbs. (98-117 Nm).
  14.  
  15. Install the cylinder head cover.
  16.  
  17. Install the PCV (Positive Crankcase Ventilation) hose.
  18.  
  19. Install the timing belt.
  20.  
  21. Install the intake manifold.
  22.  
  23. Install the exhaust manifold.
  24.  
  25. Install the spark plug cables.
  26.  
  27. Install the power steering pump bracket and bolts. Tighten the mounting bolts to 25-36 ft. lbs. (34-49 Nm); the pivot bolt to 9-11 ft. lbs. (12-15 Nm).
  28.  
  29. Install the power steering pump.
  30.  
  31. Install the accelerator cable.
  32.  
  33. Install the brake booster hose.
  34.  
  35. Connect the hose of the PCSV (Purge Control Solenoid Valve) side.
  36.  
  37. Connect the fuel inlet hose of the delivery pipe side.
  38.  
  39. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
  40.  
  41. Install the heater hose.
  42.  
  43. Install the upper radiator hose and lower radiator hose.
  44.  
  45. Install the intake air hose and air cleaner assembly.
  46.  
  47. Install the engine cover.
  48.  
  49. Reconnect the battery terminals.
  50.  
  51. Install the air duct.
  52.  
  53. Fill with engine coolant.
  54.  
  55. Start the engine and check for leaks.
  56.  
  57. Recheck engine coolant level and oil level.
  58.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    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. 


    NOTE
    Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center. 

  2.  
  3. Remove the air duct.
  4.  
  5. Remove the cowl grill and wiper motor.
  6.  
  7. Remove the strut bar.
  8.  
  9. Disconnect the negative terminal from the battery.
  10.  
  11. Drain the engine coolant. Remove the radiator cap to speed draining.
  12.  
  13. Remove the engine cover.
  14.  
  15. Remove the intake air hose and air cleaner assembly.
  16.  
  17. Remove the coolant reservoir tank.
  18.  
  19. Remove the upper radiator hose and lower radiator hose.
  20.  
  21. Remove the heater hoses and throttle body heater hose.
  22.  
  23. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.
  24.  
  25. Remove the fuel inlet hose from delivery pipe.
  26.  
  27. Remove the brake booster vacuum hose.
  28.  
  29. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage.
  30.  
  31. Remove the PCV hose.
  32.  
  33. Remove the intake manifold. 
  34.  
  35. Remove the power steering pump.
  36.  
  37. Remove the timing belt.  
  38.  
  39. Remove the spark plug cable. 
  40.  
  41. Remove the cylinder head covers.
  42.  
  43. Remove the camshaft sprocket.
  44.  
  45. Remove the camshaft bearing caps.
  46.  
  47. Remove the camshafts.
  48.  

To install:


NOTE
Thoroughly clean all parts to be assembled. Always use a manifold gasket. Rotate the crankshaft, set the No.1 piston at TDC.

  1. 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. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown - 2.7L engine

  2.  
  3. Apply new engine oil to the thrust portion and journal of the camshafts. 
  4.  
  5. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. 
  6.  
  7. Install the camshafts.
  8.  
  9. Install the camshaft bearing caps. Tightening torque:

    M6 (38mm) (Mark 7): 7-9 ft. lbs. (10-12 Nm).
     
    M6 (50 mm) (Mark 10):  10-12 ft. lbs. (14-16 Nm).
     

  10.  
  11. Using a driver, install the camshaft bearing oil seal.

    Click image to see an enlarged view

    Fig. Installing the camshaft bearing oil seal - 2.7L engine

  12.  
  13. Temporarily install the camshaft sprocket bolts. 
  14.  
  15. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket bolts to 65-80 ft. lbs. (90-110 Nm).
  16.  
  17. Install the cylinder head covers.
  18.  
  19. Install the spark plug cables.
  20.  
  21. Install the timing belt.
  22.  
  23. Install the exhaust manifold.
  24.  
  25. Install the power steering pump.
  26.  
  27. Install the intake manifold.
  28.  
  29. Install the PCV hose.
  30.  
  31. Install the accelerator cable.
  32.  
  33. Install the brake booster vacuum hose.
  34.  
  35. Install the fuel inlet hose.
  36.  
  37. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
  38.  
  39. Install the heater hoses and throttle body heater hose.
  40.  
  41. Install the upper radiator hose and lower radiator hose.
  42.  
  43. Install the coolant reservoir tank.
  44.  
  45. Install the intake air hose and air cleaner assembly.
  46.  
  47. Install the engine cover.
  48.  
  49. Connect the negative terminal to the battery.
  50.  
  51. Install the strut bar.
  52.  
  53. Install the cowl grill and wiper motor.
  54.  
  55. Install the air duct.
  56.  
  57. Fill with engine coolant.
  58.  
  59. Start the engine and check for leaks.
  60.  
  61. Recheck engine coolant level and oil level.
  62.  

 
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