Kia Sportage 2005-06

Cylinder Head

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Removal & Installation



2.0L Engine


Click image to see an enlarged view

Fig. Cylinder head and related parts - 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 exhaust manifold.
  36.  
  37. Remove the intake manifold.
  38.  
  39. Remove the timing belt.
  40.  
  41. Remove the PCV (Positive Crankcase Ventilation) hose.
  42.  
  43. Remove the cylinder head cover.
  44.  
  45. Remove the camshaft sprocket.
  46.  
  47. Insert a stopper pin or other device into timing chain auto tensioner and remove the auto tensioner.
  48.  
  49. Remove the camshaft bearing caps and camshafts.
  50.  
  51. Remove the OCV (Oil Control Valve).
  52.  
  53. Remove the OCV (Oil Control Valve) filter.
  54.  
  55. Remove the water hose from water pipe.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence - 2.0L engine

  56.  
  57. Using 8mm and 10mm hexagon wrenches, 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.
    CAUTION
    Head warpage or cracking could result from removing bolts in an incorrect order.

  58.  
  59. Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench.
    CAUTION
    Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

  60.  

To install:


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.



Click image to see an enlarged view

Fig. Cylinder head gasket installation - 2.0L engine



Click image to see an enlarged view

Fig. Cylinder bolt torque sequence - 2.0L engine

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

  2.  
  3. Place the cylinder head onto the block carefully in order to prevent damaging the gasket. If the gasket is damaged, fluid leakage could occur.
  4.  
  5. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. Using 8mm and 10mm hexagon wrenches, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown:

    M10 bolts: 23-27 Nm (17-19 ft. lbs.) +60-65 degrees, + an additional 60-65 degrees
     
    M12 bolts: 28-31 Nm (20-23 ft. lbs.) +60-65 degrees, + an additional 60-65 degrees
     

  6.  
  7. Install the OCV (Oil Control Valve) filter. Tighten to 40-50 Nm (30-37 ft. lbs.)
    NOTE
    Always use a new OCV (Oil Control Valve) filter gasket. Keep the OCV filter clean.

  8.  
  9. Install the OCV (Oil Control Valve). Tighten to 10-12 Nm (7-9 ft. lbs.)
    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 OCV.

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

2.7L Engines


Click image to see an enlarged view

Fig. Cylinder heads and gaskets - 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. 
  12.  
  13. Remove the radiator cap to speed draining.
  14.  
  15. Remove the engine cover.
  16.  
  17. Remove the intake air hose and air cleaner assembly.
  18.  
  19. Remove the coolant reservoir tank.
  20.  
  21. Remove the upper radiator hose and lower radiator hose.
  22.  
  23. Remove the heater hoses and throttle body heater hose.
  24.  
  25. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.
  26.  
  27. Remove the fuel inlet hose from delivery pipe.
  28.  
  29. Remove the brake booster vacuum hose.
  30.  
  31. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage.
  32.  
  33. Remove the PCV hose.
  34.  
  35. Remove the intake manifold. 
  36.  
  37. Remove the power steering pump.
  38.  
  39. Remove the exhaust manifold.  
  40.  
  41. Remove the timing belt.  
  42.  
  43. Remove the spark plug cable. 
  44.  
  45. Remove the cylinder head covers.
  46.  
  47. Remove the camshaft sprocket.
  48.  
  49. Remove the camshaft bearing caps.
  50.  
  51. Remove the camshafts.
  52.  
  53. Remove the timing belt rear cover.
  54.  
  55. Remove the water temperature control assembly and water pipe.
  56.  
  57. Uniformly loosen and remove the 8 cylinder head bolts on each cylinder head in several passes and in the sequence shown, then repeat for the other side, as shown.  Remove the 16 cylinder head bolts and plate washer. 

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence - 2.7L engine

  58.  

To install:


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



Click image to see an enlarged view

Fig. Head gasket installation - 2.7L engine

  1. Install the cylinder head gaskets on the cylinder block.
  2.  
  3. Place the cylinder head carefully, in order not to damage the gasket with the bottom part of the end.
  4.  
  5. Install cylinder head bolts. Tighten to:

    Step 1: 25 Nm (18 ft. lbs.)
     
    Step 2: + 60 degrees
     
    Step 3: + 45 degrees
     

  6.  
  7. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. 
  8.  
  9. Install the plate washer to the cylinder head bolt. 
  10.  
  11. Install and uniformly tighten the cylinder head bolts on each cylinder head in several passes and in the sequence shown, then repeat for the other side, as shown. 

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence - 2.7L engine

  12.  
  13. Install the water pipe and water temperature control assembly (A). Tighten to 15-20 Nm (11-14 ft. lbs.) 

    Click image to see an enlarged view

    Fig. Water pipe and water temperature control assembly - 2.7L engine

  14.  
  15. Install the timing belt rear cover (A). Tighten to 10-12 Nm (7-9 ft. lbs.). 
  16.  
  17. Install the camshafts.
  18.  
  19. Install the cylinder head covers.
  20.  
  21. Install the spark plug cables.
  22.  
  23. Install the timing belt.
  24.  
  25. Install the exhaust manifold.
  26.  
  27. Install the power steering pump.
  28.  
  29. Install the intake manifold.
  30.  
  31. Install the PCV hose.
  32.  
  33. Install the accelerator cable.
  34.  
  35. Install the brake booster vacuum hose.
  36.  
  37. Install the fuel inlet hose.
  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 hoses and throttle body heater hose.
  42.  
  43. Install the upper radiator hose and lower radiator hose.
  44.  
  45. Install the coolant reservoir tank.
  46.  
  47. Install the intake air hose and air cleaner assembly.
  48.  
  49. Install the engine cover.
  50.  
  51. Connect the negative terminal to the battery.
  52.  
  53. Install the strut bar.
  54.  
  55. Install the cowl grill and wiper motor.
  56.  
  57. Install the air duct.
  58.  
  59. Fill with engine coolant.
  60.  
  61. Start the engine and check for leaks.
  62.  
  63. Recheck engine coolant level and oil level.
  64.  

 
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